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APRILIA Caponord 1200 2016, Manual, Page: 357 / 573

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APRILIA Caponord 1200 2016 Manual Download Page 357

•

Replace the O-Rings on oil ducts.

Before refitting

UPON REFITTING THE CRANKSHAFT, GREASE THE SHAFT BUSHING-CONNECTING ROD
COUPLING.

Inspecting the crankshaft components

Crankshaft axial clearance check

•

The shaft axial clearance on the crank-

case should be checked with a dial

gauge mounted on the specific dial

gauge support.

•

The clearance should be between 0.1

- 0.26 mm (0.0039 - 0.0102 in).

•

If the clearance is beyond tolerance,

check the reference surfaces.

Specific tooling

020714Y

 

Dial gauge mount

Removal

•

Mark the position of the original semi-bushings on the crankcase.

Caponord 1200 - Caponord 1200 Rally

Engine

ENG - 357

Summary of Contents for Caponord 1200 2016

Page 1: ...MANUALE STAZIONE DI SERVIZIO 2Q000020 Caponord 1200 Caponord 1200 Rally ...

Page 2: ...f the vehicle itself All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only While the basic features as described and illustrated in this manual remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publica...

Page 3: ...to continually improve its products and the relative documentation The main technical modifications and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will...

Page 4: ...Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee ...

Page 5: ... MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS COOLING SYSTEM COOL SYS BODYWORK BODYW PRE DELIVERY PRE DE ...

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 8: ...AINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE EN GINE SWITCHED OFF DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR AVOID ANY CONTACT WITH NAKED FLAME SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot parts The engine and the exhaust system components get very hot and remain in this co...

Page 9: ...LUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES RINSE THEM IMMEDIATELY WITH PLENTY OF COLD CLEAN WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELEC...

Page 10: ...ave adapted to one another following normal wear Some components must be used together or replaced entirely Keep away from heat sources REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY WITHOUT JAMMING AND OR NOISE OTHERWISE THEY NEED TO BE REPLACED Only use ORIGINAL Aprilia SPARE PARTS Comply with lubricant and consumables use guidelines Lubricate parts whenever possible before reassemb...

Page 11: ...QUES CAUTION IF UNSCREWING A SELF LOCKING NUT IT MUST BE REPLACED WITH A NEW ONE CAUTION REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELEMENTS LOCATED ON WHEELS BRAKES WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A FUN DAMENTAL ROLE IN GUARANTEEING THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT THE PRESCRIBED VALUES REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING ELEMENTS AND ALWA...

Page 12: ...let The chassis number is handy when purchasing spare parts CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME HOWEVER THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE IDENTIFICATION NUMBER VIN HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED OPTION 01 This number consists of numbers and letters as in the example shown below ZD4VKA000YSXXXXXX KEY ZD4 WM...

Page 13: ... 513 68 lb Dry weight without fuel Caponord 1200 Travel Pack 247 kg 544 54 lb OPTION 02 SIZES Specification Desc Quantity Max length Caponord 1200 Rally 2280 mm 89 76 in Max width at hand guards 1000 mm 39 37 in Max height fully extracted windshield 1440 mm 56 69 in Saddle height 870 mm 34 25 in Centre to centre distance Caponord 1200 Rally 1575 mm 62 01 in Kerb weight Caponord 1200 Rally 275 kg 6...

Page 14: ...dary Final drive gear ratio 17 42 Capacities OPTION 01 CAPACITY Specification Desc Quantity Fuel tank reserve included 24 l 5 28 UK gal 6 34 US gal Fuel reserve 4 l 0 88 UK gal 1 06 US gal Engine oil 3 1 l without oil filter change 0 68 UK gal 0 82 US gal 3 35 l with oil filter change 0 74 UK gal 0 88 US gal Coolant 2 5 l 0 55 UK gal 0 66 US gal Seats 2 Maximum weight limit 473 kg 1 042 78 lb OPTI...

Page 15: ...kOhm OPTION 01 WARNING LIGHTS Specification Desc Quantity Turn indicators LED High beam light LED Fuel reserve LED Cruise control warning light LED Gear in neutral LED General warning LED ABS LED ATC LED OPTION 02 WARNING LIGHTS Specification Desc Quantity Turn indicators LED High beam light LED Fuel reserve LED Cruise control warning light LED Gear in neutral LED General warning LED ABS LED MI LE...

Page 16: ...spring preload on right stanchion manually adjustable Travel 170 mm 6 69 in Rear Caponord 1200 Oscillating swingarm connected with cantilever type link to a Sachs single shock absorber with adjustment of hydraulic braking during extension and spring preload with knob Rear Caponord 1200 Travel Pack Caponord 1200 Rally Oscillating swingarm connected with cantilever type link to a Sachs single shock ...

Page 17: ...dially mounted calliper with four Ø 32 mm 1 26 in pistons and two calliper pads Rear 240 mm 9 45 in diam disc brake with 35 mm 1 38 in diam single piston calliper Wheels and tyres OPTION 01 WHEEL RIMS Specification Desc Quantity Type Light alloy rims with extractable bolt Front 3 50 x 17 Rear 6 00 x 17 OPTION 02 WHEEL RIMS Specification Desc Quantity Type with spokes Front 3 00 x 19 Rear 4 50 x 17...

Page 18: ... Tyre type standard DUNLOP QUALIFIER II Only for 78 kW PIRELLI ANGEL GT versions Front tyre 120 70 M C 19 60V Front tyre pressure rider only 2 4 bar 240 kPa 34 81 PSI rider passenger 2 5 bar 250 kPa 36 26 PSI Rear tyre 170 70 M C 17 72V Rear tyre pressure rider only 2 6 bar 260 kPa 37 71 PSI rider passenger 2 8 bar 280 kPa 40 61 PSI Supply FUEL SYSTEM Specification Desc Quantity Type Electronic in...

Page 19: ... 1 TEFL screw fasten onto Fork Hubs M6x40 4 10 Nm 7 37 lb ft 2 Screw Piston fixing to the stem base 2 30 Nm 22 13 lb ft 3 Upper cap 2 20 Nm 14 75 lb ft 4 Upper cap locking nut 2 20 Nm 14 75 lb ft ADD Version Caponord 1200 Caponord 1200 Rally Characteristics CHAR 19 ...

Page 20: ...es 1 Sensor upper cover screw M6x20 1 10 Nm 7 37 lb ft 2 Sensor lower cover screw M6x12 2 10 Nm 7 37 lb ft 3 Screw Piston fixing to the stem base 2 30 Nm 22 13 lb ft 4 Upper cover 2 20 Nm 14 75 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 20 ...

Page 21: ... 44 2 77 lb ft 4 SHC screw fastening U bolt onto fork yoke M10x70 2 50 7 5 Nm 36 88 5 53 lb ft 5 SHC screw fastening fork stanchions to top yoke M8x30 2 25 3 75 Nm 18 44 2 77 lb ft Loctite 243 6 Self locking ring nut M35x1 1 25 5 Nm 18 44 3 69 lb ft FRONT BRAKE CALLIPER pos Description Type Quantity Torque Notes 1 Callipers fastening screws M10x55 4 50 7 5 Nm 36 88 5 53 lb ft Caponord 1200 Caponor...

Page 22: ...FRONT BRAKE PUMP pos Description Type Quantity Torque Notes 1 Brake pump fixing screws M6 2 10 1 5 Nm 7 37 1 10 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 22 ...

Page 23: ... 76 lb ft 2 Anti vibration weight fastening screws 2 20 4 Nm 14 75 2 95 lb ft CLUTCH CONTROL pos Description Type Quantity Torque Notes 1 Clutch pump fixing screws M6 2 10 1 5 Nm 7 37 1 10 lb ft 2 Throttle control fixing screws M6 3 10 Nm 7 37 lb ft OPTION 01 Caponord 1200 Caponord 1200 Rally Characteristics CHAR 23 ...

Page 24: ...uantity Torque Notes 1 Wheel axle M25 x 1 25 1 80 12 Nm 59 8 85 lb ft 2 Wheel nut M25 x 1 25 1 80 12 Nm 59 8 85 lb ft 3 Front brake disc fixing screws M8x20 12 30 Nm 22 13 lb ft OPTION 02 Characteristics Caponord 1200 Caponord 1200 Rally CHAR 24 ...

Page 25: ...85 lb ft 3 Front brake disc fixing screws M8x20 12 30 Nm 22 13 lb ft OIL RADIATOR pos Description Type Quantity Torque Notes 1 Fastening nipple to oil radiator M16x1 5 2 18 Nm 4 05 lb ft 2 Oil radiator tubes fastening M16x1 5 4 15 Nm 11 06 lb ft 3 Fastening nipple to engine M16x1 5 2 42 Nm 30 97 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 25 ...

Page 26: ...ue Notes 1 Instrument panel to trellis fixing screws M8x25 4 25 5 Nm 18 43 3 68 lb ft COOLING SYSTEM pos Description Type Quantity Torque Notes 1 Electric fan fastener screw M4x45 6 3 Nm 2 21 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 26 ...

Page 27: ...37 lb ft 3 Flanged TE screw fastening expan sion tank M6x20 3 10 Nm 7 37 lb ft TOP FAIRING_WINDSHIELD pos Description Type Quantity Torque Notes 1 Windshield on support fastener screw M6x18 4 10 Nm 7 37 lb ft 2 Bracket retainer screw M6x25 4 10 Nm 7 37 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 27 ...

Page 28: ... 47 lb ft 4 Front mudguard fixing screw M6x40 4 12 1 8 Nm 8 85 1 33 lb ft 5 Control unit support fixing screw M6x20 1 10 Nm 7 37 lb ft 6 Lug on support fastener screw M6x12 2 10 Nm 7 37 lb ft 7 Control unit support fixing screw M6x25 2 10 Nm 7 37 lb ft 8 Lug on support fastener screw M5 2 6 Nm 4 42 lb ft 9 Spacer SHC screw M8 1 Tighten by hand Loct 243 Characteristics Caponord 1200 Caponord 1200 R...

Page 29: ...G pos Description Type Quantity Torque Notes 1 Deflector fixing screw M5x12 2 6 Nm 4 42 lb ft 2 Deflector fixing screw M5x16 2 6 Nm 4 42 lb ft Central part Caponord 1200 Caponord 1200 Rally Characteristics CHAR 29 ...

Page 30: ...m 36 88 lbf ft Loctite 270 2 TCEI screw fastening Pin to gearbox lever and Gearbox Lever to knurled shaft M6x16 2 12 Nm 8 85 lbf ft 3 LH lock nut for ball joint M6 1 10 Nm 7 37 lbf ft 4 RH lock nut for ball joint M6 1 10 Nm 7 37 lbf ft 5 RH ball joint on gearbox control lever M6 1 10 Nm 7 37 lbf ft 6 Pinion protector fixing screw M6x12 2 10 Nm 7 37 lbf ft 7 LH ball joint on gearbox control lever M...

Page 31: ...ad self tapping screw fas tening covers filter box M5x20 10 3 Nm 2 21 lb ft 2 Cross head self tapping screw fas tening blow by tank M5x20 2 3 Nm 2 21 lb ft 3 Intake duct fixing screw M5 4 6 1 2 Nm 4 43 0 89 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 31 ...

Page 32: ...b ft SEAT POST FRAME pos Description Type Quantity Torque Notes 1 Seat post fixing screw M8x35 4 35 5 3 Nm 25 81 3 91 lb ft Loctite 243 2 Seat post frame retainer nut M8 2 35 5 3 Nm 25 81 3 91 lb ft 3 Counter plate fixing screw M10x30 1 50 7 5 Nm 36 88 7 5 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 32 ...

Page 33: ...frame side panels M12 4 80 Nm 59 lbf ft 3 Flanged TE screw fastening chain roller bracket to LH plate M8x35 1 25 Nm 18 44 lbf ft Loctite 243 4 Flanged TE screw fastening chain roller to chain roller bracket M8x45 1 25 Nm 18 44 lbf ft Loctite 243 5 Screw fastening chain roller bracket to LH plate M8x20 1 25 Nm 18 44 lbf ft Loctite 243 Caponord 1200 Caponord 1200 Rally Characteristics CHAR 33 ...

Page 34: ... lb ft 2 Level indicator fixing screws M6x16 4 3 0 45 Nm 2 21 0 33 lb ft 3 Saddle fixing M5 x 9 5 1 3 0 45 Nm 2 21 0 33 lb ft 4 Fuel tank cap fixing screw M5 x 14 4 3 0 45 Nm 2 21 0 33 lb ft 5 Joint 2 3 0 45 Nm 2 21 0 33 lb ft OPTION 01 Characteristics Caponord 1200 Caponord 1200 Rally CHAR 34 ...

Page 35: ...10x33 2 50 Nm 36 88 lb ft Loctite 243 2 Plate fastening screws M8x30 3 25 5 Nm 18 43 3 68 lb ft Loctite 243 3 Stand screw M10 1 25 5 Nm 18 43 3 68 lb ft Loctite 243 4 Stand nut M10x1 25 1 25 5 Nm 18 43 3 68 lb ft Loctite 243 OPTION 02 Caponord 1200 Caponord 1200 Rally Characteristics CHAR 35 ...

Page 36: ...tite 243 3 Stand nut M10x1 25 1 25 5 Nm 18 43 3 68 lb ft Loctite 243 OPTION 01 DISCHARGE pos Description Type Quantity Torque Notes 1 TBEI silencer protection screws M6x16 3 5 Nm 3 69 lb ft 2 SHC silencer flange screws M8x25 2 18 3 6 Nm 13 28 2 66 lb ft 3 Resonator fixing clamp 1 4 5 1 Nm 3 32 0 74 lb ft OPTION 02 Characteristics Caponord 1200 Caponord 1200 Rally CHAR 36 ...

Page 37: ...ty Torque Notes 1 TBEI silencer protection screws M6x16 3 5 Nm 3 69 lb ft 2 SHC silencer flange screws M8x25 2 18 3 6 Nm 13 28 2 66 lb ft 3 Resonator fixing clamp 1 4 5 1 Nm 3 32 0 74 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 37 ...

Page 38: ...e fixing screw M5X15 1 6 1 2 Nm 4 42 0 88 lb ft Loctite 243 5 Brake lever push rod fixing screw M6 x 20 1 10 1 5 Nm 7 37 1 10 lb ft 6 Brake lever push rod fixing nut M6 1 10 1 5 Nm 7 37 1 10 lb ft FOOTRESTS pos Description Type Quantity Torque Notes 1 Rear brake pump fixing screws M6x20 2 10 1 5 Nm 7 37 1 11 lb ft Loctite 243 2 Footrest support fixing screws M8x40 4 30 4 5 Nm 22 12 3 31 lb ft Loct...

Page 39: ...Quantity Torque Notes 1 Covers fastening screws M5x9 4 3 0 60 Nm 2 21 0 44 lb ft SADDLE pos Description Type Quantity Torque Notes 1 Saddle fixing screw M5x12 1 6 Nm 4 42 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 39 ...

Page 40: ... M5x20 8 6 Nm 4 42 lb ft 2 Compartment fixing screw M5x12 2 6 Nm 4 42 lb ft SIDE FAIRINGS pos Description Type Quantity Torque Notes 1 Fairing fastener screw M5x9 2 6 Nm 4 42 lb ft 2 Fairing fastener screw M5x16 4 6 Nm 4 42 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 40 ...

Page 41: ...ROTARY SENSOR pos Description Type Quantity Torque Notes 1 Reaction rod fixing nut M6 2 8 Nm 5 9 lb ft Back side Caponord 1200 Caponord 1200 Rally Characteristics CHAR 41 ...

Page 42: ...5 90 7 37 lb ft 2 ABS ECU fastener nut M6 1 10 Nm 7 37 lb ft REAR SUSPENSION pos Description Type Quantity Torque Notes 1 Upper SHC mounting screw M10x50 1 50 Nm 36 88 lb ft 2 Lower SHC mounting screw M10x59 1 50 Nm 36 88 lb ft ADD Version Characteristics Caponord 1200 Caponord 1200 Rally CHAR 42 ...

Page 43: ...D pos Description Type Quantity Torque Notes 1 Upper SHC mounting screw M10x50 1 50 Nm 36 88 lb ft 2 Lower SHC mounting screw M10x59 1 50 Nm 36 88 lb ft OPTION 01 Caponord 1200 Caponord 1200 Rally Characteristics CHAR 43 ...

Page 44: ...r brake disc fixing screws M8x18 5 30 Nm 22 13 lb ft OPTION 02 REAR WHEEL pos Description Type Quantity Torque Notes 1 Rear wheel axle M25x1 25 1 120 18 Nm 88 50 13 27 lb ft 2 Flexible coupling self locking nut M10 5 55 8 25 Nm 40 57 6 08 lb ft 3 Rear brake disc fixing screws M8x18 5 30 Nm 22 13 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 44 ...

Page 45: ...rew fastening rear stand bushing M6x40 2 10 Nm 7 37 lb ft 5 TSEI screw fastening chain guard to swingarm M5x9 1 6 Nm 4 42 lb ft Loctite 243 6 TBEI Chainguard fixing screw M5x9 1 4 Nm 2 95 lb ft 7 TSEI screw fastening chain guide to swingarm M5x9 2 6 Nm 4 42 lb ft Loctite 243 8 Flanged TBEI screw fastening chain slider M5x9 2 6 Nm 4 42 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 45...

Page 46: ...crews on wheel ad justment M6x16 4 10 2 Nm 7 37 1 47 lb ft Loctite 270 LUGGAGE RACK pos Description Type Quantity Torque Notes 1 Luggage rack screw 3 9x14 2 2 Nm 1 47 lb ft 2 Luggage rack cover screw M8x20 2 25 Nm 18 44 lb ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 46 ...

Page 47: ...ggage rack screw 5x14 5 3 Nm 2 21 lb ft REAR BODYWORK pos Description Type Quantity Torque Notes 1 Tail fairing fastener screw M5x12 6 6 Nm 4 42 lb ft 2 Panniers connection fixing screw 4 3 License plate holder fastener screw M6 3 10 Nm 7 37 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 47 ...

Page 48: ...t SIDE BAG HOLDER pos Description Type Quantity Torque Notes 1 Bag holder fixing screw M8x70 4 25 5 Nm 18 44 3 69 lb ft Loctite 243 2 Bag holder fixing screw M8x20 2 25 5 Nm 18 44 3 69 lb ft Loctite 243 3 Crossbeam fixing screw M6x20 2 10 2 Nm 7 38 1 48 lb ft Loctite 243 4 Screw fixing bag hook M6x30 4 10 2 Nm 7 38 1 48 lb ft Loctite 243 Characteristics Caponord 1200 Caponord 1200 Rally CHAR 48 ...

Page 49: ...ial screw for fastening head cover M6 8 9 Nm 6 64 lb ft 2 Special screw for fastening head cover M6 2 9 Nm 6 64 lb ft 3 Oil breather fastener screw M6 2 5 50 Nm 4 06 lbf ft Spark plugs 2 10 12 Nm 7 38 8 85 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 49 ...

Page 50: ... Head stud bolt fastener nut tighten ing M10x1 25 8 13 Nm 9 59 lbf ft 135 135 Lubricate the threads before tight ening 4 Fastener for Head Cylinder Outer side crankcase M6 2 12 Nm 8 85 lbf ft 5 Fastener for Head Cylinder Inner side crankcase M6 4 12 Nm 8 85 lbf ft 6 Nut fastening Stud Bolts Head M6 4 12 Nm 8 85 lbf ft 7 Nut fastening Stud Bolts Head M8 2 26 Nm 19 18 lb ft 8 Bleed union fastener sc...

Page 51: ...e Notes 1 Chain tensioner fastener screw M6 4 13 Nm 9 59 lb ft 2 Cylinder plate fastener screw M6 4 7 84 9 81 Nm 5 78 7 23 lb ft 3 Chain tensioner adjustment screw M6 2 5 50 Nm 4 06 lb ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 51 ...

Page 52: ...w M24x1 5 2 40 Nm 29 50 lbf ft 3M SCOTCH GRIP 2353 3 Special screw for fastening mobile fixed shoes M8 4 19 Nm 14 01 lbf ft 3M SCOTCH GRIP 2353 4 Cam tower head fastener screws M6 16 12 Nm 8 85 lbf ft 5 Camshaft retainer plate fastener screw torx M5 8 8 5 Nm 6 26 lbf ft 3M SCOTCH GRIP 2353 Characteristics Caponord 1200 Caponord 1200 Rally CHAR 52 ...

Page 53: ... 3M SCOTCH GRIP 2353 CRANKSHAFT pos Description Type Quantity Torque Notes 1 Crankshaft primary gear fastener nut M24x1 5 1 300 Nm 221 27 lbf ft Anticlockwise nut 2 Connecting rod screw M10 4 15 30 Nm 11 06 22 13 lbf ft 50 2 final control torque 65 78 Nm 47 94 57 53 lbf ft Lubricate the threads before tight ening Caponord 1200 Caponord 1200 Rally Characteristics CHAR 53 ...

Page 54: ...il filter 1 14 Nm 10 33 lbf ft 5 Oil pressure regulator valve M18x1 5 1 42 Nm 30 98 lbf ft 6 Oil pump fixing screw M6 2 5 6 Nm 3 69 4 42 lbf ft 3M SCOTCH GRIP 2353 7 Rose pipe fixing screw M6 2 12 Nm 8 85 lbf ft 8 Oil pump driven gear fastener nut M6 1 11 Nm 8 11 lbf ft 9 By Pass plate fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 242 10 Oil cooling radiator nipple M16x1 5 2 42 5 Nm 31 35 lbf ft...

Page 55: ...smodromic se lector drum Selector sprocket M8 1 20 Nm 14 75 lb ft 3M SCOTCH GRIP 2353 4 Gear sensor fastener screw M5 2 5 50 Nm 4 06 lb ft Loctite 270 5 Selector pin fastener onto clutch side crankcase half M10x1 5 1 16 Nm 11 80 lb ft Loctite 242 6 Gear retainer pawl fastener pin 1 11 13 Nm 8 11 9 59 lb ft 7 Gear retainer pawl fastener flanged nut 1 10 12 Nm 7 38 8 85 lb ft Caponord 1200 Caponord ...

Page 56: ...tener nut M24x1 1 170 Nm 125 38 lbf ft Chamfer 3 Fastening oil filler plug on Clutch cov er 1 2 Nm 1 48 lbf ft 4 Screw fastening fixing Plate Clutch control Mounting M5 3 5 50 Nm 4 06 lbf ft Loctite 242 5 Screw fastening clutch control mounting on flywheel side crankcase half M6 2 8 Nm 5 90 lbf ft Characteristics Caponord 1200 Caponord 1200 Rally CHAR 56 ...

Page 57: ... Torque Notes 1 Clutch spring fastener screw M6 6 11 Nm 8 11 lb ft WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 11 13 Nm 9 59 lbf ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 57 ...

Page 58: ... Quantity Torque Notes 1 Spark plug 4 11 Nm 8 11 lb ft 2 Freewheel Ring fastener screw M6 6 14 Nm 10 33 lb ft 3M SCOTCH GRIP 2353 3 Screw fixing rotor Crankshaft 12 mm 0 47 in M12x1 25 1 130 Nm 95 88 lb ft 3 Screw fixing rotor Crankshaft 14 mm 0 55 in M14x1 5 1 190 200 Nm 140 14 147 51 lb ft 4 Screw fastening Stator Flywheel Cover M6 3 9 Nm 6 64 lb ft 5 Screw fastening pick up Flywheel cover M5 2 ...

Page 59: ...retainer fastener screw M6 3 10 Nm 7 38 lbf ft Loctite 270 2 Piston oil jet fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 270 3 Tapered plug for crankshaft main bearing lubrication M8x1 4 15 Nm 11 06 lbf ft Caponord 1200 Caponord 1200 Rally Characteristics CHAR 59 ...

Page 60: ...nder Piston Play on fitting Cylinder piston clear ance A A Type A A 105 990 105 997 mm 4 1728 4 1731 in 105 928 105 935 mm 4 1704 4 1707 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance B B Type B B 105 997 106 004 mm 4 1731 4 1734 in 105 935 105 942 mm 4 1707 4 1709 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance C C Type C C 106 004 106 011 mm 4 1734 4 1736 in 105 942 ...

Page 61: ... housing diameter 53 954 53 960 mm 2 1241 2 1244 in Crankcase class 2 Bearing housing diameter 53 960 53 966 mm 2 1244 2 1246 in INTERNAL MARKING ON SECOND GENERATION CRANKCASES Crankcases are classified in two classes 1 or 2 depending on the diameter of the main bearing seat The class is indicated on both crankcase halves specifically in the starter gear area on flywheel side crankcase halves and...

Page 62: ...ng the flywheel cover MAIN BEARINGS Block journal Crankcase class 1 Crankcase class 2 Block journal class 4 l v Half bearings A red Half bearings B blue Block journal class 5 l v Half bearings B blue Half bearings C yellow Block journal class 6 l v Half bearings E green Half bearings A red Block journal class 7 l f Half bearings A red Half bearings B blue Block journal class 8 l f Half bearings B ...

Page 63: ...PRIMARY REDUCTION GEAR ALREADY COU PLED CRANKCASE CLASSES 02 Specification Desc Quantity Crankcase class A Centre distance 110 50 110 54 mm 4 3504 4 3519 in Crankcase class B Centre distance 110 46 110 50 mm 4 3488 4 3504 in Class one Two different pinion classes A or B are available selected in relation to the centre to centre dis tance between the primary reduction gears On class B pinions only ...

Page 64: ...G RODS Class according to crankshaft weight Original connecting rod class colour Original connecting rod class E marking Spare part connecting rod class E1 Brown connecting rod E1 Cat A E2 Blue connecting rod E2 Cat A E3 Yellow connecting rod E3 Cat A E4 Green connecting rod E4 Cat A E5 Pink connecting rod E5 Cat B E6 Black connecting rod E6 Cat B E7 White connecting rod E7 Cat B CAUTION WHEN ORDE...

Page 65: ...See also Removing the flywheel cover Caponord 1200 Caponord 1200 Rally Characteristics CHAR 65 ...

Page 66: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 67: ... 020709Y Engine support 020710Y Engine plate AP8140187 U bolt for motor support 020850Y Primary gear lock 020712Y Handle for removing the flywheel cover 020713Y Flywheel extractor Caponord 1200 Caponord 1200 Rally Special tools S TOOLS 67 ...

Page 68: ...ount 9100896 Clutch bell stopper 020716Y Connecting stem lock 020894Y Pin snap ring fitting tool 020895Y Piston installation ring 020719Y Timing pin 020382Y Tool to extract valve cotters Special tools Caponord 1200 Caponord 1200 Rally S TOOLS 68 ...

Page 69: ...Y Bushing for valve removal 020720Y Timing tool 020376Y Adaptor handle 020891Y 25 mm 0 98 in adapter 020362Y 12 mm guide 020724Y Punch cage with rollers gearbox control stem Caponord 1200 Caponord 1200 Rally Special tools S TOOLS 69 ...

Page 70: ...Y Bushing extractor 020727Y Bushing punch 020966Y Steering adjustment socket 020193Y Gauge for oil pressure check AP8140612 Fuel pressure gauge AP8140199 Tool storage panel Special tools Caponord 1200 Caponord 1200 Rally S TOOLS 70 ...

Page 71: ...p for pre load pipe 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion 020922Y Diagnostic tool 020957Y Key for upper fork nut 020958Y Fork cartridge protection Caponord 1200 Caponord 1200 Rally Special tools S TOOLS 71 ...

Page 72: ...res code Description AP8140149 Guard for assembly operations AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight Special tools Caponord 1200 Caponord 1200 Rally S TOOLS 72 ...

Page 73: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 74: ... SCHEDULED MAINTENANCE TABLE km x 1000 mi x 1000 1 0 6 10 6 2 20 12 4 30 18 6 40 24 9 Rear shock absorber I I Spark plug R R Drive chain 7 I I I I I Transmission cables and controls I I I Steering bearings and steering clearance I I I Wheel bearings I I Diagnosis by tool I I I I I Brake discs I I I Air filter R R Engine oil filter R R R Fork I I General vehicle operation I I I Valve clearance A A ...

Page 75: ...uid 2 I I I Brake fluid 2 I I I Coolant 2 I I I Fork oil 1 R Engine oil R R R Light aiming I I Fork oil seals I I I I Flexible coupling 6 I I Clutch lever pin 7 L L L L L Tyres pressure wear 5 I I I I I Wheels I I I Bolts and nuts tightening I I I Stand joint L L L L L Suspension and setting I I I Fault warning light on instrument panel 4 Spokes tension I I I I I Fuel lines 3 I I Clutch wear I I B...

Page 76: ... calcium soap based grease colour black contains EP Extreme Pressure additives excellent water re pellent properties Spray grease for chains Spray lubricant grease Brake fluid DOT 4 Synthetic brake fluid SAE J 1703 FMVSS 116 ISO 4925 CU NA NC 956 DOT4 Anti freeze liquid ready to use colour red Ethylene glycol antifreeze liquid with or ganic inhibition additives Red ready to use ASTM D 3306 ASTM D ...

Page 77: ...oils Unscrew and remove the two screws fixing coils to head cover Slide out the front coils Unscrew and remove the front spark plugs REAR SPARK PLUGS Lift the tank Unscrew and remove the rear coil fix ing screws Slide out the rear coils Unscrew and remove the rear spark plugs Caponord 1200 Caponord 1200 Rally Maintenance MAIN 77 ...

Page 78: ...ea ches 1 mm 0 039 in Make sure the washer is in good con ditions Installation Once the washer is fitted screw the spark plug carefully to avoid damaging the thread Screw the spark plug to the prescribed torque CAUTION TIGHTEN THE SPARK PLUG CORRECTLY OTHERWISE THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE DAMAGED USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG OTHERWISE ENGINE DURATION AND PERFORMANC...

Page 79: ...ABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTRA URBAN CONDITIONS ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE Switch off the engine and wait at least five minutes to allow the lubricant to drain back into the sump Keep the vehicle upright on a level sur face and with both wheels on the ground Check the oil level from the sight glass on the ...

Page 80: ...nd remove the filler plug 1 Drain the oil into the container allow several minutes for oil to drain out com pletely Replace the sealing washer of the drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Screw and tighten the drainage plug 2 Replace the oil filter Restore the correct engine oil level using the recommended engine oil See also Engine oil filter Check Engine o...

Page 81: ...x cover COVER THE INTAKE DUCTS WITH A CLEAN CLOTH TO PREVENT FOREIGN BODIES FROM ENTERING THE IN TAKE DUCTS UPON REFITTING BEFORE REPLACING THE FILTER CASE COVER MAKE SURE THAT THE CLOTH OR OTHER OBJECTS ARE NOT LEFT INSIDE MAKE SURE THAT THE FILTER ELEMENT IS CORRECTLY POSITIONED SO NO UNFILTERED AIR CAN PASS DO NOT FORGET THAT THE EARLY USE OF THE PISTON AND CYLINDER SEGMENTS CAN BE CAUSED BY A ...

Page 82: ...nt If valve clearance is not within the tolerance range adjust as follows Take the engine to the TDC Lock the camshafts by using the cor responding timing pins Specific tooling 020719Y Timing pin Characteristic Valve clearance at intake 0 15 0 20 mm 0 0059 0 0079 in Outlet valve clearance 0 20 0 25 mm 0 0079 0 0098 in Remove one cam shaft at a time leave the other camshaft in position and secured ...

Page 83: ...Calibrated pad 2 85 7 Calibrated pad 2 90 8 Calibrated pad 2 95 9 Calibrated pad 3 00 10 Calibrated pad 3 05 11 Calibrated pad 3 10 12 Calibrated pad 3 15 13 Calibrated pad 3 20 14 Calibrated pad 3 25 15 Calibrated pad 3 30 16 Calibrated pad 3 35 17 Calibrated pad 3 40 18 Calibrated pad 2 55 19 Calibrated pad 2 50 20 Calibrated pad 2 45 21 Calibrated pad 2 40 CAUTION BEFORE REMOVING THE BIG END CO...

Page 84: ... Apply THREEBOND to the head at the points indicated in figure Maintenance Caponord 1200 Caponord 1200 Rally MAIN 84 ...

Page 85: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 86: ...IS SELECTED AND IS DISPLAYED PRESS THE KEY TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 7 READ TH...

Page 87: ...EADING WITH ENGINE AT IDLE AND ENGINE TEMPERATURE 65 c FRONT THROTTLE CORRECTION OR REAR THROTTLE CORRECTION WITH ENGINE AT IDLE ARE THE PARAMETERS INCLUDED WITHIN 0 8 0 8 INTERVAL AND IN THE SAME SCREEN PAGE ARE THE FRONT THROT POT 1 DEGREES AND REAR THROT POT 1 DEGREES WITH EN GINE AT IDLE OR A 0 5 CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT CYLINDER MUST ...

Page 88: ... 2 2 IS THE FUEL PUMP RUNNING YES go to point 3 NO go to the FUEL PUMP CHECK 3 DOES THE DIAGNOSTIC TOOL COMMUNICATE WITH THE CONTROL UNIT IN OTHER WORDS AFTER SELECTING FUEL IN INJECTION AND PERFORMING THE SUBSEQUENT INSTRUCTIONS ARE THE PARAMETERS STATES ETC DISPLAYED WHEN THE IGNITION KEY IS TURNED TO THE ON POSITION YES go to point 4 NO go to the DIAGNOSTIC TOOL CONNECTION CHECK 4 WITH DIAGNOSI...

Page 89: ...oint 10 if everything functions correctly go to point 11 10 DEPENDING ON THE SPECIFIC FAULT SEE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS NEUTRAL SENSOR or ELECTRICAL SYSTEM CHECKS AND CONTROLS GEAR SENSOR or ELECTRICAL SYSTEM CHECKS AND CON TROLS SIDE STAND END 11 REPLACE THE CONTROL UNIT END 12 IS THE FALL SENSOR IN VERTICAL POSITION YES go to 13 NO go to 14 13 REFER TO THE CHAPTER ELECTRICA...

Page 90: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 91: ...2 lbf ft 5 Self tapping screw fastening de mand sensor mounting to demand sensor 5x14 3 4 Nm 2 35 lbf ft 6 TBEI screw fastening relay support to demand sensor mounting M6x16 4 10 Nm 7 37 lbf ft 7 TEFL screw fastening cableway to demand sensor mounting M6x12 1 10 Nm 7 37 lbf ft 8 TEFL horn fixing screw M6x12 1 10 Nm 7 37 lbf ft TBEI starter relay fixing screw M6x10 2 10 Nm 7 37 lbf ft Components ar...

Page 92: ...Key 1 Engine speed sensor 2 Intake air pressure sensor 3 Intake air temperature sensor 4 Instrument panel 5 Engine control unit 6 Headlamp Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 92 ...

Page 93: ... sensor 16 Engine speed sensor pick up 17 Engine temperature sensor 18 Battery 19 Lambda probe 20 Fall sensor optional equipment 21 Main injection relay 22 Rear speed ABS sensor 23 Voltage regulator 24 ABS control unit Modulator 25 Front speed ABS sensor 26 EVC VCU control unit OPTION 02 Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 93 ...

Page 94: ...Key 1 Engine speed sensor 2 Intake air pressure sensor 3 Intake air temperature sensor 4 Instrument panel 5 Engine control unit 6 Headlamp Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 94 ...

Page 95: ...IFIED BASED ONLY ON THE FOLLOWING INDICATIONS THIS SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES RELAY LAYOUT ON THE ELECTRICAL CIRCUIT DIAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the electrical circuit diagram 6 Location on the vehicle under the top fairing near the headlamp START UP RELAY Location on the electrical circuit diagram 39 Location on the vehicle under th...

Page 96: ... secured to the frame instrument panel support and saddle mounting any critical issues and particular checks on connections and routing in order to achieve the vehicle reliability targets Other details not required for this purpose may be vague or even incorrect Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harnes...

Page 97: ...nnector check correct routing FRONT SECTION TABLE I 10 Connectors for Right and Left Light switch Front Stop Switch Clutch Switch front fork MAP sensor with rubber plug fitted properly front fork CDCi FRONT SECTION TABLES B C D 11 ABS Control Unit Connector correct positioning of the cap and correct cable harness routing 12 Front and rear ABS sensors connector speed CENTRAL SECTION TABLE A2 13 Aux...

Page 98: ...rect positioning of the Front and Rear Lambda probe 33 Check the connection and correct routing of the rotary sensor on the saddle mounting Left hand side 34 Check the T Map on the fork left stanchion for correct securing and cable routing 35 Check that the cables on the handlebar area are all soft When the handlebars are turned they should not be in traction 36 Check correct insertion of the oil ...

Page 99: ...D THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 99 ...

Page 100: ...ing the handlebar all the way both to the right and to the left the cables must not be under ten sion but they must also not be too slack with the handlebar straight TABLE B ELASTIC CLAMP ON FRONT BRAKE AND CLUTCH MICROSWITCHES Rubber clamp short Rubber clamp short Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 100 ...

Page 101: ...er clamps long TABLE C LEFT AND RIGHT LIGHT SWITCH Ensure that on the Right Light Switch of the aDD version the Heated Handgrips and Cruise con trols are present Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 101 ...

Page 102: ... connector is secured well The sheath must stay under the boot so that the cables are not visible Secure the two cables to the plastic cable grommet using the rubber clamp Rubber clamp short TABLE E INSTRUMENT PANEL SUPPORT Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 102 ...

Page 103: ... Large plastic clamps 4 5x280 mm 0 18x11 02 in Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 103 ...

Page 104: ...n to the rear shock absorber connector boot it must be inserted 1 1 5 cm Rubber clamp short Group the connectors of the various components and secure them using a clamp Large plastic clamp 4 5x280 mm 0 18x11 02 in Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 104 ...

Page 105: ...on the connectors of the components as il lustrated in the photo TABLE F DASHBOARD Check that the dashboard fastening lever is locked by the appropriate tab See red circle The boot must be inserted well and touch the bot tom of the dashboard TABLE G HORN Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 105 ...

Page 106: ...seats once the component is inserted Also check for the correct connection of all the bulbs and the correct routing of the cable harness 1 Headlamp screw gasket 2 Cable guide 3 Headlamp screw gasket TABLE I IGNITION SWITCH ASSEMBLY CABLE ROUTING The aerial cable must be routed behind the key contacts cable in order to prevent the tank from damaging it Electrical system Caponord 1200 Caponord 1200 ...

Page 107: ...tor as illustrated in the photo and ensure that it is fastened well Large plastic clamp 4 5x280 mm 0 18x11 02 in Large plastic clamp 4 5x280 mm 0 18x11 02 in TABLE L CABLE ROUTING FOR INSERTION IN FILTER BOX Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 107 ...

Page 108: ... in the photo and ensure that it is fastened well Pay particular attention that the yellow gasket is not pinched Connector support Position the Lambda Probe connector as illustra ted in the photo and ensure that it is fastened well Pay particular attention that the yellow gasket is not pinched Connector support Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 108 ...

Page 109: ...Small plastic clamp 2 5x160 mm 0 1x6 3 in Position the Left Hand Fan connector as illustrated in the photo and ensure that it is fastened well Before fitting the fairing remove it from the support tab and secure it to the radiator hose with a clamp Small plastic clamp 2 5x160 mm 0 1x6 3 in TABLE N VOLTAGE REGULATOR CABLE ROUTING AND CONNECTIONS Caponord 1200 Caponord 1200 Rally Electrical system E...

Page 110: ...of their seats once the component is inserted Check that all the connectors are correctly secured and positioned as illustrated in the photo Large plastic clamp 4 5x280 mm 0 1x11 02 in Small plastic clamp 2 5x160 mm 0 1x6 3 in TABLE O SPEED SENSOR CABLE ROUTING Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 110 ...

Page 111: ...TION Incorrect positioning of the sensor and or tightening of this screw may cause the ABS to malfunction Plastic clamp 2 5x160 mm 0 1x6 3 in Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 111 ...

Page 112: ... connects the left caliper to the ABS ECU This way it is ensured that the two securing points do not have relative movements and that the cable does not rub on the mudguard Cable grommet Cable grommets Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 112 ...

Page 113: ...n the cover and the frame as illustrated in the photo Route the front ABS Sensor above the cable har ness that goes to the instrument panel support TABLE P EVC VCU CABLE ROUTING Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 113 ...

Page 114: ...S RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A ENGINE Insert the injector connectors all the way until hearing a click The GREEN connector goes on the front cylinder the green water temperature sensor can be used as a point of reference Electr...

Page 115: ...ith the BLUE label and that the grey Security Lock is closed Check that the connector with WHITE tape is se cured will on the Demand WITHOUT the label and that the grey Security Lock is closed Connector support Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 115 ...

Page 116: ... 0 18x11 02 in As illustrated in the figure fasten the two Front Coil cables together using the appropriate cable grom met Cable grommet Check that the two Rear Coil connectors are con nected Check that the yellow rubber parts are not pinched 1 Cable grommet 2 Cable grommet Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 116 ...

Page 117: ... the filter box temperature sensor is cor rectly connected Check that the Rear ABS connector is secured correctly Check that the boot is inserted well and that the clamp fastens part of it and part of the sheath as illustrated in the figure Small plastic clamp 2 5x160 mm 0 1x160 in Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 117 ...

Page 118: ... that the cable grommet secures the ground cable the relay cable and the two rear coil cables Cable grommet To secure the cable on the engine block use the end closest to the label Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 118 ...

Page 119: ...S SCREW MAY CAUSE THE VEHICLE TO CATCH FIRE TABLE A2 ABS CONTROL UNIT CABLE Check that the rubber guard is mounted as illus trated in the figure Ensure that the ABS connector slide is well se cured Ensure that the ABS connector boot has been in serted well Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 119 ...

Page 120: ... 0 18x11 02 in TABLE A3 STARTER MOTOR Position the positive cable as illustrated in the fig ure and tighten the nut that connects the cable to the starter motor to torque Cover the nut and the square terminal of the cable with 0 5 grams of wa terproof dielectric grease then insert the boot on them and check that it has the hole Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 120 ...

Page 121: ...otor cable and incorrect securing may cause the vehicle to catch fire TABLE A4 FRONT LAMBDA PROBE For correct routing the front lambda probe must go into the cable grommet mounted on the front en gine head Cable grommet TABLE B FRAME Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 121 ...

Page 122: ...of the cover on the frame keep the clamp wide Large plastic clamp 4 5x280 mm 0 18x11 02 in Small plastic clamps 2 5x160 mm 0 1x6 3 in TABLE C FUEL TANK Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 122 ...

Page 123: ...gh the cable grommet as illus trated in the figure Check that the Lambda Probe connector is con nected well and that the yellow rubber gasket is not pinched Secure the cable with a clamp in or der to prevent contact with the exhaust Large plastic clamp 4 5x280 mm 0 18x11 02 in Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 123 ...

Page 124: ...g of the Lambda Probe cable as illustrated in the figure TABLE E GROUND CABLE ROUTING ON SAD DLE MOUNTING Large plastic clamps 4 5x280 mm 0 18x11 02 in Large plastic clamp 4 5x280 mm 0 18x11 02 in TABLE F ROUTING UNDER RIDER SADDLE Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 124 ...

Page 125: ...E G REAR SHOCK ABSORBER HOSE ROUTING WHERE APPLICABLE Insert the white connector and then the semi transparent connector with the boot just inserted Then close everything back up as shown in the photo Take care for the routing highlighted by red circles Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 125 ...

Page 126: ...bout 30 mm 1 18 in from the metallic reference 2 rubber clamps short combined to gether CENTRAL TABLE H SIDE STAND IF FITTED Small plastic clamp 2 5x160 mm 0 1x6 3 in Cable guide CENTRAL TABLE I ALARM CONNECTORS AND THEIR POSITIONING Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 126 ...

Page 127: ...rge plastic clamp 4 5x280 mm 0 18x11 02 in TABLE L GEAR SENSOR Check the connections for 1 Side stand if fitted 2 Gear sensor The smallest connector stays free Insert the connectors into the boot Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 127 ...

Page 128: ...D AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A REAR ABS SENSOR ROUTING Route the ABS sensor cable as shown in the fig ure Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 128 ...

Page 129: ...CAUTION Incorrect positioning of the sensor and or tightening of this screw may cause the ABS to malfunction Cable grommets Cable grommet Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 129 ...

Page 130: ...012 0 079 in TABLE B LICENSE PLATE HOLDER PRE FITTING Licence plate holder cable harness Check that the drainage hole for the water from both turn indicators both Front and Rear is facing downward TABLE C TAIL FAIRING ROUTING Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 130 ...

Page 131: ...uses are present CAUTION Incorrect securing of the two screws on the starter relay the one that joins the red cables and incorrect cable routing may cause the vehicle to catch fire Check that the connector is inserted well and that no PINs are pulled out Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 131 ...

Page 132: ...support as illustrated in the figure Position the USB socket connector as illustrated in the figure Check that the connector is connected well and that the yellow gasket is not pinched Large plastic clamp 4 5x280 mm 0 18x11 02 in Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 132 ...

Page 133: ...ng harness circled in red may cause the vehicle to catch fire TABLE C1 FALL SENSOR IF FITTED Position the fall sensor is illustrated in the figure Route the cable and the connector in side the battery compartment Connect the Fall Sensor to the relative connector General wiring diagram OPTION 01 CAPONORD 1200 Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 133 ...

Page 134: ...key 1 MULTIPLE CONNECTORS Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 134 ...

Page 135: ...HIFT 15 FRONT STOP SWITCH 16 REAR STOP SWITCH 17 CLUTCH SWITCH 18 IGNITION SWITCH 19 IMMOBILIZER AERIAL 20 SAFETY RELAY 21 TAIL LIGHT 22 LICENSE PLATE LIGHT 23 REAR RIGHT TURN INDICATOR 24 REAR LEFT TURN INDICATOR 25 EVC CONTROL UNIT 26 27 28 29 30 31 EXHAUST VALVE MOTOR 32 ALTERNATOR 33 VOLTAGE REGULATOR 34 REAR ABS SENSOR 35 FRONT ABS SENSOR 36 ABS CONTROL UNIT 37 MAIN FUSES 2 38 STARTER MOTOR 3...

Page 136: ...RONT CYLINDER LAMBDA PROBE 58 REAR CYLINDER INJECTOR MARELLI INTERNAL 59 FRONT CYLINDER INJECTOR MARELLI INTERNAL 60 REAR SIDE COIL 61 FRONT SIDE COIL 62 REAR CENTRAL COIL 63 FRONT CENTRAL COIL 64 SPARK PLUG 65 REAR MOTORISED THROTTLE 66 FRONT MOTORISED THROTTLE 67 DEMAND SENSOR 68 ENGINE SPEED SENSOR 69 7SM MOTOR CONTROL UNIT 70 ANTI THEFT LED IF FITTED 71 ANTI THEFT IF FITTED 72 FRONT MAP SENSOR...

Page 137: ...78 REAR INJECTOR 2 SYNERJET EXTERNAL 80 BLUEDASH IF FITTED 81 FOG LIGHT LED IF FITTED CAPONORD 1200 TRAVEL PACK Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 137 ...

Page 138: ...key 1 MULTIPLE CONNECTORS Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 138 ...

Page 139: ...H SWITCH 18 IGNITION SWITCH 19 IMMOBILIZER AERIAL 20 SAFETY RELAY 21 TAIL LIGHT 22 LICENSE PLATE LIGHT 23 REAR RIGHT TURN INDICATOR 24 REAR LEFT TURN INDICATOR 25 VCU CONTROL UNIT 26 PUMP MOTOR 27 REAR SOLENOID VALVE 28 FRONT SOLENOID VALVE 29 REAR ROTARY SENSOR 30 FRONT TEMPERATURE AND PRESSURE SENSOR 31 EXHAUST VALVE MOTOR 32 ALTERNATOR 33 VOLTAGE REGULATOR 34 REAR ABS SENSOR 35 FRONT ABS SENSOR...

Page 140: ...NDER LAMBDA PROBE 58 REAR CYLINDER INJECTOR MARELLI INTERNAL 59 FRONT CYLINDER INJECTOR MARELLI INTERNAL 60 REAR SIDE COIL 61 FRONT SIDE COIL 62 REAR CENTRAL COIL 63 FRONT CENTRAL COIL 64 SPARK PLUG 65 REAR MOTORISED THROTTLE 66 FRONT MOTORISED THROTTLE 67 DEMAND SENSOR 68 ENGINE SPEED SENSOR 69 7SM MOTOR CONTROL UNIT 70 ANTI THEFT LED IF FITTED 71 ANTI THEFT IF FITTED 72 FRONT MAP SENSOR 73 REAR ...

Page 141: ...ASH IF FITTED 81 FOG LIGHT LED IF FITTED Colour key Ar Orange Az Light blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red Ro Pink V Green Vi Violet OPTION 02 CAPONORD 1200 RALLY Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 141 ...

Page 142: ...key 1 MULTIPLE CONNECTORS 2 FRONT LEFT TURN INDICATOR 3 FRONT HEADLAMP 4 FRONT RIGHT TURN INDICATOR 5 HIGH BEAM LIGHTS RELAY 6 LIGHT RELAY Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 142 ...

Page 143: ...E LIGHT 23 REAR RIGHT TURN INDICATOR 24 REAR LEFT TURN INDICATOR 25 VCU CONTROL UNIT 26 PUMP MOTOR 27 REAR SOLENOID VALVE 28 FRONT SOLENOID VALVE 29 REAR ROTARY SENSOR 30 FRONT TEMPERATURE PRESSURE SENSOR 31 EXHAUST VALVE MOTOR 32 ALTERNATOR 33 VOLTAGE REGULATOR 34 REAR ABS SENSOR 35 FRONT ABS SENSOR 36 ABS CONTROL UNIT 37 MAIN FUSES 2 38 STARTER MOTOR 39 START UP RELAY 40 MAIN FUSE 1 41 BATTERY 4...

Page 144: ... INTERNAL 60 REAR SIDE COIL 61 FRONT SIDE COIL 62 REAR CENTRAL COIL 63 FRONT CENTRAL COIL 64 SPARK PLUG 65 REAR MOTORISED THROTTLE 66 FRONT MOTORISED THROTTLE 67 DEMAND SENSOR 68 ENGINE SPEED SENSOR 69 7SM MOTOR CONTROL UNIT 70 ANTI THEFT LED IF FITTED 71 ANTI THEFT IF FITTED 72 FRONT MAP SENSOR 73 REAR MAP SENSOR 74 WATER TEMPERATURE SENSOR 75 SECONDARY FUSES 76 AUXILIARY FUSE 2 EVC 77 FRONT INJE...

Page 145: ... TROUBLESHOOTING PROCEDURES ON THE VEHICLE CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V CONNECTOR CHECK PROCEDURE The procedure includes the following checks 1 Observation and check of the connector correct position on the component or on the coupling con nector making sure that the locking catch is re leased 2 Observation of the terminals on the connector no rust marks or dirt should be present an...

Page 146: ...HIS TEST ARE MEANINGLESS Checking GROUND CONNECTION Purpose of check the purpose of this check is to verify that a cable or circuit is correctly connected to the ground of the vehicle Tester set the tester selector to the continuity symbol and place one of the tester probes on the vehicle ground point or on the battery negative pole and the other probe on the cable under inspection Nor mally the t...

Page 147: ...will appear on the digital display blinking slowly This message warns the rider that the key safety code must be entered To access the function hold button A pressed for a few seconds Enter the function code 222 briefly pressing but ton B Enter the new 5 digit personal code briefly press ing button B The code remains displayed upon its entering until the instrument panel is switched off Code modif...

Page 148: ...osis tool After connecting the motorcycle with the diagnosis tool turn on the instrument panel and enter the user code if requested In the screen page Activations Modify stored keys Complete activation start the procedure of the keys storage The storage of the first key takes place instantly and afterwards it is requested to enter the second key that is to be done within 20 seconds reverse countin...

Page 149: ... strument panel and from the Activations User code restoration screen page start the proce dure The identification of the first key takes place im mediately then it is requested to enter the second key to be performed within 20 seconds reverse count After the identification of at least two keys the user code is cleared to zero and it is possible to enter a new one following the appropriate procedu...

Page 150: ...ore the new key Error code B0004 ERROR READING KEY CODE The key has no transponder or the transponder is damaged Troubleshooting Replace the key and store it Error code B0005 AERIAL ELECTRICAL FAILURE A C O S C An electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting Check the sensor connector on the cable harness and the instrument panel conn...

Page 151: ...ession in progress and start a new one with the dashboard Go to the adjustments page and carry out a vehicle configuration reset Follow the instructions displayed on the PC Check in the dashboard diagnostics section for any saved errors and delete any which may be present Access the Marelli 7SM engine control unit diagnostics and check for any saved errors deleting any which may be present Diagnos...

Page 152: ...ace the sensor Error code B0002 OIL PRESSURE FAILURE Oil sensor disconnected alarm This alarm occurs when the sensor is disconnected rpm higher than 900 Identification Oil warning light flashing Troubleshooting Disconnect the connector of the component and check the insulation from ground if the insulation is not present restore the cabling otherwise replace the sensor It this error persists use a...

Page 153: ...s when for various reasons the activation button is locked Identification Fixed warning light Troubleshooting Check the correct operation of the contact of the button and the insulation from ground and from supply of PIN 15 of the instrument panel grey connector Battery recharge circuit RECHARGING SYSTEM Remove the tank and the filter casing Disconnect the three way connector 1 white NOTE THE ENGI...

Page 154: ...ed obtained by touching the two lugs Example Resistance of stage 1 read on the display 0 65 Ohm Resistance of the wires read on the display 0 47 Ohm Effective resistance stage 1 0 65 0 47 0 18 Ohm If there is a significant difference between one stage and another other than 0 15 Ohm this means that the alternator is defective and must be replaced Electrical system Caponord 1200 Caponord 1200 Rally...

Page 155: ...THOSE DETECTED WITH THE ENGINE COLD EMPTY VOLTAGE rpm 2000 6000 8000 Vm linked voltage Reference values V rms 20 30 75 85 95 105 Short circuit current For a correct detection of the short cir cuit current a connector must be pre pared that generates a downstream short circuit between the three alterna tor cables Start the engine and with an ammeter clamp measure each single cable If there is a sig...

Page 156: ...heck Function Communicates to the control unit the will to start up the engine Operation Operating principle Press the start up button to close the specific cir cuit taking the PIN 58 of the control unit to a voltage equal to zero ground closing Level in electrical circuit diagram Start up signal Location on the vehicle right light switch connector between filter box and wa ter radiator at the cen...

Page 157: ...cause Fault in the switch lock of the engine start up The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check the locking cause and restore Lights list OPTION 01 Front headlamp Characteristic Front daylight running lights 2V 5W W5WB x 2 Low beam light 12V 55W H11 x 2 High beam light 12V 55W H11 Taillight Characteristic Rear daylight running li...

Page 158: ...stop light LED Fuses AUXILIARY FUSES front left above the water radiator 1 Safety relay stop lights horn daylight running light license plate light 10 A 2 Instrument panel anti theft VCU BlueDash positive live 7 5 A 3 Engine control unit positive live 15 A 4 Permanent engine control unit positive 7 5 A 5 Coils petrol pump injectors 15 A 6 Low beam high beam light logic 15 A 7 Fans 15 A Electrical ...

Page 159: ... Battery recharge primary injection relay live positive permanent BlueDash positive 30 A B Permanent ABS control unit positive 20 A C USB jack heated handgrips anti theft GPS BlueDash 7 5 A D Spare fuses 30 20 7 5 A Control unit Unscrew and remove the control unit cover screws Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 159 ...

Page 160: ... Unscrew and remove the control unit fixing screw Slide off the control unit from the mountings and remove it from the ve hicle Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 160 ...

Page 161: ...e main component involves the control unit Location on the vehicle above the filter box connector on the 52 PIN connector ENGINE control unit 28 PIN connector VEHICLE Pin out See the CONNECTORS section DIAGNOSTICS INSTRUMENT PARAMETERS ISO Screen page screen example value with key set to ON ISO Code Type approval Code Mapping Marelli spare part code IAW7SMHW430 Frame number VIN or diagnostics inst...

Page 162: ...number of the DIAGNOSTICS INSTRUMENT that has carried out the last control unit remapping BOOT version Control unit serial number NIP Vehicle model Internal code IDVAG1 Internal code IDEEKE HW code Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 162 ...

Page 163: ...rrection rear cylinder value Front cylinder fuel adaptive correction Rear cylinder fuel adaptive correction Grip opening percentage Advance front cylinder ignition central spark plug Advance front cylinder ignition side spark plug Advance rear cylinder ignition central spark plug Advance rear cylinder ignition side spark plug Motor temperature C Intake air temperature C Front Cylinder Intake Press...

Page 164: ...osition mV Front throttle position potentiometer 2 Rear throttle position potentiometer 2 Motor temperature at start C Front cylinder injection time ms Rear cylinder injection time ms Nominal idle speed rpm Vehicle speed km h Front wheel speed km h Rear wheel circumference mm Final drive gear ratio CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS...

Page 165: ...t carried out Front throttle self acquisition Ice Interrupted Carried out Limp home Closed throttle stop Springs check Limp home self acquisition Initialise Rear throttle self acquisition Ice Interrupted Carried out Limp home Closed throttle stop Springs check Limp home self acquisition Initialise Throttle self learning with diagnostics instrument Carried out Not carried out Start up enabling Yes ...

Page 166: ...ilia Traction Control Present Not present Exhaust butterfly valve Indeterminate Search Self cleaning Operation Failure Home position search Performing ATC on bend Present Not present AQS Aprilia Quick Shift Present Not present ABS Present Not present Front brake lever Pulled Released rear brake pedal Pressed Released ADD Aprilia Dynamic Damping Present Not present Cruise control button Pressed Rel...

Page 167: ...l Rear cylinder side coil Front cylinder side coil Internal rear cylinder injector Internal front cylinder injector External front cylinder injector External rear cylinder injector Deleting stored errors Freezes and saves the parameter and states values Rpm indicator Errors ambient parameters reading STOP light Fuel pump Heater rear lambda probe Heater front lambda probe Fan DIAGNOSTICS INSTRUMENT...

Page 168: ...it is open an interruption has been detected Troubleshooting If shorted to positive check the relay electrical specifications are correct by disconnecting it from the cable harness If they are not correct replace the relay if OK restore the cable harness Blue Pink cable If shorted to negative check the relay electrical specifications are correct by disconnecting it from the cable harness If they a...

Page 169: ...does not indicate the presence of this error even in the ATT status Troubleshooting Continue fault search for the other errors detected DIAGNOSTICS INSTRUMENT ADJUSTMENTS Handle self learning Throttle self learning with diagnostics instrument EEPROM reset Saved data file download Saved data file deletion Vehicle configuration Exhaust valve step 1 Acquire home position Exhaust valve step 2 Self lea...

Page 170: ...t part on the right side connector on the control unit Pin out See the CONNECTORS section DIAGNOSTICS INSTRUMENT DATA IDMODELV current stored VEICCFG current stored HW version Boot version SW version Calibration DIAGNOSTICS INSTRUMENT PARAMETERS Battery voltage V Exhaust butterfly valve potentiometer voltage mV Rotary sensor track 1 mV Rotary sensor track 2 mV Electrical system Caponord 1200 Capon...

Page 171: ...nt suspension valve Operation Constant current fault Zero current fault Rear suspension valve Operation Constant current fault Zero current fault Cruise Control button Released Pressed Short circuit fault Open circuit fault Undetermined fault Front brake switch Released Pressed Short circuit fault Open circuit fault Rear brake switch Released Pressed Short circuit fault Open circuit fault Exhaust ...

Page 172: ... coincide the VCU is programmed for a vehicle other than the one on which it is installed Troubleshooting Change the engine control unit or reset the VCU using the diagnostics instrument in this case the VCU preparation procedure must be carried out as described in the DIAGNOSTICS INSTRUMENT ADJUSTMENTS section Control unit internal error C1200 Error cause The VCU memory has been cancelled followi...

Page 173: ...le value with key ON 12 0 V Example value with engine on 14 2 V Value drawn from the signal read without taking into account any recovery CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT LOGIC ERRORS Battery voltage P05...

Page 174: ...ow the minimum threshold 6 V with engine on 10 V with engine off or above the maximum threshold 16 V Troubleshooting Check the battery Speed sensor VEHICLE FRONT SPEED SENSOR FUNCTION To indicate the vehicle speed by read ing the front wheel turning speed OPERATION OPERATING PRINCIPLE Magne toresistive sensor a square wave pulse is gener ated with voltage approx between 11 55 V and 11 25 V WIRING ...

Page 175: ...ensor retainer If it is not OK restore it If it is OK check if the tone wheel is dirty deformed or wrongly fixed If any of this happens replace the tone wheel Otherwise replace the speed sensor 5D92 the signal becomes weak periodically Possible tone wheel fault due to deformations or dirt the surface of the wheel bearings may be deteriorated In very rare cases abnormal tone wheel vibrations Troubl...

Page 176: ...heel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK check that the tyre size is the correct one If it is not OK replace it If it is OK check that the tyre pressure is the correct one If it is not OK restore it if it is OK replace the speed sensor VEHICLE REAR SPEED SENSOR FUNCTION To indicate the vehicle speed by r...

Page 177: ...sor retainer If it is not OK restore it If it is OK check if the tone wheel is dirty deformed or wrongly fixed If any of this happens replace the tone wheel Otherwise replace the speed sensor 5DA2 the signal becomes weak periodically Possible tone wheel fault due to deformations or dirt the surface of the wheel bearings may be deteriorated In very rare cases abnormal tone wheel vibrations Troubles...

Page 178: ...it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK check that the tyre size is the correct one If it is not OK replace it If it is OK check that the tyre pressure is the correct one If it is not OK restore it if it is OK replace the speed sensor Engine rpm sensor...

Page 179: ...ICS OF THE SENSOR IF NOT OK REPLACE THE SENSOR IF OK CHECK THAT THERE IS CONTINUITY ON BOTH CABLES SUPPLY INSULATION AND GROUND INSULATION CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR IF NOT OK RE STORE THE CABLE HARNESS REPLACE THE SENSOR IF OK PERFORM THE TEST FROM PIN 20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR DIAGNOSTIC TOOL LOGIC ERRORS P0336 Engine speed sensor Sig...

Page 180: ...bles opening and closing actuate on a scroll mounted on a shaft which is sent back to its home position by a return spring On the shaft covers there are 2 double track potentiometers 4 control tracks by means of which the torque demand is read and checked The 4 potentiometers are tinned and magnetically controlled contactless they cannot be overhauled nor replaced Level in electrical circuit diagr...

Page 181: ...alue with key ON 1070 mV Example value with engine on Voltage value times 2 of the front potentiometer track B White rear connector throttle grip position sensor track C Example value with key ON 3560 mV Example value with engine on Voltage value of the rear potentiometer track C White rear connector throttle grip position sensor track D Example value with key ON 3555 mV Example value with engine ...

Page 182: ...tor Throttle Grip Position Sensor track A disconnect the connector and read the value indi cated by the diagnostics instrument if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open shorted to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK rest...

Page 183: ...rol unit if not restore the wiring DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS White rear connector throttle grip position sensor track C P0152 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 23 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PI...

Page 184: ...or connector or the control unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the switch key set to ON check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is co...

Page 185: ...e of the front side sensor tracks A B does not coincide with the value of the rear sensor tracks C D Troubleshooting Replace the throttle grip sensor DIAGNOSTICS TOOL ADJUSTABLE PARAMETERS Handle self learning RESET PROCEDURE If Marelli control unit or its mapping are replaced or if you carry out control unit EEPROM zero setting or if you replace the throttle grip sensor it is necessary to carry o...

Page 186: ...tion on the vehicle rear cylinder sensor on rear throttle body right side front cylin der sensor on front throttle body left side connector on the sensor Electrical specifications Pin out 1 Power supply 5V 2 Ground connection 3 Output signal DIAGNOSIS INSTRUMENT PARAMETERS Front Cylinder Intake Pressure Example value with key ON 1004 mbar Example value with engine on 715 mbar NOTE pressure read by...

Page 187: ... if the value does not vary it means that the cable is shorted between the control unit connector and the sensor connector restore the cable harness Replace the sensor if the value varies If the circuit is open shorted to negative check the Marelli control unit connector and the sensor connector if not OK restore If everything is OK with key set to OFF check if there is continuity between the PIN ...

Page 188: ...connector PIN 25 and the sensor connector PIN 1 if not OK restore the cable harness if OK replace the control unit if there is 5V voltage at PIN 1 and with key set to ON check the continuity to ground of the sensor connector PIN 3 if not OK restore the cable harness if OK replace the sensor DIAGNOSIS INSTRUMENT LOGIC ERRORS front cylinder air pressure sensor P0107 signal not valid Error cause Acco...

Page 189: ...Error for unexpected air intake in the rear cylinder manifold P0211 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is higher than the estimated one intake manifold condi tions Troubleshooting Check the conditions of the intake manifold and cleanliness of the hole for pressure reading Estimation error ...

Page 190: ... of the intake manifold and cleanliness of the hole for pressure reading Pressure too low at rear cylinder manifold error P0218 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the conditions of the intake manifold and cl...

Page 191: ...mple value with key ON 40 C Example value with engine on 40 C Value drawn from the signal read without taking into account any recovery the value in the example refers to an open circuit Engine temperature at start up Example value with key ON 40 C Example value with engine on 25 C The temperature value is stored during engine start up With key ON value 40 C is read CAUTION BEFORE CARRYING OUT ANY...

Page 192: ...INE connector PIN 6 or 17 and the sensor connector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If shorted to negative check sensor correct resistance if resistance is null replace the sen sor if resistance is correct it means that the Yellow Brown cable has ground connec...

Page 193: ...in out 1 0 5 V signal 2 Ground connection DIAGNOSIS INSTRUMENT PARAMETERS Air temperature Example value with key ON 45 C 113 F In case of recovery this value is set by the control unit Air temperature pre Recovery Example value with key ON 40 C 40 0 F Value drawn from the signal read without taking into account any recovery the value in the exam ple refers to an open circuit CAUTION BEFORE CARRYIN...

Page 194: ...ENGINE PIN 37 and sensor PIN 1 check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If OK check continuity between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If sh...

Page 195: ...back of the filter box Electrical specifications Heater circuit 7 9Ω at Ambient temp Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater ground connection white cable 4 Heater power supply white cable DIAGNOSTICS INSTRUMENT PARAMETERS Lambda probe Example value with key ON 0 mV Example value with engine on 100 900 mV If there is a short circuit at 5 V or above the lambda probe pa...

Page 196: ...nsor signal to keep the combustion as close as possible to the stoichiometric value DIAGNOSTICS INSTRUMENT ACTIVATION Lambda probe heating The auxiliary injection relay No 46 in the wiring diagram placed in the front relay box left side CHECK however the identification of the relay with the colour of the cables is ener gised and the heating circuit is closed to ground 5 times pin 3 of the lambda p...

Page 197: ...t resistance of the sensor if not OK replace the sensor if OK restore the cable harness green red cable If circuit is open shorted to negative check circuit continuity from probe connector PIN 3 and 4 toward the probe if it is not OK replace the probe if it is OK check the sensor connector and the Marelli control unit connector if it is not OK restore if it is OK with key set to ON and sensor conn...

Page 198: ...e probe connector and the auxiliary injection relay No 46 in the wiring diagram placed in the front relay box left side CHECK however the identification of the relay with the colour of the cables If there are also coil lower and upper injector and secondary air errors check the relay and its excitation and power line if there is voltage at PIN 4 check the Black cable ground insulation PIN 3 if not...

Page 199: ... Synerject are always working whereas the internal ones Marelli aka high pressure injectors are opened only when high power is required Level in electrical circuit diagram Coils and injectors Location A External injectors Synerject B Internal injectors Marelli on the vehicle intake manifold connector on injectors Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 199 ...

Page 200: ...TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT ACTIVATION Internal front cylinder injector The auxiliary injection relay No 46 in the wiring diagram placed in the front relay box left side CHECK however the identification of the relay with the colour of the cables is ener gised for 5 seconds...

Page 201: ...s necessary for correct activation no error indications are displayed in case of lack of activation External rear cylinder injector The auxiliary injection relay No 46 in the wiring diagram placed in the front relay box left side CHECK however the identification of the relay with the colour of the cables is ener gised for 5 seconds and the injector cable connected to control unit is closed to grou...

Page 202: ...onnector set the key to ON and check if there is a ground connection on the orange white cable if there is connection restore the cable harness If there is no connection replace the injector If the circuit is open check the connector on the component and the Marelli control unit connector if not OK restore If OK check cable continuity between the ENGINE PIN 46 and component PIN 2 and restore the c...

Page 203: ...estore the cabling otherwise replace the injector If shorted to negative disconnect the injector connector set the key to ON and check if there is a ground connection on the White Black cable if there is connection restore the cable harness If there is no connection replace the injector If the circuit is open check the connector on the component and the Marelli control unit connector if not OK res...

Page 204: ...30 seconds The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS fuel pump relay control P0230 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 73 of the VEHICLE con nector If the circuit is open short...

Page 205: ...rs connector FRONT CENTRAL COIL with long cable left side on the frame near filter box cover above the front side coil connector FRONT SIDE COIL with short cable and retaining tongue left side on the frame near filter box cover below the front central coil connector REAR CENTRAL COIL with long cable at the centre under the filter box at the back compared to connector REAR SIDE COIL with short cabl...

Page 206: ...e coil Purple Grey cable is closed to ground for 2 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation Front Side Coil The auxiliary injection relay No 46 in the wiring diagram placed in the front relay box ...

Page 207: ...ness Rear cylinder central coil P0352 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 27 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 27 of the ENGINE connector Troubleshooting If shorted to positive disconnect the coil connector set the key to ON...

Page 208: ... OK restore cable harness Rear cylinder side coil P0354 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 1 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 1 of the ENGINE connector Troubleshooting If shorted to positive disconnect the coil connector s...

Page 209: ...ntiometer signal 2 5 throttle valve control 6 ground connection DIAGNOSIS INSTRUMENT PARAMETERS Front cylinder throttle correction Example value with key ON 0 0 Example value with engine at idle 0 5 The system reading the intake pressure tries to balance the intake pressures between the front cylinder and the rear one working on the throttle position an acceptable value should be between 0 8º and ...

Page 210: ...ar throttle Potentiometer 1 voltage Example value with key ON 746 mV Example value with engine on 605 mV Front throttle Potentiometer 2 degrees Example value with key ON 5 5 Example value with engine on 2 5 With key set to ON the throttle is kept in position by the springs around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal to 0 5 When ...

Page 211: ...AUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Front throttle automatic self acquisition ice interrupted carried out limp home closed throttle stop springs check limp home self ac quisition initialise Indicates ...

Page 212: ...he two terminals If not OK restore the cable harness if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body potentiometer 2 sensor front throttle position P0122 short circuit to p...

Page 213: ...at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body potentiometer 2 sensor rear throttle position P0127 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 21 If the circuit is open shorted to negative voltage equal to zero has been detecte...

Page 214: ...ck that the resistance from the throttle control unit connector between PIN 29 and 41 is within 1 and 2 5 Ohm if it is not replace the throttle body if it is check that the throttle body is not mechanically blocked if blocked solve the problem and replace the body if it is not replace the control unit Rear throttle control circuit P0186 short circuit to positive short circuit to negative open circ...

Page 215: ... Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor front throttle position P0123 signal not valid Error cause Signal not wi...

Page 216: ...pare it to the Potentiometer 1 Front throttle voltage Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN 36 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor rear throttle posi...

Page 217: ... instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check if the throttle body and the intake duct are clean If OK replace the throttle body Front throttle mechanical springs self acquisition P0161 failed test Error cause Return time of the throttle kept in position by the springs not within the expected limits the causes can be a deterioration of ...

Page 218: ...g throttle self learning Front throttle position error P0167 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body Rear throttle Limp Home self acquisition P0180 failed test Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does not indicate t...

Page 219: ...ottle body is clean and that there is no ice or condensation in the intake duct If OK replace the throttle body Rear throttle supply voltage during self acquisition P0184 low power supply voltage Error cause The throttle power supply voltage is too low to carry out the self acquisition test correctly at each key ON The instrument panel does not indicate the presence of this error even in the ATT s...

Page 220: ...ut delete possible errors on the vehicle and then with key set to ON check that the statuses are Carried out If necessary carry out Throttle self learning process on the adjustable parameters screen page screwdriver and hammer and check again that the Throttle self learning with diagnostics instrument status indicates Carried out and that the Front throttle automatic self acquisition or Rear throt...

Page 221: ...on on the vehicle under chain pinion be hind the pinion cover connector left side on flywheel cover Electrical characteristics PIN 64 gear indication closed circuit continuity gear engaged open circuit infinite resistance Gear engaged circuit resistance 1st gear 0 8 kohm 2nd gear 0 5 kohm 3rd gear 15 0 kohm 4th gear 6 9 kohm 5th gear 2 8 kohm 6th gear 1 5 kohm Pin out White Black ground from ECU L...

Page 222: ...ised replace the sensor there is an interruption or a short circuit to positive of the pink black cable in the section between the sensor connector and the sensor or inside the sensor itself If short circuit to negative disconnect the sensor connector and with key ON check the voltage of the Grey Black cable if it is equal to zero restore the wiring harness if it is equal to approx 5V replace the ...

Page 223: ...Indication on the diagnostics instrument always up disconnect the terminals from the sensor and check if there is continuity between the two PINS with stand down if there is continuity replace the sensor if the circuit is open it means that the brown green cable from sensor PIN 2 to VEHICLE connector PIN 70 is short circuit to ground restore the cable harness Bank angle sensor IF APPLICABLE Functi...

Page 224: ...f not OK restore the cable harness If OK check continuity to ground of PIN 2 pink black cable if there is no continuity restore the cable harness otherwise with key set to ON check if there is 5V voltage at PIN 1 orange black cable If there is not check the Marelli control unit connector PIN 65 Indication on the diagnostics instrument always Tip over disconnect the connector and with sensor uprigh...

Page 225: ... normally open drive coil resistance 110 Ohm 10 DIAGNOSTICS INSTRUMENT STATUSES Fan relay on off DIAGNOSTICS INSTRUMENT ACTIVATION Fan The fan relay No 43 in the wiring dia gram is energised for 10 seconds The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activa tion CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ ...

Page 226: ...s open check the relay electrical characteristics are correct by disconnecting it from the cable harness if not OK replace the relay if OK check relay connector and VEHICLE connector of the Marelli control unit if not OK restore if OK check continuity of cable harness Brown cable RUN STOP switch Function It tells the control unit if the rider wishes to enable engine start up or to keep the engine ...

Page 227: ...harness if OK set the key to OFF and check the VEHICLE connector and the engine vehicle cable harness connector if it is not OK restore if it is OK check the continuity of the Yellow Red cable between the switch connector and VEHICLE connector PIN 78 if not OK restore the cable harness if OK replace the Marelli control unit Indication on the diagnostics instrument always on RUN disconnect the conn...

Page 228: ...thresholds defined in calibration the valve begins to open according to the programmed logic Level in electrical circuit diagram Exhaust valve control unit Caponord 1200 VCU Vehicle Control Unit Caponord 1200 Trav el Pack Location On the vehicle the motor is placed in the front lower part of the engine The valve in the exhaust duct Connector on the motor Connector 1 Caponord 1200 2 Caponord 1200 T...

Page 229: ...ing travel limit of the valve Using the appropriate adjuster screw tension the lower cable until tensioning is as close as possible to that of the upper cable at the risk of the following adjustment with the instrument failing Tightening the lower cable will probably have caused the travel limit to shift repeat the procedure until the correct position is obtained Turn the key to ON CAUTION THE ZER...

Page 230: ...always with cables disconnected and key set to ON check normal rotation of the electric motor and replace motor potentiometer does not work correctly DIAGNOSTICS INSTRUMENT ADJUSTABLE PARAMETERS Acquire exhaust butterfly valve zero position NOTE Motor is placed in a reference position to correctly search mechanical stop later Exhaust butterfly valve self acquisition NOTE Search minimum and maximum...

Page 231: ...onnect the two connectors and check the continuity of the cable between motor PIN 4 EVC PIN C1 and between motor PIN 5 EVC PIN A1 If the cable harness is intact replace the component If shorted to negative disconnect the motor connector and check ground and PIN 4 and 5 insulation if insulation is not present restore the cable harness otherwise replace the com ponent If shorted to positive short ci...

Page 232: ...rs special attention to oxidation and check cables resistance if not OK restore if OK always with cables disconnected and key set to ON check normal rotation of the electric motor and replace motor potentiometer does not work correctly DIAGNOSTICS INSTRUMENT ADJUSTABLE PARAMETERS Acquire exhaust butterfly valve zero position NOTE Motor is placed in a reference position to correctly search mechanic...

Page 233: ... two connectors and check the continuity of the cable between motor PIN 4 VCU PIN L1 and between motor PIN 5 VCU PIN L2 If the cable harness is intact replace the com ponent If shorted to negative disconnect the motor connector and check ground and PIN 4 and 5 insulation if insulation is not present restore the cable harness otherwise replace the com ponent If shorted to positive short circuit bet...

Page 234: ...place the component Command output error exhaust valve open circuit C1615 Error cause Command circuit interruption detected Recovery valve locked Troubleshooting Check the component connector and the VCU connector Disconnect the two connectors and check the continuity of the cable between motor PIN 4 VCU PIN L1 and between valve PIN 5 VCU PIN L2 If the cable harness is intact replace the component...

Page 235: ...n the handlebar for approximately 2 seconds the in dicator light on the instrument panel flashes in order to signal that Cruise Control is ON The speed set must fall within the ranges listed below 3rd gear 50 100 kph 4th gear 60 120 kph 5th gear 65 160 kph 6th gear 70 180 kph Once the desired speed is reached the system may be activated SET state by pressing the cruise control button briefly the i...

Page 236: ...or light turns off if the Cruise ON OFF button is pressed and held in the RUN STOP switch is set to STOP the key is turned to OFF Level in electrical circuit diagram Pre installations and accessories Location On the vehicle on the handlebar right hand side Connector under the dashboard cov er Pin out Br Bl Ground Gr Signal DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS VCU ERRORS Cruise Control ON OFF b...

Page 237: ...ption found on the ground cable between VCU connector PIN A4 and light switch connector PIN 2 Gr cable Troubleshooting Check the Cruise Control power cable continuity between the VCU connector PIN F4 and the light switch connector PIN 1 Br Bl cable Check the Cruise Control power cable continuity between the VCU connector PIN F4 and the light switch connector PIN 2 Gr cable If faults are found rest...

Page 238: ... 220 Ohms 10 with the button pressed If faults are found the light switch must be replaced Recovery Cruise Control does not activate Brake switch WHERE DIAGNOSIS IS APPLICABLE Function To communicate to the VCU in braking phase Operation Operating principle Depending on the brake lever condition pulled released the switch communicates the status to the VCU Level in electrical circuit diagram VCU V...

Page 239: ...nuity between PIN 1 G Ro and PIN 2 Gr N to the pulled brake lever and infinite resistance with the lever released Also check that there is continuity between PIN 3 M Bi and PIN 2 Gr N with the brake lever released and infinite resistance with the lever pulled Otherwise replace the brake switch Recovery If current is constant on the fork cruise control does not activate Front brake switch open circ...

Page 240: ...or PIN 3 M V Also check that the connector PIN 3 M V is insulated from ground and power If faults are found restore the cable harness If the checks return positive results check on the switch side connector that there is continuity between PIN 1 G Vi and PIN 2 Gr N to the pulled brake lever and infinite resistance with the lever released Also check that there is continuity between PIN 3 M V and PI...

Page 241: ...spension system to adapt hy draulic damping of the fork and shock absorbers electronically and in real time depending on the stress received Operation Operating principle Suspension damping is controlled by the VCU The solenoid valves inserted in the fork shock ab sorber adjust hydraulic braking based on the cur rent that powers them minimum current 0mA suspension is stiff max imum hydraulic braki...

Page 242: ...oubleshooting Check the component connector and the VCU connector Disconnect the two connectors and check for continuity of the cable between sensor PIN and VCU PIN C1 and restore the cable harness If the cable harness is intact replace the shock absorber Disconnect the front suspension valve and the VCU Check that there is continuity between the valve connector PIN 1 Az and VCU PIN C1 Check that ...

Page 243: ...able harness is intact replace the suspension Disconnect the rear suspension valve and the VCU Check that there is continuity between the valve connector PIN 1 R and VCU PIN F1 Check that there is continuity between the valve connector PIN 2 Green and VCU PIN E1 If faults are found restore the cable harness If the checks return positive results check on the valve side connector that the resistance...

Page 244: ...t connector and the VCU connector Disconnect the two connectors and check for continuity of the cable between Valve PIN and VCU PIN E1 and restore the cable harness If the cable harness is intact replace the valve Temperature and pressure sensor IF APPLICABLE Function Read the fork compression rebound temperature and speed Operation Operating principle The system by means of the VCU Vehicle Contro...

Page 245: ...1 and 3 If the checks return positive results replace the sensor Recovery Constant current on the fork Pressure sensor open error C1408 Error cause Circuit interruption detected Troubleshooting Check the component connector and the VCU connector Disconnect the two connectors and check for continuity of the cable between sensor PIN 4 and VCU PIN A3 and restore the cable harness If the cable harness...

Page 246: ...he VCU connector Disconnect the two connectors and check for continuity of the cable between sensor PIN 2 and VCU PIN D1 and restore the cable harness If the cable harness is intact replace the sensor Check the continuity between sensor connector PIN 1 and VCU PIN F3 Check the continuity between sensor connector PIN 2 and VCU PIN D1 Also check that there are 5V between connector PIN 1 and 3 If the...

Page 247: ... must be reset To reset place the motorcycle on the central stand with the rear wheel lifted from the ground or if there is no central stand follow the lifting instructions in the chapter Rear shock ab sorber removal DIAGNOSTIC TOOL ELECTRICAL ERRORS VCU ERRORS Rotary sensor error Output 1 short circuit or open circuit C1404 Error cause If short circuit excessive voltage is found or null voltage b...

Page 248: ...ation from ground and power between sensor PIN 5 and VCU PIN C3 if insulation is not present restore the cable harness otherwise replace the sensor If short circuit check the continuity between sensor connector PIN 5 and VCU PIN C3 If there is no continuity restore the cable harness If the circuit is open check the sensor connector and the VCU connector Disconnect the two connectors and check for ...

Page 249: ...the preload level based on the bike load in order to maintain the optimum set up The system works in two phases 1 With the vehicle at a standstill the engine run ning gear in idle side stand raised the system performs a first overall preload adjustment 2 With the vehicle in motion the system continu ously monitors cyclically each minute various signals coming from the vehicle and if certain con di...

Page 250: ...be carried out in the order de scribed Rotary sensor reset Key OFF ON Preload motor travel limits search Key OFF ON VCU errors reset Exhaust butterfly valve travel limits search 7SM engine ECU errors reset DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS VCU ERRORS Preload motor command Status Flag active error C1619 Error cause Overcurrent on preload motor Troubleshooting Check the component connector an...

Page 251: ...rch time out error C1702 Error cause Failed memorisation of the preload motor travel limits This error occurs if after 2 minutes from starting the acquisition procedure the VCU is unable to record the motor travel limits probable circuit interruption Troubleshooting Check the component connector and the VCU connector Disconnect the two connectors and check the continuity of the cable between motor...

Page 252: ...ors and check the continuity of the cable between motor PIN 1 VCU PIN M2 VCU and between motor PIN 2 VCU PIN M1 If all the above checks return a positive result replace the motor Connectors EVC EXHAUST VALVE CONTROL UNIT CAPONORD 1200 EVC pin out key A1 Exhaust valve engine B A2 CAN L line A3 Reference voltage output A4 Live supply A5 Exhaust valve TPS signal A6 A7 A8 B1 Power from battery 1 Elect...

Page 253: ...4 C5 Power ground connection 1 C6 Power ground connection 2 C7 Power ground connection 3 C8 VCU VEHICLE CONTROL UNIT CAPONORD 1200 TRAVEL PACK VCU pin out key A1 Battery supply A2 Pump engine encoder 1 A3 Front pressure sensor A4 ON OFF Cruise control Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 253 ...

Page 254: ...r D2 Front stop switch D3 D4 E1 Rear solenoid valve positive E2 Rear stop switch E3 Live supply 1 E4 F1 Rear solenoid valve negative F2 Rear stop switch F3 1 Sensors ground connection F4 2 Sensors ground connection G1 1 Sensors power supply G2 G3 G4 Digital ground connection H1 2 Sensors power supply H2 H3 Serial line H4 J1 J2 CAN H line J3 J4 K1 K2 CAN L line K3 K4 Electrical system Caponord 1200...

Page 255: ...nder 2 injector control output PIN 8 Rear lambda sensor input PIN 9 Front lambda sensor input PIN 10 Track D hand grip input PIN 11 Water temp sensor input PIN 12 Track B hand grip input PIN 13 Serial line K for diagnosis PIN 14 Rear throttle motor output PIN 15 Power ground connection 2 PIN 16 Engine speed sensor input PIN 20 Input for rear throttle potentiometer 2 signal PIN 21 Front lambda sens...

Page 256: ...control output PIN 32 Engine speed sensor input PIN 35 Input for rear throttle potentiometer 1 signal PIN 36 Air temperature sensor input PIN 37 Rear lambda sensor input PIN 38 Track A hand grip input PIN 39 Key input PIN 40 42 Front throttle motor output PIN 41 Rear lambda heating control output PIN 44 Rear cylinder 2 injector control output PIN 46 Quick shift switch PIN 47 Input for front thrott...

Page 257: ...s B D and rear throttle PIN 63 Neutral input PIN 64 Fall sensor input PIN 65 CAN L line high speed PIN 66 Rear cylinder 1 injector control output PIN 67 Start up control output PIN 69 Side stand input PIN 70 Gear input PIN 72 Auxiliary injection relay control output PIN 73 Clutch switch PIN 76 engine stop input PIN 78 Vehicle speed input PIN 79 CAN H line high speed PIN 80 Caponord 1200 Caponord 1...

Page 258: ...Dashboard Grey bodied instrument panel pinout key 1 Live supply Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 258 ...

Page 259: ...eserve warning light 10 Fuel level signal 11 Power from battery 1 12 LH indicator switch 13 14 15 Signal heated handgrips control 16 Indicators reset 17 Oil pressure warning light 18 19 20 Serial line Black bodied instrument panel pinout key 21 Power from battery 2 Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 259 ...

Page 260: ...1 30 Sensors analogue ground connection 2 31 LH front indicator 32 RH front indicator 33 LH rear indicator 34 RH rear indicator 35 Light relay 36 LH handgrip control 37 RH handgrip control 38 Power ground connection 1 39 Power ground connection 2 40 Power ground connection 3 ABS Modulator Electrical system Caponord 1200 Caponord 1200 Rally ELE SYS 260 ...

Page 261: ... network Internet The CAN network has greatly simplified the electrical sys tem layout and consequently its complexity With this communication line needless duplication of several sensors present on the motorbike has been obviated The sensor signals are shared by the two electronic elaboration units instrument panel and control unit Cable number reduction The CAN line travels through a twisted cab...

Page 262: ...sages sent through the BUS with reception confirmation or error messages and each nod decides if the message is to be processed or rejected Besides every nod can request information from the other nodes RTR Remote Transmit Request Level in electrical circuit diagram CAN line Electrical specifications between PIN 66 and 80 of the control unit approximately 130 Ohm between PIN 26 and 27 of the instr...

Page 263: ...ontrol unit CAN line towards instrument panel U1701 no signal Error cause No signal is received from the instrument panel Troubleshooting Check the connector of the instrument panel if not OK restore if OK check the continuity of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli control unit if not OK restore the cable harness if OK replace the instrument pa...

Page 264: ...e If there is no signal no signal is received from the VCU control unit In case of configuration error some devices are present e g VCU that were not foreseen in the vehicle configuration stored in the control unit Troubleshooting No signal Carry out the procedure to check PINs J2 and K2 on the VCU connector and PINs 66 and 80 on the Marelli control unit vehicle connector If NOT OK restore if OK w...

Page 265: ... b EVC control unit connector Check continuity between the EVC control unit A2 PIN and the Marelli control unit vehicle connector PIN 66 Also check continuity between the EVC control unit B2 PIN and the Marelli control unit ve hicle connector PIN 80 If NOT OK replace the cable harness if OK check correct power to PIN B1 B8 12V and proper grounding to EVC control unit PINs C5 C6 C7 If NOT OK restor...

Page 266: ...s required Engine ECU C1306 Frame Counter error Error cause Failed synchronisation between VCU and engine ECU on the sent received data packets for each packet sent the VCU increases its internal counter by 1 which resets at 15 Troubleshooting Probably contact or interruption of the cable harness that must be checked check continuity of the cable between VCU PIN K2 engine ECU VEHICLE PIN 66 VEHICL...

Page 267: ...ubleshooting Probably contact or interruption of the cable harness that must be checked check the con tinuity between VCU PIN K2 instrument panel PIN 27 black connector and between VCU PIN J2 instrument panel PIN 26 black connector Also check the insulation of the two cables from one another from power and from ground Caponord 1200 Caponord 1200 Rally Electrical system ELE SYS 267 ...

Page 268: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 269: ...me side panels M12 4 80 Nm 59 lbf ft 3 Flanged TE screw fastening chain roller bracket to LH plate M8x35 1 25 Nm 18 44 lbf ft Loctite 243 4 Flanged TE screw fastening chain roller to chain roller bracket M8x45 1 25 Nm 18 44 lbf ft Loctite 243 5 Screw fastening chain roller bracket to LH plate M8x20 1 25 Nm 18 44 lbf ft Loctite 243 Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 269 ...

Page 270: ... Flanged nut fastening side panels to engine M12 3 80 Nm 59 lb ft ENGINE pos Description Type Quantity Torque Notes 1 Flanged TE screw fastening pinion M10x1 25 1 50 Nm 36 88 lbf ft Loctite 270 Engine from vehicle Caponord 1200 Caponord 1200 Rally ENG VE 270 ...

Page 271: ...ox control lever M6 1 10 Nm 7 37 lbf ft Fastener for positive cable on engine 1 10 Nm 7 37 lbf ft TE screw fastening negative cable to engine M6x12 1 10 Nm 7 37 lbf ft Vehicle preparation Remove the battery Remove the fuel tank Remove the water radiator and oil radiator Remove the air filter box See also Fuel tank Removing the radiator Engine oil cooler Air box Disconnect the engine oil pressure s...

Page 272: ...de out bushing and O ring from gearbox secondary shaft Disengage the spring Unscrew and remove the three nuts from the front exhaust manifold Engine from vehicle Caponord 1200 Caponord 1200 Rally ENG VE 272 ...

Page 273: ...ld Remove the front exhaust manifold moving the central exhaust manifold Unscrew and remove the catalytic con verter mounting screw Unscrew and remove the three nuts from the rear exhaust manifold Remove the exhaust manifold Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 273 ...

Page 274: ...e the clutch control cylinder Lock the plunger using a clamp Undo and remove the two screws and remove the pinion protection case Unscrew and remove the two clutch support screws Engine from vehicle Caponord 1200 Caponord 1200 Rally ENG VE 274 ...

Page 275: ...nnect the gear in neutral sensor connector Slacken the gearing chain tension Unscrew and remove the screw col lect the washer and the spacer Slide off the pinion from the chain and remove Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 275 ...

Page 276: ...through the rod Removing the engine from the vehicle Carry out the operations described un der Vehicle preparation Support the engine by means of belt and hoist Working on the left side unscrew and remove the three nuts See also Vehicle preparation Engine from vehicle Caponord 1200 Caponord 1200 Rally ENG VE 276 ...

Page 277: ...e rear coil fix ing screws Slide out the rear coils Slide off the rear top pin and collect the washer Remove the two spacers The thinner spacer is on the right Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 277 ...

Page 278: ...m pin and collect the washer Remove the bottom spacer on the right side Slide off the front pin and collect the washer Remove the bottom spacer on the right side Engine from vehicle Caponord 1200 Caponord 1200 Rally ENG VE 278 ...

Page 279: ...screw Release the ground points Unscrew and remove the two screws of the ECU Move the ECU aside but keep it connected to the wiring harness Loosen the two clamps Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 279 ...

Page 280: ...e body but keep it con nected to the wiring harness Disconnect the engine temperature sensor from the front cylinder Disconnect the alternator connectors Engine from vehicle Caponord 1200 Caponord 1200 Rally ENG VE 280 ...

Page 281: ...ng out the front coils Lower the engine and take it out of the chassis Installing the engine to the vehicle Place the engine on a suitable lower stand Lift the engine Place the engine so that the rear attachments on the chassis are aligned Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 281 ...

Page 282: ...E BEING REMOVED Working from the left side tighten the three nuts Release the engine from the belt and the hoist Refit the pinion and restore the gearing chain clearance Reconnect the electric connections and clamp the cable harnesses Carry out the vehicle preparation oper ations but in reverse order restore the correct level of all fluids and carry out the adjustments that may be required Engine ...

Page 283: ...See also Vehicle preparation Adjusting Caponord 1200 Caponord 1200 Rally Engine from vehicle ENG VE 283 ...

Page 284: ...INDEX OF TOPICS ENGINE ENG ...

Page 285: ...ARE STABLE AND EN SURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE Specific tooling 020710Y Engine plate AP8140187 U bolt for motor support Gearbox Diagram Key 1 Complete gear shaft and spring 2 Selector lock 3 Selector sprocket wheel 4 M5x16 Screw 5 Sprocket wheel pawl 6 Spring 7 Pin for spring Caponord 1200 Caponord 1200 Rally Engine ENG 285 ...

Page 286: ... 14 Gear selector drum 15 M8x1 25 threaded pin 16 Selector locking plate 17 Complete main gear shaft 18 TE flanged screw M6x15 19 Complete index lever 20 Spring 21 Nut 22 Threaded pin Gearbox shafts Gearbox shafts diagram key 1 Main gear shaft Z 14 Engine Caponord 1200 Caponord 1200 Rally ENG 286 ...

Page 287: ...condary Z 32 14 3rd gear on secondary Z 30 15 4th gear on secondary Z 28 16 5th gear on secondary Z 26 17 6th gear on secondary Z 25 18 Thrust washer 19 Circlip 20 Thrust washer 21 Thrust washer 22 Thrust washer 23 Floating bushing 24 Floating bushing 25 Floating bushing Disassembling the gearbox Open the crankcase halves Slide off the gearbox lubrication diffus er pipe Remove the two bolts of the...

Page 288: ...ract the desmodromic control Remove the three gear selection forks CAUTION THE FORK FOR THE PRIMARY SHAFT IS SMALLER THAN THAT OF THE SECONDARY SHAFT THE FORKS FOR THE SECONDARY SHAFT ARE THE SAME Engine Caponord 1200 Caponord 1200 Rally ENG 288 ...

Page 289: ... fastening the pinion onto the gearbox s secondary shaft Measure the external diameter of the countersink on the hole for fastening the pinion onto the secondary shaft In order to reduce the measurement error lock the bore gauge after having set it to 15 5 mm then check whether the two ferrules are inside or outside the countersink CAUTION THE RELIABILITY OF THE MEASURED VALUE IS FUNDAMENTAL Capon...

Page 290: ...h with degreasing spray Blow with compressed air Replace the pinion s fastening ele ments with upgraded fastening ele ments as indicated in the Spare Parts Catalogue If the external diameter of the counter sink is greater than 15 50 mm replace the secondary shaft and the pinion s fastening elements with upgraded components as indicated in the Spare Parts Catalogue Engine Caponord 1200 Caponord 120...

Page 291: ...ctor sprocket M8 1 20 Nm 14 75 lb ft 3M SCOTCH GRIP 2353 4 Gear sensor fastener screw M5 2 5 50 Nm 4 06 lb ft Loctite 270 5 Selector pin fastener onto clutch side crankcase half M10x1 5 1 16 Nm 11 80 lb ft Loctite 242 6 Gear retainer pawl fastener pin 1 11 13 Nm 8 11 9 59 lb ft 7 Gear retainer pawl fastener flanged nut 1 10 12 Nm 7 38 8 85 lb ft Removing the gear selector Remove the clutch Remove ...

Page 292: ...REPLACE THE WASHER ON EVERY SERVICING Heat up the gearbox selector support plate screws Unscrew the three gearbox selector plate fastening screws and remove them Remove the plate complete with selec tor Engine Caponord 1200 Caponord 1200 Rally ENG 292 ...

Page 293: ...both pawl tips run free without jamming Reassembling the gear selector CAUTION ON REASSEMBLY ENSURE THAT THE REFERENCE MARKS ON GEARBOX SHAFT AND SELECTOR SPROCK ET ARE ALIGNED CAUTION QUALORA SIA NECESSARIO SOSTITUIRE GLI ELEMENTI DI FISSAGGIO DELLA LEVA INDEX ACCERTARSI DI ORDINARE I COMPONENTI CORRETTI ESISTONO DUE VERSIONI NON IN TERCAMBIABILI TRA LORO Caponord 1200 Caponord 1200 Rally Engine ...

Page 294: ...and crankcase in a press and install the roller cage with the specific tool CAUTION TO INSTALL THE ROLLER CAGE IN THE RIGHT HAND CRANKCASE HALF WORK WITH THE CYLINDER ON THE SIDE OF THE 1 mm STEP ON THE TOOL TURNED TO WARD THE ROLLER CAGE WHEREAS TO INSTALL THE CAGE IN THE LEFT HAND CRANKCASE HALF USE THE CYLINDER ON THE SIDE OF THE 2 mm STEP ON THE TOOL Specific tooling 020724Y Punch cage with ro...

Page 295: ...Removing the starter motor Disconnect the starter motor power supply cable Unscrew and remove the two screws and remove the starter motor Caponord 1200 Caponord 1200 Rally Engine ENG 295 ...

Page 296: ...x1 5 1 190 200 Nm 140 14 147 51 lb ft 4 Screw fastening Stator Flywheel Cover M6 3 9 Nm 6 64 lb ft 5 Screw fastening pick up Flywheel cover M5 2 3 50 Nm 2 58 lb ft Loctite 270 6 Flywheel cover fastener screw M6 10 13 Nm 9 59 lb ft 7 Screw fastening starter motor brack et to motor and crankcase M6 4 6 86 7 84 Nm 5 06 5 78 lb ft Loct 242 8 Crankshaft access cap 1 4 Nm 2 95 lb ft 9 Retainer plate fas...

Page 297: ...nspection cap Unscrew and remove the ten screws Use the appropriate tool to remove the flywheel cover Specific tooling 020712Y Handle for removing the flywheel cov er Collect the gasket and the two dowel pins Caponord 1200 Caponord 1200 Rally Engine ENG 297 ...

Page 298: ...ANEOUSLY AS THEY ARE PART OF THE SAME ELEC TRICAL BRANCH Magneto flywheel removal Remove the flywheel cover Unscrew and remove the screw and remove the retention plate Use a heater to heat the flywheel mag net Use the appropriate tool to block the flywheel and loosen the screw Specific tooling 020713Y Flywheel extractor Engine Caponord 1200 Caponord 1200 Rally ENG 298 ...

Page 299: ...n from the outer body Unscrew the screw from the crankshaft Specific tooling 020713Y Flywheel extractor Remove the flywheel complete with the free wheel Remove the start up transmission gear Check dimensions of the supports of transmission gear on crankcase and cover the limit is 12 005 mm 0 4726 in for both supports In case of malfunction the start up transmission gear cannot be over hauled There...

Page 300: ...e flywheel Remove the freewheel gear Heat the magneto flywheel with the specific heater Unscrew and remove the six screws Remove the bearing retainer and bear ing from the magneto flywheel See also Magneto flywheel removal Engine Caponord 1200 Caponord 1200 Rally ENG 300 ...

Page 301: ...rew the screw together with the washer but without tightening Place the appropriate tool for locking the flywheel Locking the flywheel in position using the specific tool tighten the screw on the crankshaft WARNING TO APPLY THE CORRECT TIGHTENING TOR QUE CHECK THE MEASUREMENT OF THE SCREW THAT MAY BE M12 OR M14 Remove the special tool Caponord 1200 Caponord 1200 Rally Engine ENG 301 ...

Page 302: ... Cover Clutch side cover M6 3 13 Nm 9 59 lbf ft 3 Screw fastening Pump Cover Clutch Cover clutch side crankcase half M6 2 13 Nm 9 59 lbf ft 4 Nut fastening water pump drive gear sprocket M6 1 12 Nm 8 85 lbf ft 5 Water pump rotor 1 4 50 Nm 3 32 lbf ft 6 Screw fastening chain tensioner slid er to water pump M6 1 8 10 Nm 5 90 7 38 lbf ft 7 Water pump support fixing screw M6 3 12 Nm 8 85 lbf ft Engine...

Page 303: ...t 3M SCOTCH GRIP 2353 Unscrew and remove the thirteen screws in a cross pattern the two screws also retaining the water pump cover are longer than the other eleven ones Drain the engine oil Detach clamp retaining water pump pipe Collect the gasket Caponord 1200 Caponord 1200 Rally Engine ENG 303 ...

Page 304: ...8 lbf ft Chamfer 3 Fastening oil filler plug on Clutch cov er 1 2 Nm 1 48 lbf ft 4 Screw fastening fixing Plate Clutch control Mounting M5 3 5 50 Nm 4 06 lbf ft Loctite 242 5 Screw fastening clutch control mounting on flywheel side crankcase half M6 2 8 Nm 5 90 lbf ft Unscrew and remove the six perimeter fastener screws Remove the clutch cover Remove the gasket Engine Caponord 1200 Caponord 1200 R...

Page 305: ...re the projection of the clutch housing from the crankcase before dis assembling when refitting check that the projection has not changed before tightening the clutch nut If the projection has changed rotate the crankshaft to cor rectly engage the engine oil pump drive gear on the clutch housing with the oil pump driven gear Disassembling the clutch CLUTCH pos Description Type Quantity Torque Note...

Page 306: ...n stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate the plates and belleville washer Remove the mushroom head clutch control rod Working on the flywheel side push the clutch control rod so that it comes out on the other side Engine Caponord 1200 Caponord 1200 Rally ENG 306 ...

Page 307: ...trol rod Fasten the clutch housing using the specific tool Specific tooling 9100896 Clutch bell stopper Unscrew and remove the clutch hub nut Remove the washer to be chamfered Caponord 1200 Caponord 1200 Rally Engine ENG 307 ...

Page 308: ... Remove the clutch hub Collect the washer between the clutch hub and the housing Collect the clutch housing Retrieve the spacer and the roller bear ings Engine Caponord 1200 Caponord 1200 Rally ENG 308 ...

Page 309: ...CAUTION THE STEEL DISCS MUST SHOW NO SCORES OR TEM PERING COLOUR Measure the thickness of the clutch plates at four positions replace them if not complying with specifications Minimum thickness of the eleven driving plates individually 2 75 mm 0 11 in Minimum thickness of the ten driven plates in dividually 2 75 2 85 mm 0 108 0 112 in MUSHROOM VALVE CHECK Check if the valve slides freely without j...

Page 310: ...e clutch bell that could lead to irregular clutch functionality Grind down the teeth or replace the bell if necessary PRIMARY DRIVEN GEAR CONTROL Check for the presence of any damage or signs of wear on the primary driven gear and replace the primary transmission s driven gear and the clutch bell if necessary Verify that the noise level is not too high during operation replace the primary transmis...

Page 311: ...all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Clutch spring length when unloaded 69 2 5 mm 2 72 0 2 in OPTION 02 For clutch packs with NOT PAINTED thrust plate spring and spring cup of 10 5mm installed on engines with serial number from 4074 to 4285 in case of replacement of the springs they must be replaced with a kit containing the fol...

Page 312: ...d the spacer Fit the clutch housing Make sure that the oil pump control drive gear of the clutch housing engag es correctly with the oil pump driven gear Place the washer correctly between the clutch housing and the hub Engine Caponord 1200 Caponord 1200 Rally ENG 312 ...

Page 313: ...orrectly engage the engine oil pump drive gear on the clutch housing with the oil pump driven gear Fit the washer and a new clutch hub nut Tighten the clutch hub nut using the specific tool Specific tooling 9100896 Clutch bell stopper Tighten the nut and proceed to caulk CAUTION MAKE SURE THE DISC RING IS INSERTED FACING THE RIGHT DIRECTION THE RING S CONE MUST BE FACING THE ENGINE Caponord 1200 C...

Page 314: ...ternate with steel discs Position all friction material discs with their teeth aligned in one of the long slots of the clutch housing Place the control rod Place the thrust plate CAUTION ENSURE TO ALIGN THE ARROW ON THRUST PLATE WITH THE MACHINED REFERENCE ON HUB Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally On reassembly replace the gasket ...

Page 315: ...e the following tools Specific tooling 020376Y Adaptor handle 020362Y 12 mm guide 020891Y 25 mm 0 98 in adapter Assemble the tool using the washer for controlled driving then paying atten tion to the assembly direction set the oil seal in its seat with marking facing the operator Place the oil seal retainer with its flat side resting against the oil seal Position the retainer ring Caponord 1200 Ca...

Page 316: ...Special screw for fastening head cover M6 8 9 Nm 6 64 lb ft 2 Special screw for fastening head cover M6 2 9 Nm 6 64 lb ft 3 Oil breather fastener screw M6 2 5 50 Nm 4 06 lbf ft Spark plugs 2 10 12 Nm 7 38 8 85 lb ft Engine Caponord 1200 Caponord 1200 Rally ENG 316 ...

Page 317: ...5 Lubricate the threads before tight ening 4 Fastener for Head Cylinder Outer side crankcase M6 2 12 Nm 8 85 lbf ft 5 Fastener for Head Cylinder Inner side crankcase M6 4 12 Nm 8 85 lbf ft 6 Nut fastening Stud Bolts Head M6 4 12 Nm 8 85 lbf ft 7 Nut fastening Stud Bolts Head M8 2 26 Nm 19 18 lb ft 8 Bleed union fastener screw M5 4 5 50 Nm 4 06 lb ft Loctite dry loc 2040 Head cover removal The oper...

Page 318: ... Fit the cover Fit the rubber blocks in their seats Start and tighten the five screws to the prescribed torque working diagonally and in stages Front head Removing camshafts Remove the head cover Unscrew and remove the two screws Remove the coolant fitting Disconnect the coolant breather pipe See also Head cover removal Engine Caponord 1200 Caponord 1200 Rally ENG 318 ...

Page 319: ... camshafts CAMSHAFT TOOTHED WHEEL CHECK Check that the camshaft gear works properly if it is damaged or does not move smoothly replace the timing chain and the camshaft gear CAMSHAFT LOBES Check that they do not show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Remove the exhaust camshaft Position the camshaft on a vice featur ing protective shoes Unscrew and re...

Page 320: ...it engage spring on decompres sion device and preload it by one turn Install the counterweight and engage the preloaded device to it Tighten the counterweight fixing screw Installing camshafts The camshaft refitting procedure is described in the Timing section See also Timing Engine Caponord 1200 Caponord 1200 Rally ENG 320 ...

Page 321: ...d the internal spring Unscrew and remove the two screws Remove the chain tensioner and re trieve the gasket Remove the camshafts complete with the gears See also Removing camshafts Disassembling the clutch Unscrew and remove the two chain slider screws Caponord 1200 Caponord 1200 Rally Engine ENG 321 ...

Page 322: ...ile chain slider Remove the primary gear following the explanation given on crankcase open ing Remove the intermediate gear with chain NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED See also Splitting the crankcase halves Unscrew and remove the two external head fixing screws Engine Caponord 1200 Caponord 1200 Rally ENG 322 ...

Page 323: ...the external screw on the flywheel side Unscrew and remove the three bottom head fixing nuts Unscrew and remove the four nuts proceeding in stages and in a diagonal pattern Caponord 1200 Caponord 1200 Rally Engine ENG 323 ...

Page 324: ...MENT TO AVOID DAMAGING OR SCRATCHING THE SPARK PLUG THREADS OR THE VALVE SEATS Check that cylinder head is not damaged or scratched replace it if necessary Check that there are no mineral deposits or rust in the cylinder head water cooled jacket remove them if necessary Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn replace the defective part s Rear head ...

Page 325: ...ting See also Head cover removal Remove the cap from flywheel cover Rotate the crankshaft until the rear cyl inder piston reaches the TDC Unscrew and remove the eight cam tower screws working in a diagonal se quence and in stages Remove the cam tower Caponord 1200 Caponord 1200 Rally Engine ENG 325 ...

Page 326: ... the timing chain and the camshaft gear CAMSHAFT LOBES Check that they do not show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Remove the exhaust camshaft Position the camshaft on a vice featur ing protective shoes Unscrew and remove the screw and collect the washer Remove the decompression device housing Engine Caponord 1200 Caponord 1200 Rally ENG 326 ...

Page 327: ...ounterweight and engage the preloaded device to it Tighten the counterweight fixing screw Installing camshafts The camshaft refitting procedure is described in the Timing section See also Timing Rear head removal Remove the magneto flywheel Unscrew and remove the screw and retrieve the washer and the internal spring Caponord 1200 Caponord 1200 Rally Engine ENG 327 ...

Page 328: ...Remove the camshafts complete with the gears See also Removing camshafts Magneto flywheel removal Unscrew and remove the two chain slider screws Unscrew and remove the chain inter mediate gear pin Pay attention to avoid damaging the O ring Engine Caponord 1200 Caponord 1200 Rally ENG 328 ...

Page 329: ...DVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Remove the mobile chain slider See also Splitting the crankcase halves Unscrew and remove the two external head fixing screws Unscrew and remove the external screw on the flywheel side Caponord 1200 Caponord 1200 Rally Engine ENG 329 ...

Page 330: ...ottom head fixing nuts Unscrew and remove the four nuts proceeding in stages and in a diagonal pattern Slide head off the stud bolts Remove the gasket between the head and the cylinder Engine Caponord 1200 Caponord 1200 Rally ENG 330 ...

Page 331: ...ATS Check that cylinder head is not damaged or scratched replace it if necessary Check that there are no mineral deposits or rust in the cylinder head water cooled jacket remove them if necessary Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn replace the defective part s Valves Valve removal Remove the head Place the head on supporting surface Number the ...

Page 332: ...pring compressing tool Specific tooling 020382Y Tool to extract valve cotters 020896Y Bushing for valve removal Remove the cotters using a magnet Release the valve springs Remove the valve spring fittings and the springs Engine Caponord 1200 Caponord 1200 Rally ENG 332 ...

Page 333: ... exceeds the specified limit determine if the valve or the guide must be replaced Characteristic Valve stem distortion 0 25 mm 0 0098 in If the valve stem when measured with a micro meter is worn to its limit and the clearance ex ceeds the specified limit replace the valve If the valve stem lies within the specific limit re place the valve guide Recheck the clearance after replacing the valve or t...

Page 334: ... measure the eccentricity If the eccentricity exceeds the specified limit re place the valve Characteristic Valve head eccentricity 0 03 mm 0 0012 in CAUTION DURING INSTALLATION OF THE NEW VALVE VERIFY THAT THE INTAKE OR EXHAUST VALVE IS ALWAYS OF THE SAME TYPE BLACK OR CHROME IN CASE WHEN CLEANING THE TWO VALVES PRESENT IN THE ENGINE THE TYPE OF VALVES IS NOT CLEAR BOTH EXHAUST AND INTAKE VALVES ...

Page 335: ...pection of the valve springs for damage distortion or loss of tension Measure the spring length at release position Valve springs minimum wear limit 1 43 8 mm 1 724 in minimum wear limit 2 36 7 mm 1 445 in Caponord 1200 Caponord 1200 Rally Engine ENG 335 ...

Page 336: ... 90 Nm 66 38 lbf ft 2 Timing drive gear fastener screw M24x1 5 2 40 Nm 29 50 lbf ft 3M SCOTCH GRIP 2353 3 Special screw for fastening mobile fixed shoes M8 4 19 Nm 14 01 lbf ft 3M SCOTCH GRIP 2353 4 Cam tower head fastener screws M6 16 12 Nm 8 85 lbf ft Engine Caponord 1200 Caponord 1200 Rally ENG 336 ...

Page 337: ...t the timing chain on the crankshaft and on the intermediate gear Remove the screw and collect the washer and the spring Fit the chain tensioner body on the cyl inder and insert a new paper gasket Tighten the two screws to the prescri bed torque Insert the spring and tighten the screw together with the washer Cam timing Timing Remove the flywheel Install the timing chains on the inter mediate gear...

Page 338: ...the nuts on cam shaft gears Install the camshafts on front head aligning them using the suitable pins Specific tooling 020719Y Timing pin Fit cam tower and tighten the eight screws working in a diagonal se quence and in stages Pre tighten the gear nut on the camshaft REFIT THE NUT WITH THE MACHINED SURFACE FACING THE GEAR THE MATERIAL ACRO NYM SHOULD BE VISIBLE Engine Caponord 1200 Caponord 1200 R...

Page 339: ...amshafts lock them on a vice with aluminium jaws then tight en the gear retaining nut to the prescri bed torque DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE ULTIMATE TIGHTENING TORQUE WITH THE SHAFT MOUNTED ON THE HEAD THIS OPERATION WOULD IRRETRIEVABLY DAMAGE THE HEAD Locking torques N m Nut fixing camshaft gears M15x1 4 90 Nm 66 38 lb ft Caponord 1200 Caponord 1200 Rally Engine ENG 339 ...

Page 340: ...ankshaft with the specific special tool Carry out the timing operations per formed on the front cylinder please remember that rear camshaft gear nuts are anticlockwise and cam position is divergent CAUTION PAY ATTENTION THAT THE FRONT HEAD CAMSHAFT MUST CONVERGE A AND THE REAR HEAD CAMSHAFT MUST DIVERGE B AS INDICATED IN THE FIGURE Specific tooling 020720Y Timing tool Cylinder piston assembly Engi...

Page 341: ...crew M6 4 7 84 9 81 Nm 5 78 7 23 lb ft 3 Chain tensioner adjustment screw M6 2 5 50 Nm 4 06 lb ft Removing the cylinder Remove the head Slide cylinder out of stud bolts collect ing the base gasket See also Front head removal Rear head removal Disassembling the piston Remove the cylinder Caponord 1200 Caponord 1200 Rally Engine ENG 341 ...

Page 342: ... piston Specific tooling 020716Y Connecting stem lock 020894Y Pin snap ring fitting tool Lock the connecting rod using circlips FOR SAFETY REASONS COVER THE CRANKCASE WITH A CLEAN CLOTH SO THAT THE PARTS DO NOT FALL IN TO THE CRANKCASE See also Removing the cylinder head Removing the cylinder Engine Caponord 1200 Caponord 1200 Rally ENG 342 ...

Page 343: ...an and flat Make sure all threads are in proper conditions Check cylinder sliding surface for signs of friction and scratches Also check the seal sur faces for damages CAUTION IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT REPLACE THE CYLINDER AND THE PISTON Caponord 1200 Caponord 1200 Rally Engine ENG 343 ...

Page 344: ...r a 10 mm 0 39 in from the piston lower border Calculate the clearance between pis ton and cylinder as follows Piston diameter P 106 000 mm 4 1732 in Piston cylinder clearance C C P Piston cylinder clearance 0 085 mm 0 00335 in Replace the cylinder the piston and the piston ring all together if not com plying with specifications PISTON RINGS Clean off any carbon deposits from the grooves in the pi...

Page 345: ... not complying with specifications Piston ring end gap Top ring with new engine 0 25 0 45 mm 0 0079 0 0177 in Wear limit 0 65 mm 0 026 in Intermediate ring with new engine 0 85 1 mm 0 0335 0 0394 in Wear limit 1 30 mm 0 051 in Oil scraper ring with new engine 0 20 0 70 mm 0 0079 0 0276 in Wear limit 0 90 mm 0 035 in PIN Clean off combustion residues from the piston crown and from the area above th...

Page 346: ... 935 mm 4 1704 4 1707 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance B B Type B B 105 997 106 004 mm 4 1731 4 1734 in 105 935 105 942 mm 4 1707 4 1709 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance C C Type C C 106 004 106 011 mm 4 1734 4 1736 in 105 942 105 949 mm 4 1709 4 1712 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance D D Type D D 106 011 106 018...

Page 347: ... the tool Specific tooling 020895Y Piston installation ring Install the second pin retainer ring on the tool guide as shown in the figure Insert tool shaft and push retainer ring inside the guide until reaching the height shown in the figure Fit a new base gasket Fit the piston cylinder assembly previ ously assembled on the stud bolts aligning pin with connecting rod big end Fit the tool in the pi...

Page 348: ... the base gasket Remove the tool and fully push cylinder on the stud bolts Selecting the base gasket Temporarily fit the piston to the cylinder without base or head gasket Engine Caponord 1200 Caponord 1200 Rally ENG 348 ...

Page 349: ...se the chart be low to identify the thickness of the cyl inder base gasket to be used for refitting Correctly identify the cylinder base gasket thickness to keep the cor rect compression ratio Remove the special tool and the cylin der Specific tooling 020720Y Timing tool BASE GASKET Specification Desc Quantity Measured protrusion 0 30 0 175 mm 0 0118 0 0069 in Gasket 0 4 mm 0 0157 in Measured prot...

Page 350: ...M6 3 10 Nm 7 38 lbf ft Loctite 270 2 Piston oil jet fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 242 3 Tapered plug for crankshaft main bearing lubrication M8x1 4 15 Nm 11 06 lbf ft 4 Calibrated Brass dowel fixed to com plete crankcase M8 2 5 50 Nm 4 06 lbf ft Engine Caponord 1200 Caponord 1200 Rally ENG 350 ...

Page 351: ...screw for gearbox lubrication 1 18 Nm 13 28 lbf ft Splitting the crankcase halves Remove the clutch Remove the complete flywheel Remove the selector Remove the starter motor Remove the oil filter Fit the special tool tightly fastening the three screws securing the tool onto the crankcase Unscrew and remove the crankshaft fastener nut anticlockwise using the special tool retrieving the washer and t...

Page 352: ...ctor for the gear removal CAUTION THE BUSHING MUST BE INSTALLED ON THE SHAFT TO AVOID DAMAGE TO THE BLOW BY SYSTEM DURING THE USE OF THE EXTRACTOR Using a heating gun heat the area shown in the figure then remove the crankshaft gear with a commercially available extractor See also Disassembling the clutch Magneto flywheel removal Engine Caponord 1200 Caponord 1200 Rally ENG 352 ...

Page 353: ...e gear sensor loosening the two fixing screws Collect the O ring See also Removing the cylinder Unscrew and remove the selector drum fastener screw Unscrew and remove the nine flywheel side M8 screws Caponord 1200 Caponord 1200 Rally Engine ENG 353 ...

Page 354: ... and remove the eleven fly wheel side M6 screws Turn the engine into horizontal position Unscrew and remove the two engine support nuts Open the crankcase halves Engine Caponord 1200 Caponord 1200 Rally ENG 354 ...

Page 355: ...kwise nut 2 Connecting rod screw M10 4 15 30 Nm 11 06 22 13 lbf ft 50 2 final control torque 65 78 Nm 47 94 57 53 lbf ft Lubricate the threads before tight ening Open the crankcase halves Remove the crankshaft See also Splitting the crankcase halves Inspecting the crankcase halves BEARINGS AND OIL SEAL CHECK Caponord 1200 Caponord 1200 Rally Engine ENG 355 ...

Page 356: ... for clearance smoothness and potential distortions CAUTION LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING If the internal ring does not rotate smoothly and silently or if there is some noise while it turns it means that the bearing is faulty and must be replaced OIL FILTER AND OIL DELIVERY PIPE CHECK Check the oil filter for damage If necessary replace the part Clean the oil net ...

Page 357: ...aft axial clearance on the crank case should be checked with a dial gauge mounted on the specific dial gauge support The clearance should be between 0 1 0 26 mm 0 0039 0 0102 in If the clearance is beyond tolerance check the reference surfaces Specific tooling 020714Y Dial gauge mount Removal Mark the position of the original semi bushings on the crankcase Caponord 1200 Caponord 1200 Rally Engine ...

Page 358: ...cations indica ted in the drawing as closely as possi ble NOTE WHEN REPLACING THE SEMI BUSHINGS ALONE THE NEW COMPONENTS MUST BE THE SAME COLOUR AS THE REMOVED COMPONENTS IF THE COLOUR OF THE OLD COMPONENTS IS NO LONGER VISIBLE USE THE TABLE TO IDENTIFY THE CORRECT COMPONENTS RE FERRING TO THE CRANKCASE AND CRANKSHAFT CLASSES Key Semi bushing joint line Fit the new bushings with the crank case col...

Page 359: ...Refitting the crankcase halves Fit the strum box if previously re moved Tighten the two strum box fixing screws Turn the engine support into horizontal position Place the left crankcase half on the engine support fitting it on the engine support plate pins CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE ENGINE AND ENGINE MOUNTING ARE STA BLE AND ENSURE THAT THE ENGINE IS SECURELY FASTENED TO THE M...

Page 360: ... EXCESSIVE USE OF THREE BOND AS THIS COULD PREVENT THE OIL FROM PASS ING BETWEEN THE GUARDS Place the right crankcase half with the aid of a rubber hammer Tighten the two fixing pins Rotate the engine and the engine support into vertical position Engine Caponord 1200 Caponord 1200 Rally ENG 360 ...

Page 361: ...crankcase Working on the left side place the nine M8 screws fixing the crankcase Tighten all the crankcase fixing screws both M6 and M8 type Tighten the two screws fixing the se lector drum Fit a new O ring in the seat Caponord 1200 Caponord 1200 Rally Engine ENG 361 ...

Page 362: ...ankshaft gear Fit the special tool tightly fastening the three screws securing the tool onto the crankcase Specific tooling 020850Y Primary gear lock Position the water pump drive gear the washer and crankshaft fastener nut and tighten it to the specified torque Engine Caponord 1200 Caponord 1200 Rally ENG 362 ...

Page 363: ...Quantity Torque Notes 1 Fastening nipple to oil radiator M16x1 5 2 18 Nm 4 05 lb ft 2 Oil radiator tubes fastening M16x1 5 4 15 Nm 11 06 lb ft 3 Fastening nipple to engine M16x1 5 2 42 Nm 30 97 lb ft Caponord 1200 Caponord 1200 Rally Engine ENG 363 ...

Page 364: ...10 33 lbf ft 5 Oil pressure regulator valve M18x1 5 1 42 Nm 30 98 lbf ft 6 Oil pump fixing screw M6 2 5 6 Nm 3 69 4 42 lbf ft 3M SCOTCH GRIP 2353 7 Rose pipe fixing screw M6 2 12 Nm 8 85 lbf ft 8 Oil pump driven gear fastener nut M6 1 11 Nm 8 11 lbf ft 9 By Pass plate fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 242 10 Oil cooling radiator nipple M16x1 5 2 42 5 Nm 31 35 lbf ft Removing Remove t...

Page 365: ... a calliper spanner lock out gear rotation and loosen the nut to re move it See also Disassembling the clutch Collect the washer Collect the gear Collect the spacer Caponord 1200 Caponord 1200 Rally Engine ENG 365 ...

Page 366: ...e oil pump Inspection Undo and remove the two fixing screws Using a thickness gauge check clear ance between rotor and stator and re place the rotor stator unit if necessary clearance between rotor and stator 0 04 0 10 mm 0 0016 in 0 0039 in Engine Caponord 1200 Caponord 1200 Rally ENG 366 ...

Page 367: ...llect the lock pin from the shaft Remove the oil pump rotor Remove the oil pump stator CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAM AGED NO EVIDENT ABRASIONS SCORES OR ANY OTH ER MARKS Caponord 1200 Caponord 1200 Rally Engine ENG 367 ...

Page 368: ...ENCES ON STA TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE IF REQUIRED REPLACE THE STATOR ROTOR UNIT Fit the oil pump Fit the protection and tighten the two retaining screws Engine Caponord 1200 Caponord 1200 Rally ENG 368 ...

Page 369: ... Fit the spacer Fit the gear Place the washer By means of a calliper spanner lock out gear rotation and tighten the retaining nut Caponord 1200 Caponord 1200 Rally Engine ENG 369 ...

Page 370: ...ere are sys tems for the recirculation of these gas oil vapours inside the intake ducts to burn them in the subsequent active phases of the engine This system separates the engine oil into oil vapour The oil vapours coming from the joints 1 and 2 are filtered and enter into the filter box through the joint 3 If there is oil in the filter box it is introduced again in the circuit through the joint ...

Page 371: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 372: ...move and empty the tank first Unscrew and remove the ring nut 1 fastening the fuel pump to the tank Remove the fuel pump 2 paying at tention not to damage it during the ex traction phase REMOVAL OF FUEL LEVEL PROBE Remove and empty the tank first Disconnect the connector 1 Power supply Caponord 1200 Caponord 1200 Rally P SUPP 372 ...

Page 373: ... Undo and remove the four screws 2 fixing the fuel level probe to the tank Remove the fuel level probe 3 Caponord 1200 Caponord 1200 Rally Power supply P SUPP 373 ...

Page 374: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 375: ... 2 10 Nm 7 37 lbf ft 2 Stainless steel TCC screw fastening upper U bolt to lower clamp M8x25 4 25 Nm 18 44 lbf ft 3 Screws fastening light switch assem bly 2 2 1 5 Nm 1 11 lbf ft 4 Anti vibration weight terminal M18 2 20 Nm 14 75 lbf ft 5 TBEI screw M6x16 2 12 Nm 8 85 lbf ft Caponord 1200 Caponord 1200 Rally Suspensions SUSP 375 ...

Page 376: ...es 1 TEFL screw fasten onto Fork Hubs M6x40 4 10 Nm 7 37 lb ft 2 Screw Piston fixing to the stem base 2 30 Nm 22 13 lb ft 3 Upper cap 2 20 Nm 14 75 lb ft 4 Upper cap locking nut 2 20 Nm 14 75 lb ft ADD Version Suspensions Caponord 1200 Caponord 1200 Rally SUSP 376 ...

Page 377: ...1 Sensor upper cover screw M6x20 1 10 Nm 7 37 lb ft 2 Sensor lower cover screw M6x12 2 10 Nm 7 37 lb ft 3 Screw Piston fixing to the stem base 2 30 Nm 22 13 lb ft 4 Upper cover 2 20 Nm 14 75 lb ft Diagram Caponord 1200 Caponord 1200 Rally Suspensions SUSP 377 ...

Page 378: ...ing fork stan chions to top yoke M8x30 2 25 Nm 18 44 lb ft 6 Headstock counter lock ring M25x1 1 Manually screw Removing the fork legs Remove the front wheel Support the stanchion and loosen the screws on the upper and then the lower plate Remove the stanchion FOR THE ADD VERSION THE PRESSURE SENSOR MUST BE DISCONNECTED BEFORE REMOVING THE LEFT STEM Undo and remove the sensor fixing screw located ...

Page 379: ...t damage the cable itself At this point the stem can be removed from the plate WARNING USING AN APPROPRIATE TOOL APPLY LEVERAGE BE TWEEN THE CABLE GUIDE AND THE CABLE TAKING CARE NOT TO DAMAGE THE CABLE Disassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STANCHIONS Caponord 1200 Caponord 1200 Rally Suspensions SUSP 379 ...

Page 380: ...e suitable equip ment Specific tooling 020957Y Key for upper fork nut NOTE THE OPERATIONS REPORTED BELOW ARE VALID FOR BOTH CAPONORD 1200 STANCHIONS AND THE RH STANCHION OF CAPONORD 1200 aDD VERSION Put the stem upright and using the ap propriate tool fasten the stem in the vice Completely unscrew the plug Specific tooling AP8140149 Guard for assembly operations Suspensions Caponord 1200 Caponord ...

Page 381: ...ress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Clamp for pre load pipe Unscrew the cap and remove it Remove the spring preload pipe Remove the lock nut and the washer Caponord 1200 Caponord 1200 Rally Suspensions SUSP 381 ...

Page 382: ...OUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE Discharge the fork remove the internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Suspensions Capo...

Page 383: ...able bushing 2 the ring 3 and the oil seal 4 from the stem Remove the lock seeger ring of the spring guide Remove the spring guide Using a hook spanner lock the pump ing member pin Remove the stem bottom screw Specific tooling 020889Y Wrench for locking pumping unit ring nut Caponord 1200 Caponord 1200 Rally Suspensions SUSP 383 ...

Page 384: ...RE DIFFERENT Specific tooling AP8140149 Guard for assembly operations Drain the oil into a container of suitable capacity to collect fluids DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERV ICING THE VEHICLE Suspensions Caponord 1200 Caponord...

Page 385: ...n Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Remove the retainer ring Take out the sleeve from the stem us ing the stem as a hammer puller Caponord 1200 Caponord 1200 Rally Suspensions SUSP 385 ...

Page 386: ...es with fork oil or sealing grease Using the special key unscrew the cap and remove the spring Pay attention to place the key in the lower seat of the lock nut Specific tooling 020957Y Key for upper fork nut 020958Y Fork cartridge protection Before removing the cap 1 from the pumping member the electric cable harness must be released To do this loosen the ring nut 2 and remove the sleeve 3 by unsc...

Page 387: ...pumping member and finally the spring Checking the components Stem Check that the sliding surface is not scratched or scored Any scoring can be removed by sanding with damp sandpaper grain 1 If the scratches are deep replace the stem Using a dial gauge check than any bending of the stem is below the limit value If it is over the limit replace the stem CAUTION Caponord 1200 Caponord 1200 Rally Susp...

Page 388: ...and or cracks otherwise replace it Spring Check the spring is in good conditions Check that the following components are in good conditions upper bushing lower bushing plunger If there is evidence of excessive wear or damage replace the component concerned CAUTION REMOVE ANY IMPURITIES FROM THE BUSHINGS BEING CAREFUL NOT TO SCRATCH THEIR SURFACES Suspensions Caponord 1200 Caponord 1200 Rally SUSP ...

Page 389: ... CAPONORD 1200 STANCHIONS AND THE RH STANCHION OF CAPONORD 1200 aDD VERSION Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges with fork oil or sealing grease Fit the dust gaiter the retainer ring and the dust scraper on the stem Caponord 1200 Caponord 1200 Rally Suspensions SUSP 389 ...

Page 390: ...the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight Insert the retainer ring in its position Suspensions Caponord 1200 Caponord 1200 Rally SUSP 390 ...

Page 391: ... the stem Using a hook spanner lock the pump ing member pin and tighten the fixing screw on the fork end to the prescribed torque Specific tooling 020889Y Wrench for locking pumping unit ring nut Insert the spring guide and lock it in place using the respective snap ring Position the forks vertically Insert the base washer Caponord 1200 Caponord 1200 Rally Suspensions SUSP 391 ...

Page 392: ... oil Insert the washer that will be supported on the spring Insert and hand tighten the nut on the pumping member pin Place the preload pipe Tighten the appropriate tool on the pumping member pin rod and keep it raised to allow inserting a wrench in the nut by compressing the spring Specific tooling 020890Y Support rod of pumping unit stan chion AP8140147 Spacer retaining device Suspensions Capono...

Page 393: ...O THE ADD VERSION Lock the pumping member in a vice using the special tool Lubricate the sliding edges with fork oil or sealing grease Using the special key unscrew the cap and remove the spring Pay attention to place the key in the lower seat of the lock nut Specific tooling 020957Y Key for upper fork nut 020958Y Fork cartridge protection Caponord 1200 Caponord 1200 Rally Suspensions SUSP 393 ...

Page 394: ...red and manually tighten the ring nut against the cap Insert the key on the ring nut seat Using a wrench and the special tool tighten the cap and the ring nut to the prescribed torque Protect the bushing seat with adhesive tape Suspensions Caponord 1200 Caponord 1200 Rally SUSP 394 ...

Page 395: ...ge them passing over the hole on the stem Remove the adhesive tape Install the fixed bushing on the stem Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight Caponord 1200 Caponord 1200 Rally Suspensions SUSP 395 ...

Page 396: ... of the stem CAUTION PAY PARTICULAR ATTENTION TO THE CORRECT INSER TION OF THE PUMPING MEMBER INSIDE THE STEM IN THE RIGHT POSITION THE PUMPING MEMBER SHOULD NOT TURN ALSO DURING THE SCREW TIGHTENING AL WAYS CHECK THAT THE PUMPING MEMBER IS NOT TURNING Filling oil Place the sleeve upright in a vice fitted with protection jaws Compress the sleeve in the stanchion Put a support under the stem so as ...

Page 397: ...in from the edge of the sleeve without spring or pre loading tube Characteristic Fork oil also check if the air level in the stem is correct 441 cc 26 91 cu in for each stem aDD version LH stem oil level 130 2 mm 5 12 0 08 in from the sleeve edge without spacer spring and plug assembly RH stem oil level 120 2 mm 4 72 0 08 in from the sleeve edge without spacer spring and plug assembly Characterist...

Page 398: ... 50 7 5 Nm 36 88 5 53 lb ft 5 SHC screw fastening fork stanchions to top yoke M8x30 2 25 3 75 Nm 18 44 2 77 lb ft Loctite 243 6 Self locking ring nut M35x1 1 25 5 Nm 18 44 3 69 lb ft Adjusting play Place the vehicle so that the front wheel is off the ground Carry out a handlebar rotation test us ing a dynamometer at the hand grip external end The handlebar resistance to rotation must be of 550 150...

Page 399: ...so as to keep both wheels on the ground Disconnect the ADD system connector Undo and remove the ADD sensor cov er fixing screw Remove the cover Remove the sensor Remove the ADD sensor cover lower fixing screw Caponord 1200 Caponord 1200 Rally Suspensions SUSP 399 ...

Page 400: ...HE CABLE Unscrew and remove the U bolt four fixing screws Remove the U bolt Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out Undo and remove the upper cap on the steering yoke pin Working from both sides loosen the screws fixing the stanchions to the up per plate Suspensions Caponord 1200 Caponord 1200 Rally SUSP 400 ...

Page 401: ...me tool loosen the ring nut and tighten it again to the prescri bed torque Refit the handlebar components and carry out a handlebar rotation test us ing a dynamometer at the hand grip external end The handlebar resistance to rotation must be of 550 150 g 1 21 0 33 lb in both directions Specific tooling 020966Y Steering adjustment socket Caponord 1200 Caponord 1200 Rally Suspensions SUSP 401 ...

Page 402: ...he fork stanchions Remove the upper steering yoke After removing the self locking ring nut and the ring nut remove the dust gaiter ring Remove the internal dust gaiter ring Remove the bearing upper seat Remove the bearing Suspensions Caponord 1200 Caponord 1200 Rally SUSP 402 ...

Page 403: ...se the lower and upper bearing rollers Insert the steering bearing seat using a punch in the steering column Pre mount the dust gaiter 3 the lower bearing guide 2 and the lower bearing 1 on the steering yoke Recommended products Lithium based grease Lithium calcium soap based grease colour black contains EP Extreme Pressure additives excellent water repellent properties Caponord 1200 Caponord 1200...

Page 404: ... Insert the lower plate into the steering column Insert the bearing Insert the bearing upper seat Insert the internal dust gaiter ring Suspensions Caponord 1200 Caponord 1200 Rally SUSP 404 ...

Page 405: ...riate tool Specific tooling 020966Y Steering adjustment socket Tighten the self locking ring nut to the prescribed torque using an appropriate tool Specific tooling 020966Y Steering adjustment socket Insert the internal dust gaiter ring Caponord 1200 Caponord 1200 Rally Suspensions SUSP 405 ...

Page 406: ...ppropriate tool Specific tooling 020966Y Steering adjustment socket Tighten the self locking ring nut to the prescribed torque using an appropriate tool Specific tooling 020966Y Steering adjustment socket Position the steering yoke Suspensions Caponord 1200 Caponord 1200 Rally SUSP 406 ...

Page 407: ...m both sides tighten the screws fixing the stanchions to the up per plate Tighten the upper cap on the steering yoke pin Correctly position the handlebar and the yoke insert and tighten the fixing screws Caponord 1200 Caponord 1200 Rally Suspensions SUSP 407 ...

Page 408: ...nd secure the lower cover of the ADD sensor after positioning it Insert the sensor correctly Position and secure the ADD sensor cover Connect the ADD sensor connector Rear Suspensions Caponord 1200 Caponord 1200 Rally SUSP 408 ...

Page 409: ...PENSION Pos Description Type Quantity Torque Notes 1 Upper SHC mounting screw M10x50 1 50 Nm 36 88 lb ft 2 Lower TCEI mounting screw M10x80 1 50 Nm 36 88 lb ft ADD Version Caponord 1200 Caponord 1200 Rally Suspensions SUSP 409 ...

Page 410: ...el if the vehicle is not equipped with a central stand Use the centre stand with special sup ports for the lifting brackets 1 as shown in the figure Use the two lifting brackets as shown in the figure Install the two lifting brackets in the rel ative supports previously installed on the centre stand Place the stand under the vehicle so that the lifting brackets will act on the lower part of the si...

Page 411: ...ly fix the vehicle on the lift DO NOT LIFT THE VEHICLE WITH THE REAR HANDLE DO NOT USE MOTORCYCLE JACK STANDS ANCHORED TO THE REAR SWINGARM THE FOLLOWING PROCEDURE APPLIES TO THE ADD VERSION Disconnect the electric motor connec tor 1 Release the elastic that keeps the elec tric motor in position Caponord 1200 Caponord 1200 Rally Suspensions SUSP 411 ...

Page 412: ...screw and remove the shock ab sorber upper fixing screw Unscrew and remove the shock ab sorber lower fixing screw Disconnect the shock absorber valve Suspensions Caponord 1200 Caponord 1200 Rally SUSP 412 ...

Page 413: ...connect the cabling from the sup port bracket After removing the two fastening screws of the support bracket remove it Put the shock absorber in the special tool for the spring compression CAUTION MAKE SURE NOT TO DAMAGE THE CABLE HARNESS AND THE TUBE BETWEEN THE MOTOR AND THE SHOCK ABSORBER Caponord 1200 Caponord 1200 Rally Suspensions SUSP 413 ...

Page 414: ...ing Remove the retainer ring Discharge the spring and remove the suspension from the specific tool Remove the lock plate of the spring making sure not to damage the cable harness Suspensions Caponord 1200 Caponord 1200 Rally SUSP 414 ...

Page 415: ...sible to carry out a bleeding and replace the oil in the suspension using a special pump Loosen the bleeding valve from sus pension Insert and tighten the special joint Connect the tube for the oil bleeding filling to the joint Caponord 1200 Caponord 1200 Rally Suspensions SUSP 415 ...

Page 416: ... bleeding filling to the tool After the bleeding and the oil filling re move the tube from the joints Remove the joints Insert and tighten the screw for bleeding the suspension Suspensions Caponord 1200 Caponord 1200 Rally SUSP 416 ...

Page 417: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 418: ...2 Nm 59 8 85 lb ft 2 Wheel nut M25 x 1 25 1 80 12 Nm 59 8 85 lb ft 3 Front brake disc fixing screws M8x20 12 30 Nm 22 13 lb ft Removal OPTION 01 Support the front part of the motorcycle Unscrew the screws fixing the front pli ers and slide them off the disc Chassis Caponord 1200 Caponord 1200 Rally CHAS 418 ...

Page 419: ... slightly with a rubber mallet so that the hole on the opposite side is exposed Remove the wheel axle by inserting a screwdriver in the holes on the pin Support the wheel while extracting the pin and then remove it Collect the spacer from the front wheel right side OPTION 02 Caponord 1200 Caponord 1200 Rally Chassis CHAS 419 ...

Page 420: ...screw and remove the fixing nut 1 of the wheel axle Retrieve the sealing washer 2 Loosen the screws 3 on the wheel axle clamps of both fork legs Unscrew and remove the fixing screws 4 of the front clamp 5 Slide the clamp from the brake disc 5 Chassis Caponord 1200 Caponord 1200 Rally CHAS 420 ...

Page 421: ...ent or noise If one or both bearings are not conformant Replace both wheel bearings CHECKING RADIAL AND AXIAL PLAY Check the radial and axial play Axial play minimal axial play is permitted Radial none If one or both bearings are not conformant Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE SEALS Check the condition of the seal...

Page 422: ...excessive eccentricity is usually caused by worn or damaged bearings Replace the rim if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2 mm 0 0079 in REMOVAL OF FRONT WHEEL BEARINGS Carry out the removal of the front wheel Remove the dust gaiter 1 Remove the Seeger ring 2 Remove the bearing 3 using a gener ic bearing ex...

Page 423: ... 88 50 13 27 lb ft 3 Rear brake disc fixing screws M8x18 5 30 Nm 22 13 lb ft Rimozione OPTION 01 Place the vehicle on its rear service stand Fasten the vehicle handlebar to the bench using belts To facilitate operations it is advisable to remove the chain protection by un screwing the two screws Caponord 1200 Caponord 1200 Rally Chassis CHAS 423 ...

Page 424: ...ew and remove the nut on the wheel axle Collect the thrust washer and the right chain tensioner slider See also Adjusting Working on the left side hit the wheel axle lightly so as to take out the head from its housing Working on the right side slide off the wheel axle together with the chain guide slider Remove the wheel by freeing the disc from the brake calliper Chassis Caponord 1200 Caponord 12...

Page 425: ...emove the sprocket and the bolts Unscrew and remove the five screws and remove the anti vibration buffer holder Check the flexible couplings according to the routine maintenance table See also Adjusting OPTION 02 Loosen the nut on the wheel axle 1 Caponord 1200 Caponord 1200 Rally Chassis CHAS 425 ...

Page 426: ...he gearing chain ten sion acting on both nuts as indicated in the figure Unscrew and remove the nut 1 Collect the washer 2 Retrieve the right chain tensioner slider 3 Chassis Caponord 1200 Caponord 1200 Rally CHAS 426 ...

Page 427: ... sprocket from the sprock et guard Remove the flexible couplings 1 from their seats as indicated in the figure Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR REAR WHEEL BEARINGS Check the bearings installed on the wheel CHECKING ROTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise I...

Page 428: ... SEALS WITH COMPONENTS OF THE SAME TYPE REAR WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity 1 Replace the wheel axle if the eccentricity exceeds the limit value 1 Characteristic Maximum eccentricity 0 25 mm 0 0098 in REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usua...

Page 429: ... spacer 1 Remove the dust gaiter 2 Remove the seeger ring 3 Remove the bearing 4 using a gener ic bearing extractor REMOVAL OF LEFT SIDE REAR WHEEL BEARING Remove the sprocket guard and the sprocket Retrieve the bushing 1 Remove the spacer 2 Caponord 1200 Caponord 1200 Rally Chassis CHAS 429 ...

Page 430: ... the Seeger ring 4 Remove the bearing 5 from the sprocket guard using a generic bearing extractor Then using a generic bearing extractor remove the bearing 6 Chassis Caponord 1200 Caponord 1200 Rally CHAS 430 ...

Page 431: ...g chain guard to swingarm M5x9 1 6 Nm 4 42 lb ft Loctite 243 6 TBEI Chainguard fixing screw M5x9 1 4 Nm 2 95 lb ft 7 TSEI screw fastening chain guide to swingarm M5x9 2 6 Nm 4 42 lb ft Loctite 243 8 Flanged TBEI screw fastening chain slider M5x9 2 6 Nm 4 42 lb ft Removing Remove the exhaust system Support the vehicle by means of the engine service stand and a hoist with belts fastened to the rear ...

Page 432: ... REMOVING THE WHEEL OTHERWISE THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT RESULTING IN BRAKE FLUID LEAKAGE Unscrew and remove the shock ab sorber lower screw and collect the nut Fasten the shock absorber to the chas sis With the specific box spanner un screw and remove the locking ring nut Chassis Caponord 1200 Caponord 1200 Rally CHAS 432 ...

Page 433: ...g on the right side unscrew and remove the swingarm bolt UPON REMOVING THE REAR SWINGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN See also Removing the rear wheel Drive chain Removing The transmission chain although closed has a different coloured hammerlock where provided which should be used to perform opening disas sembling procedures NOTE WHERE PRESENT THE HAMMERLOCK 1 MAY ALSO BE IDENTIFIE...

Page 434: ...ve the chain proceed as follows Partially remove the pins 3 using a generic chain breaker Remove the outer plate 4 Remove the outer O ring rings 5 Remove the inner plate 6 Chassis Caponord 1200 Caponord 1200 Rally CHAS 434 ...

Page 435: ...ent P N Ognibene 529510001 The different chain pitches which may be checked with the instrument are indicated on the instrument itself There are three reference markings for each chain pitch indicated on the instrument These in dicate from right to left the correct measurements for 1 New chain with length near nominal value 2 Chain with chain stretch of 1 5 3 Chain with chain stretch of 3 which mu...

Page 436: ... correct marking on the in strument Installing After fitting the chain on the pinion and on the crown put the inner O rings 1 back onto the hammerlock pins 2 and connect the two ends of the transmis sion chain Place the outer O rings 3 on the pins Compress the outer plate 4 using the appropriate generic tool CAUTION BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZE THE CH...

Page 437: ...n of the specific tool 90 and re engage the link pin again checking riveting at points B Grease the chain and record the clearance Adjusting The vehicle has an endless chain without master link NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE Caponord 1200 Caponord 1200 Rally Chassis CHAS...

Page 438: ...JUSTMENT CAUTION THE SPECIFIC OPTIONAL REAR SUPPORT STAND IS NECESSARY TO ADJUST THE CHAIN If you need to adjust chain tension after the check Place the vehicle on its rear service stand OPT Loosen the nut 1 completely Loosen both lock nuts 4 Actuate on the adjuster screws 5 and adjust the chain clearance checking that the references 2 3 match on both sides of the vehicle Tighten both lock nuts 4 ...

Page 439: ...D OR SEIZED LINKS MUST BE LUBRICATED AND RESTORED TO PROPER WORKING ORDER THE DRIVE CHAIN HAS SEAL RINGS BETWEEN THE LINKS WHICH KEEP THE GREASE INSIDE BE EXTREMELY CAREFUL WHEN ADJUSTING LUBRICATING WASHING AND REPLACING THE CHAIN CLEANING AND LUBRICATION Do not wash the chain with water jets vapour jets high pressure water jets and highly flammable sol vents Wash the chain with naphtha or kerose...

Page 440: ...43 3 68 lb ft Loctite 243 4 Stand nut M10x1 25 1 25 5 Nm 18 43 3 68 lb ft Loctite 243 Centre stand NOTE IF THE REPLACEMENT OF THE CENTRE STAND FIXING SCREWS IS NECESSARY INSTALL THE NEW SCREWS THAT ARE PRE IMPREGNATED WITH SCOTCH GRIP THIS SCREW TYPE MUST BE REPLACED EVERY TIME IT IS REMOVED WHERE CONTEMPLATED Working on the left side unscrew and remove the central stand fixing screw Chassis Capon...

Page 441: ...the two central stand fixing screws NOTE IF THE REMOVED SCREWS MUST NOT BE REPLACED RESTORE THE LOCTITE DURING THE REFITTING FOR A CORRECT TIGHTENING Remove the centre stand Side stand Remove the gearshift lever first Disconnect the stand sensor Caponord 1200 Caponord 1200 Rally Chassis CHAS 441 ...

Page 442: ...cription Type Quantity Torque Notes 1 TBEI silencer protection screws M6x16 3 5 Nm 3 69 lb ft 2 SHC silencer flange screws M8x25 2 18 3 6 Nm 13 28 2 66 lb ft 3 Resonator fixing clamp 1 4 5 1 Nm 3 32 0 74 lb ft Removing the tail pipe OPTION 01 Chassis Caponord 1200 Caponord 1200 Rally CHAS 442 ...

Page 443: ...ove the exhaust valve motor Unscrew and remove the three ex haust end cover fixing screws Remove the cover Unscrew and remove the two fixing screws Remove the exhaust end OPTION 02 Undo and remove the fixing screw 1 Caponord 1200 Caponord 1200 Rally Chassis CHAS 443 ...

Page 444: ... Unscrew and remove the fixing screws 2 Remove the heat guard 3 Undo and remove the two fixing screws 4 Undo and remove the fixing screw 5 Chassis Caponord 1200 Caponord 1200 Rally CHAS 444 ...

Page 445: ...nd 8 Removing the catalytic converter Remove the exhaust end first Unscrew and remove the catalytic con verter fixing screw CAUTION DURING THE ASSEMBLY AND REFITTING PAY ATTEN TION TO THE GASKET Remove the catalytic converter See also Removing the tail pipe Caponord 1200 Caponord 1200 Rally Chassis CHAS 445 ...

Page 446: ... MANIFOLD COMPLETE WITH A RESONATOR FIXED WITH A METAL CLAMP THE FRONT EXHAUST MANIFOLD IN THE TWO OPTIONS ARE DIFFERENT SO IN CASE OF REPLACEMENT PAY ATTENTION NOT TO INTERCHANGE THEM Disengage the spring Unscrew and remove the three nuts from the front and rear exhaust mani fold Chassis Caponord 1200 Caponord 1200 Rally CHAS 446 ...

Page 447: ...t manifold and the catalytic con verter Disconnect the front and rear lambda probe Remove the exhaust manifolds OPTION 02 Carry out the removal of the side fair ing Unscrew and remove the screw 1 Caponord 1200 Caponord 1200 Rally Chassis CHAS 447 ...

Page 448: ... Remove the clamp 2 Remove the cover 3 Disconnect the lambda probe connec tor 4 Remove the spring 5 Chassis Caponord 1200 Caponord 1200 Rally CHAS 448 ...

Page 449: ...Carry out the manifold removal Undo and remove the lambda probe 1 from the point indicated in the fig ure See also Removing the tail pipe Engine oil cooler Remove the fairing lug Drain the engine oil Remove both side fairings Working on the right side unscrew the two oil pipes Caponord 1200 Caponord 1200 Rally Chassis CHAS 449 ...

Page 450: ...de body panels Working on the left side unscrew and remove the screw from the front cylin der Remove the seeger ring and slide off the pin Remove the oil radiator together with support and horn Chassis Caponord 1200 Caponord 1200 Rally CHAS 450 ...

Page 451: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 452: ...OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM ABS ABS SYSTEM pos Description Type Quantity Torque Notes 1 ABS ECU fastener screw M6x25 3 8 10 Nm 5 90 7 37 lb ft 2 ABS ECU fastener nut M6 1 10 Nm 7 37 lb ft Braking system Caponord 1200 Caponord 1200 Rally BRAK SYS 452 ...

Page 453: ...ABS ECU control unit pin configuration PIN 1 GND Ground PIN 2 PCC1 Vehicle identification ground connection PIN 3 Speed signal to ECU PIN 4 IGN Injection PIN 5 CAN H line PIN 6 CAN L line PIN 8 WL Alarm warning light PIN 11 R_SIGN Rear ABS sensor signal PIN 12 R_GND Rear ABS sensor ground connection Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 453 ...

Page 454: ... identification ground connection PIN 16 ISO_K K line diagnosis PIN 18 KL30 Power supply Foreword Key 1 Rear brake calliper 2 Modulator 3 Front bleed valve 4 Front brake reservoir 5 Front brake callipers 6 Rear brake pump 7 Rear brake reservoir Braking system Caponord 1200 Caponord 1200 Rally BRAK SYS 454 ...

Page 455: ...ating diagram ABS functional diagram key 1 Front system circuit 2 Front brake master cylinder 3 Front brake control lever 4 Rear system circuit Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 455 ...

Page 456: ...d by mode the ABS processor controls the wheel speed instant by instant to assess any slippage of the wheels When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS ABS Cycle phases the following operations refer to the front circuit but they are also valid for the rear A Brake activation the rider starts braking as he would ...

Page 457: ...road The rider is fully responsible for riding at a suitable speed based on weather and road conditions always leaving an appropriate safety margin Under no circum stances can the ABS system compensate for the rider s misjudgement or improper use of brakes Sometimes when the brake is operated the tyre locks with a consequent loss of grip which makes it difficult to control the vehicle A position s...

Page 458: ...check the ABS warning light stops flashing when the speed is under 5 km h 3 1 mph If the ABS warning light remains on when the vehicle is running it means that a fault has been detected and the ABS system has been automatically deactivated IN CASE OF FAILURE OR WITH ABS DISCONNECTED THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS SYSTEM ABS enable disable By short pressing the button B move the va...

Page 459: ...ABS system is not detected the ABS warning light flashes When the 5 km h 3 11 mph are exceeded if errors are not detected the ABS warning light turns off if at least one malfunction is detected the ABS warning light turns on permanently The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The detection of malfunctions may require more or less tim...

Page 460: ...NO go to 8 7 CONTACT TECHNICAL SERVICE 8 CHECK A Cable continuity between PIN 8 of the ABS control unit connector and PIN 28 of the instrument panel B Check connectors refer to the operations described in the chapter If the previous checks are OK the causes might be C ABS control unit malfunction D Instrument panel malfunction Use of diagnostics instrument for ABS system Abs screen pages ECU INFO ...

Page 461: ...o vides the following indication Identification pro vided by ECU the ECU also requires a CAN message from the injection ECU in order to determine vehicle ID NOTE the X in the table identifies the connector pin is grounded CAPONORD 1200 and all motorcycles equipped with ABS control units connected via CAN line PARAMETERS screen page This screen shows the parameters measured by the several sensors e...

Page 462: ...last detec tion Battery voltage Speed Ambient parameter error reading 2 Number of error detections number of times the error has been detected by the control unit Ambient parameter error reading 3 for example if it indicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Ambient parameter error reading ...

Page 463: ...rks irregularly 5DA1 Faulty sensor or signal interference Rear speed sensor the signal de creases periodically 5DA2 Possible tone wheel fault due to deformations or dirt the surface of the wheel bearings may be de teriorated In rare cases abnormal tone wheel vibrations Rear spd sensor no signal or detec ted speed too low in relation to the front wheel 5DA3 Faulty sensor or missing sensor or tone w...

Page 464: ...ntrol unit pa rameters ADJUSTMENTS Characteristic Value example Unit of measure ment Notes Coding 1 Allows for the coding of a new control unit or else the recoding of the existing control unit Coding 2 Vehicle identification is done according to the con nection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory Coding 3 The identification can be read on th...

Page 465: ...ctor 2 By unscrewing the nuts remove and plug the brake oil pipes following this sequence 3 4 6 5 Slide off the rear system pipes from the hooks 7 Undo and remove the three screws collect the washers and remove the ABS modulator Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 465 ...

Page 466: ...ng oil pipe to swingarm M5x12 4 8 Nm 5 90 lbf ft 4 Flanged self locking nut M6 1 10 Nm 7 37 lbf ft 5 Screw nut fastening pedal to brake lever M6 1 10 Nm 7 37 lbf ft 6 Brake pipe union M10x1 2 25 Nm 18 44 lbf ft 7 Flanged TE screw fastening rear disc M8x18 5 25 Nm 18 44 lbf ft Loctite 243 8 TCEI screw M6x16 2 12 Nm 8 85 lbf ft Flanged TE screw M6x16 1 10 Nm 7 37 lbf ft Braking system Caponord 1200 ...

Page 467: ...xing pipe to callipers M10x1 2 25 Nm 18 44 lbf ft 2 TEFL screw Fixing calliper to fork stems M10x1 25 4 50 Nm 36 88 lbf ft Loctite 270 Rear brake disc Removal Carry out the removal of the rear wheel Undo and remove the five fixing screws 1 Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 467 ...

Page 468: ...C BRAKE Carry out the removal of the front wheel Undo and remove the six fixing screws 1 Remove the brake disc 2 REMOVAL OF RIGHT FRONT BRAKE Carry out the removal of the front wheel Unscrew and remove the three fixing screws 1 of the tone wheel 2 Braking system Caponord 1200 Caponord 1200 Rally BRAK SYS 468 ...

Page 469: ... Retrieve the tone wheel 2 Undo and remove the six fixing screws 3 Retrieve the brake disc 4 Front brake pads Removal OPTION 01 Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 469 ...

Page 470: ... at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE OPTION 02 Remove the cotter pin 1 Unscrew and remove the pin 2 Remove the clip 3 Braking system Caponord 1200 Caponord 1200 Rally BRAK SYS 470 ...

Page 471: ...NG THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE Rear brake pads Removal OPTION 01 Remove the cotter pin Remove the pin by sliding it back wards Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 471 ...

Page 472: ...y out the exhaust removal Remove the cotter pin 1 Slide off and remove the pin 2 to wards the inside of the wheel Remove the pad 3 CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE Bleeding the braking system PREPARING THE VEHICLE Braking system Caponord 1200 Caponord 1200 Rally BRAK SYS 472 ...

Page 473: ...onnect the brake pipe to the pump line coupling Fill the reservoir with new DOT4 brake fluid REGULAR BLEEDING SYSTEM Connect the bleed bottle to the bleed screw of the front brake calliper Operate the brake lever Open the bleed screw until all the pres sure has been release and then close it Release the brake lever After releasing the lever wait two sec onds so that the brake fluid flows into the ...

Page 474: ...THING IS OK CONTINUE BLEEDING OPERATIONS US ING THE DIAGNOSIS INSTRUMENT BRAKE BLEEDING AFTER ABS CONTROL UNIT REPLACEMENT VEHICLE PREPARATION Connect the bleed bottle to the bleed screws of the front and rear callipers and open it Fully press down the lever and the brake pedal and fix them into position with the respective locking devices Close the bleed screws of the front and rear callipers and...

Page 475: ...BRAKING SYSTEM BLEED AS DESCRIBED AT THE BEGINNING OF THE CHAPTER Check the stroke and the sensitivity of both the lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that there are no leaks in the braking system and if everything is OK continue bleeding operations using the diag nostics instrument as described Detach the bleed hoses and close the bleed scre...

Page 476: ...ain to the correct tightening torque BLEEDING SYSTEM WITH DIAGNOSTICS INSTRUMENT This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy The operations described here are valid for both systems even though the description refers to the front system FRONT With diagnostics instrument properly connected select the function FRONT BRAKE BLEEDIN...

Page 477: ...ew open until the fluid in the tube is clear and free of air bubbles Close the bleed screw Repeat this procedure on the remain ing bleed valves of the system and close them all to the prescribed tight ening torque Remove the bleeding unit Always fill the reservoir up to the reference MAX and refit the cap Check the stroke and the sensitivity of both the lever and the brake pedal If after bleeding ...

Page 478: ...Front brake pump FRONT BRAKE PUMP pos Description Type Quantity Torque Notes 1 Brake pump fixing screws M6 2 10 1 5 Nm 7 37 1 10 lb ft Braking system Caponord 1200 Caponord 1200 Rally BRAK SYS 478 ...

Page 479: ... 2 0 4 0 08 Nm 0 29 0 05 lb ft 3 Spring linking pin M5x7 1 6 1 2 Nm 4 42 0 88 lb ft Loctite 243 4 Microclip plate fixing screw M5X15 1 6 1 2 Nm 4 42 0 88 lb ft Loctite 243 5 Brake lever push rod fixing screw M6 x 20 1 10 1 5 Nm 7 37 1 10 lb ft 6 Brake lever push rod fixing nut M6 1 10 1 5 Nm 7 37 1 10 lb ft Caponord 1200 Caponord 1200 Rally Braking system BRAK SYS 479 ...

Page 480: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS ...

Page 481: ... tank and the left side fairing with a cloth so to avoid contact with the brake fluid Remove the cover and the rubber gas ket of the tank of the clutch pump tank Remove the protective cap of the bleed screw on the throttle control Insert a wrench and a rubber pipe to the bleed screw so to be able to easily recover the oil inside a container Caponord 1200 Caponord 1200 Rally Clutch system CLU SYS 4...

Page 482: ...EDING OPERATIONS OF THE CLUTCH CIRCUIT PAY ALWAYS ATTENTION TO THE BRAKE FLU ID LEVEL IN THE PUMP TANK IF THE LEVEL IS NOT SUFFICIENT NEW AIR WILL ENTER THE CIRCUIT AGAIN THEREFORE IT IS IMPORTANT TO PERIODICALLY RE FILL THE FLUID AND KEEPING A CORRECT LEVEL IN SIDE THE TANK Removing the clutch master cylinder Carry out the removal of the left handg uard Carry out the removal of the left mirror Un...

Page 483: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 484: ...Nm 2 21 lb ft 2 Flanged TE screw fastening left Ra diator to trellis M6x25 1 10 Nm 7 37 lb ft 3 Flanged TE screw fastening expan sion tank M6x20 3 10 Nm 7 37 lb ft Electric fan OPTION 01 Remove the radiator Tighten the three screws on radiator front side Cooling system Caponord 1200 Caponord 1200 Rally COOL SYS 484 ...

Page 485: ...move the radiator Tighten the three screws 1 from the radiator front side See also Removing the radiator Unscrew and remove the two nuts 2 and the special nut 3 Remove the electric fan 4 Collect the three spacers 5 Then collect from the front part the three screws 1 and the three dished washers 6 Procedure valid for both electric fans Caponord 1200 Caponord 1200 Rally Cooling system COOL SYS 485 ...

Page 486: ...leeve Remove the cap Slide off the sleeve and empty the sys tem completely CAUTION SHOULD GREASE BE NOTED IN THE WATER THIS IS TO BE CONSIDERED NORMAL BECAUSE DURING THE AS SEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LU BRICATION OF THE SAME IS REQUIRED IN ORDER TO PREVENT DAMAGE OPTION 02 Cooling system Caponord 1200 Caponord 1200 Rally COOL SYS 486 ...

Page 487: ...the figure Remove the cover 2 Slide off the sleeve 3 and empty the system completely CAUTION SHOULD GREASE BE NOTED IN THE WATER THIS IS TO BE CONSIDERED NORMAL BECAUSE DURING THE AS SEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LU BRICATION OF THE SAME IS REQUIRED IN ORDER TO PREVENT DAMAGE Caponord 1200 Caponord 1200 Rally Cooling system COOL SYS 487 ...

Page 488: ...ening water pump drive gear sprocket M6 1 12 Nm 8 85 lbf ft 5 Water pump rotor 1 4 50 Nm 3 32 lbf ft 6 Screw fastening chain tensioner slid er to water pump M6 1 8 10 Nm 5 90 7 38 lbf ft 7 Water pump support fixing screw M6 3 12 Nm 8 85 lbf ft 8 Water pump support plug M6x10 1 6 5 Nm 4 79 lbf ft 3M SCOTCH GRIP 2353 Removal COVER REMOVAL Drain off the cooling circuit completely Unscrew and remove t...

Page 489: ...screw and remove the anticlock wise screw Remove the rotor REMOVING THE COMPLETE H2O PUMP Remove the clutch cover Unscrew and remove the three H2O pump retaining screws Remove the H2O pump and extract the control chain NOTE WHEN REMOUNTING THE PUMP REPLACE THE O RINGS Caponord 1200 Caponord 1200 Rally Cooling system COOL SYS 489 ...

Page 490: ... to the securing bracket For an easier removal of the radiator lock lower pin remove the screw 2 on the engine head that secures the radi ator clamp Remove the Seeger locking 3 of the right side lower radiator pin Extract the left side pin 4 of the mo torcycle Cooling system Caponord 1200 Caponord 1200 Rally COOL SYS 490 ...

Page 491: ...rew 5 of the water radiator Unhook the water radiator from the pin present on the left side and remove it Thermostatic valve Traditional circuit three way thermostatic valve 1 Hot water inlet from big ends 2 Outlet to short circuit direct to the pump 3 Outlet to radiator Caponord 1200 Caponord 1200 Rally Cooling system COOL SYS 491 ...

Page 492: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 493: ...Windshield on support fastener screw M6x18 4 10 Nm 7 37 lb ft 2 Bracket retainer screw M6x25 4 10 Nm 7 37 lb ft FRONT FAIRING pos Description Type Quantity Torque Notes 1 Deflector fixing screw M5x12 2 6 Nm 4 42 lb ft Caponord 1200 Caponord 1200 Rally Bodywork BODYW 493 ...

Page 494: ... Front with rear lug fixing screw 3 9x14 2 2 Nm 1 47 lb ft 4 Front mudguard fixing screw M6x40 4 12 1 8 Nm 8 85 1 33 lb ft 5 Control unit support fixing screw M6x20 1 10 Nm 7 37 lb ft 6 Lug on support fastener screw M6x12 2 10 Nm 7 37 lb ft 7 Control unit support fixing screw M6x25 2 10 Nm 7 37 lb ft 8 Lug on support fastener screw M5 2 6 Nm 4 42 lb ft 9 Spacer SHC screw M8 1 Tighten by hand Loct ...

Page 495: ...antity Torque Notes 1 Covers fastening screws M5x9 4 3 0 60 Nm 2 21 0 44 lb ft SIDE FAIRINGS pos Description Type Quantity Torque Notes 1 Fairing fastener screw M5x9 2 6 Nm 4 42 lb ft Caponord 1200 Caponord 1200 Rally Bodywork BODYW 495 ...

Page 496: ...e Quantity Torque Notes 2 Fairing fastener screw M5x16 4 6 Nm 4 42 lb ft SADDLE pos Description Type Quantity Torque Notes 1 Saddle fixing screw M5x12 1 6 Nm 4 42 lb ft Bodywork Caponord 1200 Caponord 1200 Rally BODYW 496 ...

Page 497: ...rew M5x12 2 6 Nm 4 42 lb ft LUGGAGE RACK pos Description Type Quantity Torque Notes 1 Luggage rack screw 3 9x14 2 2 Nm 1 47 lb ft 2 Luggage rack cover screw M8x20 2 25 Nm 18 44 lb ft 3 Luggage rack fastener screw M8x25 3 25 Nm 18 44 lb ft 4 Luggage rack screw 5x14 5 3 Nm 2 21 lb ft Caponord 1200 Caponord 1200 Rally Bodywork BODYW 497 ...

Page 498: ... Type Quantity Torque Notes 1 Tail fairing fastener screw M5x12 6 6 Nm 4 42 lb ft 2 Panniers connection fixing screw 4 3 License plate holder fastener screw M6 3 10 Nm 7 37 lb ft Bodywork Caponord 1200 Caponord 1200 Rally BODYW 498 ...

Page 499: ...ustment M6x16 4 10 2 Nm 7 37 1 47 lb ft Loctite 270 REAR LIGHTS pos Description Type Quantity Torque Notes 1 Turn indicator fixing screw M5x16 2 6 Nm 4 42 lb ft 2 Taillight screw M5x16 2 6 Nm 4 42 lb ft 3 License plate light nut M5 1 6 Nm 4 42 lb ft Caponord 1200 Caponord 1200 Rally Bodywork BODYW 499 ...

Page 500: ...ity Torque Notes 1 Switch fastener shear head screw 1 Manual 2 TE screw fastening saddle lock bat tery compartment to saddle mount ing M6x25 2 10 Nm 7 37 lb ft To reuse Loctite 243 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 500 ...

Page 501: ...astening rider footrest mounting to frame M8x35 4 30 Nm 22 12 lb ft Loct 243 4 Footrest rubber fastener narrow nut M5 4 6 Nm 4 42 lb ft 5 TCEI screw fastening rider footrest mounting M6x16 6 10 Nm 7 37 lb ft AIR FILTER BOX pos Description Type Quantity Torque Notes 1 Cross head self tapping screw fas tening covers filter box M5x20 14 3 Nm 2 21 lb ft Cross head self tapping screw fas tening blow by...

Page 502: ...75 2 21 lb ft 2 Level indicator fixing screws M6x16 4 3 0 45 Nm 2 21 0 33 lb ft 3 Saddle fixing M5 x 9 5 1 3 0 45 Nm 2 21 0 33 lb ft 4 Fuel tank cap fixing screw M5 x 14 4 3 0 45 Nm 2 21 0 33 lb ft 5 Joint 2 3 0 45 Nm 2 21 0 33 lb ft Bodywork Caponord 1200 Caponord 1200 Rally BODYW 502 ...

Page 503: ...TANK COVER pos Description Type Quantity Torque Notes 1 Covers fastening screws M5x9 4 3 0 60 Nm 2 21 0 44 lb ft Caponord 1200 Caponord 1200 Rally Bodywork BODYW 503 ...

Page 504: ... screws M8x25 4 25 5 Nm 18 43 3 68 lb ft Seat Insert the key in the lock located on the left fairing Turn the key clockwise Remove the rear saddle Unscrew and remove the front saddle fixing screw Remove the front saddle Instrument panel OPTION 01 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 504 ...

Page 505: ... Loosen the two fastening screws Remove the dashboard upper cover Remove the two screws fastening the lower cover of the dashboard Remove the cover Caponord 1200 Caponord 1200 Rally Bodywork BODYW 505 ...

Page 506: ...Remove the instrument panel OPTION 02 Remove the windscreen Undo and remove the two fixing screws 1 Remove the dashboard upper cover 2 Undo and remove the two fixing screws 3 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 506 ...

Page 507: ... OPTION 01 The following procedure refers to one single part of the dashboard but is val id for both Unscrew and remove the two lower screws of the left dashboard Unscrew and remove the upper screw of the left dashboard Remove the dashboard Caponord 1200 Caponord 1200 Rally Bodywork BODYW 507 ...

Page 508: ...l dashboard Unscrew and remove the screw in the lower part of the light unit Remove the headlight assembly Unscrew and remove the light unit up per fixing screw Undo and remove the light unit lower screw Bodywork Caponord 1200 Caponord 1200 Rally BODYW 508 ...

Page 509: ...form the removal correct and complete it must be done from both sides of the vehicle Remove the complete bumper Undo and remove the six fixing screws 1 Remove the two dashboards 2 Undo and remove the two fixing screws 3 Collect the two washers 4 Unscrew and remove the two screws 5 Undo and remove the two screws 6 and collect the two washers 7 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 509 ...

Page 510: ...ront fairing 9 together with the headlight assembly Unscrew and remove the screw 10 Unscrew and remove the four fixing screws 11 Collect the four washers 12 Unscrew and remove the two screws 13 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 510 ...

Page 511: ... plate holder first Unscrew and remove the two fixing screws Disconnect the connector then re move the rear light unit See also Tail guard Footrest RIGHT FOOTREST Unscrew and remove the upper screw 1 Unscrew and remove the two outer screws 2 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 511 ...

Page 512: ...and remove the two external screws Loosen the gear shift lever rod screw Slide off the gear shift lever rod Remove the left footrest Side fairings OPTION 01 The following procedure refers to one single fairing but is valid for both Remove the rear expansion cap Bodywork Caponord 1200 Caponord 1200 Rally BODYW 512 ...

Page 513: ... Remove the front expansion cap Release the fairing from its fasteners Remove the fairing Caponord 1200 Caponord 1200 Rally Bodywork BODYW 513 ...

Page 514: ...e lock must be removed OPTION 02 The following procedure refers to one single vehicle side but is valid for both Unscrew and remove the screw 1 Remove the expansion cap 2 Remove the expansion cap 3 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 514 ...

Page 515: ...ts fas teners For the left side fairing the cable of the saddle lock 6 must be removed Once the left side fairing is removed the lower fairing can be removed as shown in the following Remove the expansion cap 1 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 515 ...

Page 516: ...r side fairing 2 License plate holder Remove the cover 1 Undo and remove the fixing screw 2 Undo and remove the four fixing screws 3 and remove the plastic cov er 4 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 516 ...

Page 517: ...ts 5 locked undo and remove the two screws operating from the lower side of the tail fairing Collect the two washers 6 Disconnect the connector 7 Remove the clamp 8 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 517 ...

Page 518: ...the connector 9 Remove the license plate holder 10 Air box Remove the air filter box cover Remove the four screws Remove the two intake ducts See also Air filter Bodywork Caponord 1200 Caponord 1200 Rally BODYW 518 ...

Page 519: ... the air temperature sensor Remove the three clamps disconnect the breather tubes and the recovery tube Remove the entire Blow by tank air filter box Splash guard OPTION 01 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 519 ...

Page 520: ... Operating from both sides unscrew and remove the four fixing screws Remove the rear splash guard OPTION 02 Remove the expansion cap 1 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 520 ...

Page 521: ...s 2 Remove the mudflap 3 Fuel tank OPTION 01 Before accessing the tank 1 the side covers 2 the central cover 3 and the tank cap 4 must be removed Unscrew and remove the rear fixing screw Caponord 1200 Caponord 1200 Rally Bodywork BODYW 521 ...

Page 522: ... Unscrew and remove the front fixing screw Remove the three expansion caps on the inside of the fairing Remove the internal upper expansion cap Bodywork Caponord 1200 Caponord 1200 Rally BODYW 522 ...

Page 523: ...cap placed on the side part of the fairing near the turn indicator Disconnect the turn indicator connec tor Remove the side plastic Undo and remove the six fixing screws of the central cover of the tank Caponord 1200 Caponord 1200 Rally Bodywork BODYW 523 ...

Page 524: ...screw and remove the four fixing screws of the tank cap Remove the tank cap Remove the tank central cover Undo and remove the two mounting fixing screws Bodywork Caponord 1200 Caponord 1200 Rally BODYW 524 ...

Page 525: ...ct the level sensor Working from both sides disconnect both breather pipes Unscrew and remove the two fixing screws that connect the tank to the un derfairing Caponord 1200 Caponord 1200 Rally Bodywork BODYW 525 ...

Page 526: ...N 02 Remove the passenger and the rider saddle Remove the tail fairing Remove the side fairings The removal of the side tank cover refers to one single vehicle side but applies for both Remove the expansion cap 1 Remove the two expansion caps 2 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 526 ...

Page 527: ... Undo and remove the fixing screw 3 Undo and remove the fixing screw 4 Undo and remove the fixing screw 5 Undo and remove the fixing screw 6 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 527 ...

Page 528: ... Undo and remove the fixing screw 7 Undo and remove the fixing screw 8 Disconnect the turn indicator connec tor 9 Remove the side tank cover 10 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 528 ...

Page 529: ... Unscrew and remove the four screws 11 Remove the fuel tank cap 12 Unscrew and remove the two fixing screws 13 Remove the central cover 14 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 529 ...

Page 530: ...the supporting clamp 16 Disconnect the breather tubes placed under the front part of the vehicle Undo and remove the two nuts 17 and collect the two thrust washers Disconnect the fuel gauge connector 22 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 530 ...

Page 531: ...BOTH OP TIONS CHECK THAT THE VENTS ARE NOT BLOCKED TO AVOID CRUSHING GENTLY PULL THE VENTS AS INDI CATED AND BRING THE TANK IN ITS POSITION See also Seat Tail guard Side fairings Undo and remove the two fixing screws 18 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 531 ...

Page 532: ...nnect the fuel pump connector 19 Disconnect the preload pipe connector 20 Disconnect the fuel pipe 21 Rear Remove the lock and turn the key an ticlockwise Bodywork Caponord 1200 Caponord 1200 Rally BODYW 532 ...

Page 533: ...or the case on the opposite side Rear grab rail Remove the passenger saddle Remove the plastic that covers the handgrip central fixing screw Unscrew and remove the five rear fix ing screws Caponord 1200 Caponord 1200 Rally Bodywork BODYW 533 ...

Page 534: ...front fix ing screws Unscrew and remove the two central fixing screws Disconnect the saddle lock by undoing the two screws Remove the handgrip See also Seat Windscreen OPTION 01 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 534 ...

Page 535: ...n tion to recover the Teflon washers Remove the windscreen Pay special attention to the correct position of the Teflon washers when refitting OPTION 02 Unscrew and remove the four fixing screws 1 Collect the four washers 2 Caponord 1200 Caponord 1200 Rally Bodywork BODYW 535 ...

Page 536: ... support Undo and remove the two instrument panel support fixing screws Remove the instrument panel paying attention to the cable harness Undo and remove the two shells fixing screws of the instrument support Disconnect the connectors Bodywork Caponord 1200 Caponord 1200 Rally BODYW 536 ...

Page 537: ...k Remove the expansion tank Unscrew and remove the screw indi cated in the figure Disconnect the connector of the ADD management control unit Unscrew and remove the two ADD control unit fixing screws Remove the control unit Caponord 1200 Caponord 1200 Rally Bodywork BODYW 537 ...

Page 538: ...connector Unscrew and remove the left fairing lug fixing screw Unscrew and remove the left fairing lug rear fixing screw Unscrew and remove the front fairing lug fixing screw Bodywork Caponord 1200 Caponord 1200 Rally BODYW 538 ...

Page 539: ...ring lug Unscrew and remove the two right fair ing lug fixing screws Remove the right fairing lug Undo and remove the two upper fixing screws of the right duct bulkhead Caponord 1200 Caponord 1200 Rally Bodywork BODYW 539 ...

Page 540: ...ng screw of the right duct bulkhead Remove the right duct bulkhead Undo and remove the fairing lug lower screw Unscrew and remove the fixing screw of the left part of the fairing lug Bodywork Caponord 1200 Caponord 1200 Rally BODYW 540 ...

Page 541: ... fixing screw of the oil radiator support Undo and remove the fairing lug lower screw Undo the two upper fixing screws of the fairing lug Undo the radiator fixing screw Caponord 1200 Caponord 1200 Rally Bodywork BODYW 541 ...

Page 542: ... Undo and remove the stud bolt Disconnect the radiator pipe Remove the expansion caps Separate the two radiators and remove the radiator protection Bodywork Caponord 1200 Caponord 1200 Rally BODYW 542 ...

Page 543: ...the eight fixing screws of the two covers Remove the two covers Disconnect the battery and remove it Tail guard OPTION 01 Remove the side panniers support by unscrewing the two fastening screws Caponord 1200 Caponord 1200 Rally Bodywork BODYW 543 ...

Page 544: ...and the li cense plate support Remove the tail fairing OPTION 02 Remove the side panniers supports Remove the rear handle Remove the mudflap Remove the license plate support Remove the two expansion caps 1 Bodywork Caponord 1200 Caponord 1200 Rally BODYW 544 ...

Page 545: ...crews 2 Remove the tail fairing 3 Undo and remove the six fixing screws 4 Remove the right 5 and left 6 tail fairing from the seat post closure 7 See also Rear grab rail Splash guard Caponord 1200 Caponord 1200 Rally Bodywork BODYW 545 ...

Page 546: ...ir deflectors Undo and remove the upper screw Unscrew and remove the front screw placed near the radiator Unscrew and remove the rear screw Remove the duct Bodywork Caponord 1200 Caponord 1200 Rally BODYW 546 ...

Page 547: ...rs to one single fair ing but is valid for both Cut and remove the clamp Remove the relay indicated in the fig ure Disconnect the voltage regulator Cut and remove the clamp Release the cables Caponord 1200 Caponord 1200 Rally Bodywork BODYW 547 ...

Page 548: ... Remove the relay box Cut and remove the clamp Bodywork Caponord 1200 Caponord 1200 Rally BODYW 548 ...

Page 549: ... Remove the inside fairing Caponord 1200 Caponord 1200 Rally Bodywork BODYW 549 ...

Page 550: ...INDEX OF TOPICS ...

Page 551: ...PRE DELIVERY PRE DE ...

Page 552: ...ews Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Elec...

Page 553: ...O CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING I...

Page 554: ... braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PR...

Page 555: ... the antivibration weight Fit the rubber ring in the hand guards Position and fasten the top screw en suring to insert the bushing between the hand guard and the handlebar fas tening point Caponord 1200 Caponord 1200 Rally Pre delivery PRE DE 555 ...

Page 556: ...00 Rally OPTION 02 The vehicle comes equipped with additional head lamps clamped to the windscreen fixing brackets Remove the clamps indicated in the figure Position the additional headlamps be tween the two fork sleeves over the front mudguard as indicated in the fig ure Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 556 ...

Page 557: ...IVE SHEATH AGAIN TO THE CORRECT POSI TION PROCEED AS INDICATED IN THE FOLLOWING The procedure applies for both additional head lamps Undo and remove the three fixing screws 1 Remove the lower fork plate 2 and the horn 3 Unhook the supply cable from its cable grommet 4 Slide the sheath downwards until it completely covers the supply cable of the additional headlamp Apply in the points indicated in ...

Page 558: ...AT THE ELECTRIC CONNECTOR OF THE ADDITIONAL HEADLAMP IS DISCONNECTED AND CAUSES THE NON USE OF THE ADDITIONAL HEADLAMP IF THIS OCCURS PROCEED AS INDICATED IN THE FOLLOWING Connect the connector 5 as indicated in the figure Insert the connector in the special seat in the zone below the air deflector Fix the connector in the special hook indicated in the figure Pre delivery Caponord 1200 Caponord 12...

Page 559: ...mper 2 Insert the two screws 4 adjusting them without tightening them Before proceeding to mount the bump er it is recommended to apply the pro tections on both sides of the vehicle to avoid damaging the paint of the frame and of the body Caponord 1200 Caponord 1200 Rally Pre delivery PRE DE 559 ...

Page 560: ...e vehicle as indicated in the figure Place the bumper as shown in the fig ure Insert the rubber 1 on the pin 5 lo cated under the central part of the front headlamp Position the bumper to the frame as in dicated in the figure Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 560 ...

Page 561: ...t the nut 7 Tighten the screw 6 and the nut 7 Position the top part of the left bumper in the middle of the adhesive label lo cated on the frame Insert the fixing bracket 8 Caponord 1200 Caponord 1200 Rally Pre delivery PRE DE 561 ...

Page 562: ...ure of the left bumper Insert the two screws 11 without tight ening them After inserting the fixing screws and before tightening to torque proceed with a manual assessment of the bumper in order to place it symmetri cally in respect to the body Tighten the fixing screws 4 and 11 to the torque of 10 Nm 7 38 lb ft Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 562 ...

Page 563: ... 38 lb ft Tighten the two screws 6 and the two nuts 7 left side and right side to the torque of 50 Nm 36 88 lb ft Insert the two rubbers 2 in the seats of the additional headlamps Insert the two bushings 3 inside the rubbers 2 Caponord 1200 Caponord 1200 Rally Pre delivery PRE DE 563 ...

Page 564: ...the four nuts 6 in both addition al headlamps without tightening Only tighten the rear nuts 6 to the tor que of 10 Nm 7 38 lb ft the front nut indicated in the figure is only tightened after the adjustment of the light beam of the additional headlamps Apply three cable ties 7 in both addi tional headlamps as indicated in the figure Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 564 ...

Page 565: ...from the front view Make sure to engage to the cable grommets indicated in the figure the additional headlamps cables ADDITIONAL HEADLAMPS ADJUSTMENT Place the trip ready vehicle and with the additional headlamps distant 1 m 39 37 in from a vertical wall The upper edge of the light beam must be at least 5 m 0 20 in lower than the height of the optical centre of the addi tional headlamps from the g...

Page 566: ... torque 10 Nm 7 38 lb ft Horizontal adjustment Directly act on the screw 2 turning it clockwise to align the light beam to wards the road centre and anticlock wise to obtain an inverse alignment LIST OF FIXING COMPONENTS key 1 Adjustment screw 2 Adjustment screw 3 Washer Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 566 ...

Page 567: ...al bumper 15 Right side bumpers 16 Left side bumpers 17 Fixing brackets 18 Frame protection decal SIDE SUITCASE standard AND TOP BOX op tional LOCK FIXING Insert the lock in the side suitcase pay ing attention to insert it in the correct direction Repeat the same procedure for the top box Caponord 1200 Caponord 1200 Rally Pre delivery PRE DE 567 ...

Page 568: ...ndscreen 2 on the sup port brackets Insert the two washers in the points in dicated in the figure 3 and the four plastic washers 4 Tighten the four screws 3 BATTERY FITTING Remove the passenger saddle and the tool kit Undo and remove the fixing screw 1 of the rider saddle Remove the rider saddle Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 568 ...

Page 569: ...of the negative pole 9 Refit the covers 3 and 4 and of the rider and passenger saddle REAR VIEW MIRRORS FITTING Insert and tighten the rear view mirror 1 in the seat indicated in the figure Once the desired position is reached keep the nut locked 2 and tighten the nut 3 OIL SUMP GUARD FITTING Insert the six rubbers 1 in the proper seats of the oil sump guard 2 Caponord 1200 Caponord 1200 Rally Pre...

Page 570: ...l sump guard 2 in the four spacers 4 on both vehicle sides Operating from both sides of the vehi cle insert and tighten the four fixing screws 5 Operating from both sides of the vehi cle insert and tighten the two fixing screws 6 Pre delivery Caponord 1200 Caponord 1200 Rally PRE DE 570 ...

Page 571: ...05 309 312 315 321 352 365 370 481 482 Coil 205 Connecting rods Connectors 252 coolant 486 489 Coolant 486 489 Crankcase 60 288 322 329 350 351 355 359 Crankshaft 60 350 355 357 359 Cylinder 60 341 343 346 349 353 482 D Diagnostics 460 Drive chain 15 433 E ECU 255 460 Electric fan 225 484 Electrical system 15 91 96 552 Engine oil 79 271 449 Engine temperature sensor 190 Exhaust 227 442 446 Exhaust...

Page 572: ...8 300 328 352 Maintenance 10 74 Mudguard O Oil filter 80 Oil pressure sensor 220 R Radiator 271 485 490 537 Rear head 324 327 331 341 Rear wheel 423 433 Recommended products 76 Run Stop switch 226 S Saddle Scheduled maintenance 74 Shock absorbers 409 Side fairings 512 Side stand 222 441 Side stand sensor 222 Spark plug 76 Spark plugs Speed sensor 174 Stand 222 440 441 Start up 156 Starter motor 29...

Page 573: ...Tyres 17 U Use 460 W Warning lights Water pump 488 Wiring diagram 133 ...

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