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APRILIA CAPONORD 1200, Service Station Manual

The APRILIA CAPONORD 1200, a powerful and versatile adventure bike, gets even better with the comprehensive "Service Station Manual". Packed with vital information, this manual is a must-have for maintenance and repairs. Download it for free from manualshive.com to unlock the full potential of your Aprilia Caponord 1200.

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•

Compress the valve springs with the

specific wrench and with the spring

compressing tool.

Specific tooling

020382Y

 

Tool for removing valve cotters fitted

with part 012

020896Y

 

Bushing for valve removal

•

Remove the cotters using a magnet.

•

Release the valve springs.

•

Remove the valve spring fittings and

the springs.

CAPONORD 1200

Engine

ENG - 257

Summary of Contents for CAPONORD 1200

Page 1: ...MANUALE STAZIONE DI SERVIZIO 2Q000020 CAPONORD 1200 ...

Page 2: ...l spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication beforeh...

Page 3: ...ally 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 be prepar...

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: ...AUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant contains eth...

Page 9: ... WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY O...

Page 10: ...ore reassembling them When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings OR cotter pins and screws with new parts if the thread is damaged When assemb...

Page 11: ...TO LOOSEN OR EVEN DETACH CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period T...

Page 12: ...identifier code VK model A00 version variation 0 free digit Y year of manufacture S production plant S Scorzè XXXXXX serial number 6 digits ENGINE NUMBER The engine number is printed on the base of the engine crankcase left hand side Engine No CHASSIS NUMBER The chassis number is stamped on the right side of the headstock Chassis No Dimensions and mass DIMENSIONS Specification Desc Quantity Max le...

Page 13: ...r Air filter Sponge Cooling Fluid GEARBOX Specification Desc Quantity Type Mechanical 6 speeds with foot lever on the left hand side of the engine Transmission GEAR RATIOS Specification Desc Quantity Gear ratio Gear primary drive 40 69 1st gear ratio 14 36 secondary 2nd gear ratio 17 32 secondary 3rd gear ratio 20 30 secondary 4th gear ratio 22 28 secondary 5th gear ratio 23 26 secondary 6th gear ...

Page 14: ...uise control warning light LED Gear in neutral LED General warning LED ABS LED ATC LED BULBS Specification Desc Quantity Low high beam light 12V 55W H11 Front daylight running lights 12V 5W Turn indicators 12V 10W White light Rear daylight running light stop light LED Licence plate light 12V 5W Multifunction display lighting LED Frame and suspensions CHASSIS Specification Desc Quantity Type Compon...

Page 15: ...rm connected with cantilever type link to a Sachs single shock absorber with adjustment of hydraulic braking during extension and compression semi active Aprilia Dynamic Damping technology with piggy back tank and au tomated management or manually on instrument panel of spring preload via electro hydraulic system Wheel travel 150 mm 5 90 in SIZES A AND B Specification Desc Quantity Size B 129 2 mm...

Page 16: ...der passenger 2 8 bar 280 kPa 40 61 PSI Supply FUEL SYSTEM Specification Desc Quantity Type Electronic injection Multipoint Throttle valve diameter Ø 52 mm 2 05 in Fuel Premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM Tightening Torques Chassis Front side FRONT BRAKE CALLIPER pos Description Type Quantity Torque Notes 1 Callipers fastening screws M10x55 4 50 7 5 Nm 36 88 5 53 lb f...

Page 17: ...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 CAPONORD 1200 Characteristics CHAR 17 ...

Page 18: ...3 75 Nm 18 44 2 76 lb ft 2 Anti vibration weight fastening screws 2 20 3 Nm 14 75 2 21 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 Characteristics CAPONORD 1200 CHAR 18 ...

Page 19: ...ntity Torque 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 CAPONORD 1200 Characteristics CHAR 19 ...

Page 20: ...1 10 Nm 7 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 Characteristics CAPONORD 1200 CHAR 20 ...

Page 21: ...xing screw 3 9x14 2 2 Nm 1 47 lb ft 4 Front mudguard fixing screw 4 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 TCEI screw M8 1 Tighten by hand Loct 243 CAPONORD 1200 Characteristics CHAR 21 ...

Page 22: ...ONT FAIRING 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 Characteristics CAPONORD 1200 CHAR 22 ...

Page 23: ... 25 1 50 Nm 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 contr...

Page 24: ... Type Quantity Torque Notes 1 Cross head 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 Characteristics CAPONORD 1200 CHAR 24 ...

Page 25: ... bracket M10x30 1 50 Nm 36 88 lbf ft 2 Flanged nut fastening Trellis to 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 Loct...

Page 26: ...n Type Quantity Torque Notes 1 Plastic ring nut 1 20 3 Nm 14 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 1 3 0 45 Nm 2 21 0 33 lb ft Characteristics CAPONORD 1200 CHAR 26 ...

Page 27: ...ening 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 EXHAUST pos Description Type Quantity Torque Notes 1 Fixing screw protection M6x16 3 5 1 Nm 3 68 0 74 lb ft CAPONORD 1200 Characteristics CHAR 27 ...

Page 28: ...Loctite 243 2 Microswitch fixing nuts M6 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 1 10 1 5 Nm 7 37 1 10 lb ft Characteristics CAPONORD 1200 CHAR 28 ...

Page 29: ...on 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 Loctite 243 CAPONORD 1200 Characteristics CHAR 29 ...

Page 30: ...tion Type 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 Characteristics CAPONORD 1200 CHAR 30 ...

Page 31: ...ener screw 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 CAPONORD 1200 Characteristics CHAR 31 ...

Page 32: ...ck side ABS SYSTEM pos Description Type Quantity Torque Notes ABS ECU fastener screw M6x25 1 10 Nm 7 37 lbf ft Loctite 243 ABS ECU fastener nut M6 2 10 Nm 7 37 lbf ft Characteristics CAPONORD 1200 CHAR 32 ...

Page 33: ... 50 Nm 36 88 lb ft 2 Lower TCEI mounting screw M10x80 1 50 Nm 36 88 lb ft ADD Version REAR SUSPENSION ADD Pos Description Type Quantity Torque Notes 1 Upper TCEI mounting screw M10x50 1 50 Nm 36 88 lb ft 2 Lower TCEI mounting screw M10x80 1 50 Nm 36 88 lb ft CAPONORD 1200 Characteristics CHAR 33 ...

Page 34: ...rque Notes 1 Fastening screws flexible coupling M10 5 2 Rear wheel axle 1 120 18 Nm 88 50 13 27 lb ft SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm Pin adjustment bushing 1 12 Nm 8 85 lb ft Characteristics CAPONORD 1200 CHAR 34 ...

Page 35: ... 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 TBEI 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 REAR MUDGUARD Pos Description Type Quantity Torque Notes 1 Mudguard fixing screws on wheel adjustment 1 10 2 Nm 7 37 1 47 lb ft Loctite 243 CAPONORD ...

Page 36: ...rque 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 Characteristics CAPONORD 1200 CHAR 36 ...

Page 37: ... connection fixing screw 4 3 License plate holder fastener screw M6 3 10 Nm 7 37 lb ft 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 Characteristics CHAR 37 ...

Page 38: ...s 1 Special screw for fastening head cover M6 8 9 Nm 6 64 lbf ft 2 Special screw for fastening head cover M6 2 9 Nm 6 64 lbf 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 lbf ft Characteristics CAPONORD 1200 CHAR 38 ...

Page 39: ...ht ening 3 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 lbf ft 8 Bleed union ...

Page 40: ...tity Torque 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 Characteristics CAPONORD 1200 CHAR 40 ...

Page 41: ...tener 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 5 Camshaft retainer plate fastener screw torx M5 8 8 5 Nm 6 26 lbf ft 3M SCOTCH GRIP 2353 CAPONORD 1200 Characteristics CHAR 41 ...

Page 42: ... 06 lbf ft 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 Characteristics CAPONORD 1200 CHAR 42 ...

Page 43: ...lbf ft 4 Oil 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...

Page 44: ...stening Desmodromic 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 Characteristi...

Page 45: ...Clutch fastener 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 CAPONORD 1200 Characteristics CHAR 45 ...

Page 46: ...e Quantity Torque Notes 1 Clutch spring fastener screw M6 6 11 Nm 8 11 lbf ft WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 11 13 Nm 9 59 lbf ft Characteristics CAPONORD 1200 CHAR 46 ...

Page 47: ...ption Type 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 M12x1 25 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 ...

Page 48: ...1 Bearing 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 Characteristics CAPONORD 1200 CHAR 48 ...

Page 49: ...tials Cylinder 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 i...

Page 50: ... Bushing seat diameter 53 954 53 960 mm 2 1241 2 1244 in Crankcase class 2 Bushing seat 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 a...

Page 51: ...ver MAIN BUSHINGS Main journal Crankcase class 1 Crankcase class 2 Class 4 main journal l v Semi bushing type A red Semi bushing type B blue Class 5 main journal l v Semi bushing type B blue Semi bushing type C yellow Class 6 main journal l v Semi bushing type E green Semi bushing type A red Class 7 main journal l f Semi bushing type A red Semi bushing type B blue Class 8 main journal l f Semi bus...

Page 52: ...ated on the clutch side crankcase half in the gearbox control mechanism area NOTE IN THE EVENT OF CRANKCASE REPLACEMENT THE PRI MARY REDUCTION GEAR IS SUPPLIED READY MESHED CRANKCASE CLASSES 02 Specification Desc Quantity Crankcase class A Centre to centre distance 110 50 110 54 mm 4 3504 4 3519 in Crankcase class B Centre to centre distance 110 46 110 50 mm 4 3488 4 3504 in Class one Two differen...

Page 53: ...d must be selected in accordance with the dimension class of the crank pin BUSHINGS Crank pin diameter Connecting rod class 1 Crankshaft class 0 Semi bushing type E green Crankshaft class 1 Semi bushing type A red Crankshaft class 2 Semi bushing type B blue Crankshaft class 3 Semi bushing type C yellow Selecting connecting rods Not all weight classes are available as spare parts Only the two most ...

Page 54: ...S TABLE Product Description Specifications ENI i RIDE PG 15W 50 Engine oil Use branded oils with performance equivalent to or exceeding API SJ JASO MA ACEA A3 JASO MA2 specifica tions FUCHS TITAN SAF 1091 Fork oil Caponord 1200 OJ RACING FORK OIL TYPE 01 Fork oil Caponord 1200 Travel Pack FUCHS TITAN SAF 1091 Actuator oil of the active rear single shock absorber Caponord 1200 Travel Pack AGIP MP G...

Page 55: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 56: ...ode Description 020709Y Engine support 020710Y Engine plate AP8140187 Engine support stand 020850Y Primary gear lock 020712Y Handle for Flywheel cover removal 020713Y Flywheel extractor Special tools CAPONORD 1200 S TOOLS 56 ...

Page 57: ...on 020714Y Dial gauge mounting 9100896 Clutch housing locking tool 020716Y Connecting rod locking 020894Y Pin snap ring fitting tool 020895Y Piston installation ring 020719Y Timing pin CAPONORD 1200 Special tools S TOOLS 57 ...

Page 58: ... Description 020382Y Valve cotters removal tool 020896Y Bushing for valve removal 020720Y Timing tool 020376Y Adapter handle 020891Y Adapter 25 mm 0 98 in 020362Y 12 mm guide Special tools CAPONORD 1200 S TOOLS 58 ...

Page 59: ... control rod roller cage punch 020726Y Extractor for bushings 020727Y Punch for bushings 020884Y 46 mm wrench for steering ring nut 020193Y Gauge for oil pressure check AP8140612 Fuel pressure gauge CAPONORD 1200 Special tools S TOOLS 59 ...

Page 60: ...anel 8140426 Hooks for panel 020888Y Pliers for pre fill pipe 020889Y Pumping member ring nut locking span ner 020890Y Pumping member stanchion support rod 020922Y P A D S 020957Y Key for upper fork nut Special tools CAPONORD 1200 S TOOLS 60 ...

Page 61: ...ode Description 020958Y Fork cartridge protection AP8140149 Protection for fitting operations AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight CAPONORD 1200 Special tools S TOOLS 61 ...

Page 62: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 63: ...ED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Replace at whichever of the following occurs first 40 000 km 24854 mi or 48 months 2 Replace every 2...

Page 64: ...ent panel 4 Fuel lines 3 I I Clutch wear I I Brake pad wear I I I I I Labour time Caponord 1200 minutes 110 130 320 130 410 Labour time Caponord 1200 ADD minutes 110 130 320 130 460 Spark plug At regular intervals remove the spark plug and clean off any carbon deposits or replace as required CAUTION ALWAYS REPLACE ALL SPARK PLUGS EVEN IF ONLY ONE NEEDS REPLACING Remove the saddle Remove the side f...

Page 65: ... coils 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 Maintenance MAIN 65 ...

Page 66: ... 1 0 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 THE ENGINE DURATION AND PERFORMANCE...

Page 67: ...L TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTRAURBAN 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...

Page 68: ...capacity under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and 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 Fill up to the right engine ...

Page 69: ...e the ten screws Remove the filter box cover COVER THE INTAKE DUCTS WITH A CLEAN CLOTH SO THAT FOREIGN BODIES DO NOT GET INTO THE INLET DUCTS UPON REFITTING AND BEFORE PLACING THE FILTER BOX COVER MAKE SURE NEITHER THE CLOTH NOR ANY OTHER OBJECT HAS BEEN LEFT INSIDE THE FILTER BOX MAKE SURE THE FILTERING ELEMENT IS CORRECTLY PLACED SO THAT UNFILTERED AIR DOES NOT FLOW IN DO NOT FORGET THAT EARLY W...

Page 70: ...tween the cam of the camshaft and the valve bucket tappet Take note of the measurement 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...

Page 71: ...d 2 65 3 Calibrated pad 2 70 4 Calibrated pad 2 75 5 Calibrated pad 2 80 6 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 Calibr...

Page 72: ... Apply THREEBOND on the head cover perimeter along the gasket housing Apply THREEBOND on the head in the areas indicated in the figure Maintenance CAPONORD 1200 MAIN 72 ...

Page 73: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 74: ...Engine Troubleshooting CAPONORD 1200 TROUBL 74 ...

Page 75: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 76: ...ing screw M6x12 1 10 Nm 7 37 lbf ft TBEI starter relay fixing screw M6x10 2 10 Nm 7 37 lbf ft Electrical system installation INTRODUCTION Scope and applicability The scope of this document is to define exclusively the passages of the electrical cabling of the vehicle its positioning and fastening on the frame instruments holding support and saddle mounting the pos sible critical issues and the par...

Page 77: ...gure 1 Front section 2 Central section 3 Rear section SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES ALL VER SIONS It is extremely important that any security locks for the following connectors are properly connected and correctly tightened to ensure proper engine and therefore proper vehicle operation 1 Dashboard connector and cap 2 Demand Master and Slave connectors check the clo...

Page 78: ...f the corrugated under the saddle is hidden downwards 24 Check the connection of the rear CDCi shock absorber and if the cap is well inserted 25 Check the passage of the rear CDCi cable and the correct cabling passage 26 Check the connection of the rear shock absorber preload 27 Check the connection of the USB port 28 Check the connection of the starter relay under the saddle and if the fuses are ...

Page 79: ...ck the presence of the clamp retaining the horn s cables 41 Check the GAP between the tone wheel and the ABS sensors it must be between 0 5 and 2mm 42 Check the correct tightening of the front and rear ABS sensors screws General wiring diagram CAPONORD 1200 CAPONORD 1200 Electrical system ELE SYS 79 ...

Page 80: ...key 1 MULTIPLE CONNECTORS Electrical system CAPONORD 1200 ELE SYS 80 ...

Page 81: ...ITCH 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 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 B...

Page 82: ...NDER 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 MAP SENSOR 74 WATER TEMPERATURE SENSOR 75 SECONDARY FUSES 77 FRONT INJECTO...

Page 83: ...key 1 MULTIPLE CONNECTORS CAPONORD 1200 Electrical system ELE SYS 83 ...

Page 84: ...H 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 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 ...

Page 85: ...FRONT 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 SENSO...

Page 86: ...HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE 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 co...

Page 87: ...nce is null or a few tenths of an Ohm CAUTION THE CIRCUIT SHOULD NOT BE ENERGISED OTHERWISE THE TEST IS IRRELE VANT GROUND CONNECTION check Check goal this control is to check if a cable or a circuit is in contact with the vehicle ground connection Tester set the tester on the continuity symbol and place one tester probe on the vehicle ground connection or on the battery terminal and the other pro...

Page 88: ... transponder but it is not within the recognised ones Troubleshooting Store 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...

Page 89: ... Go to the adjustments page and configure the vehicle Close the current diagnosis session Enter the instrument panel diagnosis and do a KEY OFF KEY ON Enter the instrument panel diagnosis and make sure the error is present To solve the error go to the adjustments page and carry out a Vehicle configuration reset Follow the instructions on the screen Delete the errors stored by the instrument panel ...

Page 90: ...amaged replace 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 per...

Page 91: ...alarm occurs 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 NO...

Page 92: ...is subtracted 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 ELE SYS ...

Page 93: ...SS THAN 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 ...

Page 94: ...ystem check 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 ...

Page 95: ...169 signal not valid Error 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 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...

Page 96: ...5 A 5 Coils petrol pump injectors 15 A 6 Low beam high beam light logic 15 A 7 Fans 15 A 8 VCU positive live 15 A only Caponord 1200 Travel Pack Spare fuses 7 5 10 15 A MAIN FUSES under the saddle remove the battery protection A 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 G...

Page 97: ...Control unit Unscrew and remove the control unit cover screws CAPONORD 1200 Electrical system ELE SYS 97 ...

Page 98: ...rew Slide off the control unit from the mountings and remove it from the ve hicle NOTE DURING THE REFITTING PAY PARTICULAR ATTENTION TO FIX THE CONTROL UNIT IN THE MOUNTINGS CONTROL UNIT Diagnosis Function Electrical system CAPONORD 1200 ELE SYS 98 ...

Page 99: ...he 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 instrument serial number Drawing number Person in charge for last programming Indicates the series number of the DIAGNOSTICS INSTRUMENT that has carried out the last control unit remap...

Page 100: ...DIAGNOSTICS INSTRUMENT PARAMETERS Engine revs rpm Front throttle position pot 1 Electrical system CAPONORD 1200 ELE SYS 100 ...

Page 101: ...ar Cylinder Intake Pressure mbar Reference Rear Cylinder Intake Pressure mbar Battery voltage V Exhaust butterfly valve target position Blue connector throttle grip position sensor track A mV Blue connector throttle grip position sensor track B mV White connector throttle grip position sensor track C mV White connector throttle grip position sensor track D mV Tension Front throttle Potentiometer 1...

Page 102: ... loop Lean in half closed loop Front lambda probe Operative Inoperative Rich Inoperative Lean Inoperative Start up Rear lambda probe Operative Inoperative Rich Inoperative Lean Inoperative Start up Front cylinder value Rich Lean Not detected Rear cylinder value Rich Lean Not detected Engine status Indefinite Key ON Running engine Stopped Power latch Power latch 2 Power latch finished Engine mode I...

Page 103: ...Down Up fall sensor Normal Tip over Fan relay On Off RUN STOP switch Run Stop Clutch lever Pulled Released Gear engaged 0 1 2 3 4 5 6 Indeterminate Throttle grip Slightly twisted Choked Fully twisted Rpm sensor signals panel Synchronized Partially synchronized Not synchronized Button during ATC setting Pressed Released Button during ATC setting Pressed Released ATC Aprilia Traction Control Present...

Page 104: ...Not present Cruise control button Pressed Released Cruise control Enabled Disabled Set Cruise control button Pressed Released Button cruise control Pressed Released ACC Aprilia Cruise Control Present Not present Speedometer unit of measurement kph mph Vehicle configuration Valid Not valid EVC Exhaust Valve Control Present Not present DIAGNOSTICS INSTRUMENT ACTIVATION Rear cylinder central coil Fro...

Page 105: ...it not operational Error cause Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status Error RAM P0604 circuit not operational Error cause Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status Error ROM P0605 circuit not operational Error cause Replace injection ECU The instrument panel ...

Page 106: ...arness connector and ENGINE connector of the Marelli control unit if not OK restore if OK check continuity of cable harness Blue Pink cable DIAGNOSTICS INSTRUMENT LOGIC ERRORS Level 2 safety reset P0608 Error cause As the level 2 safety system comparison between requested torque and calculated torque has detected a fault the control unit has reset engine C gravity The instrument panel does not ind...

Page 107: ... SELF LEARNING AND CHECK THE TWO AUTOMATIC FRONT THROTTLE SELF LEARNING AND AUTOMATIC REAR THROTTLE SELF LEARNING STATUSES ARE PERFORMED See also Cylinders synchronisation CONTROL UNIT Diagnosis IF APPLICABLE Function it manages the suspensions system the exhaust butterfly valve and the self diagnosis function Level in electrical circuit diagram Each level in which the main component involves the ...

Page 108: ...r C Current front valve mA Current rear valve mA Number operations preload motor Exhaust butterfly valve target position Exhaust butterfly valve upper travel limit Exhaust butterfly valve lower travel limit Maximum travel preload in impulses DIAGNOSTICS INSTRUMENT STATUSES Suspensions map Indeterminate 1 8 Preload level Indeterminate 1 5 Preload motor Electrical system CAPONORD 1200 ELE SYS 108 ...

Page 109: ...erfly valve output Not active Active Short circuit Fault Open Circuit Fault Preload motor control output Not active Active Short circuit Fault Open Circuit Fault Rotary sensor reset Not Carried out Carried out DIAGNOSTICS INSTRUMENT ACTIVATION Reset control unit Front Suspension Valve Rear suspension valve Exhaust butterfly valve Preload motor DIAGNOSTICS INSTRUMENT ERRORS Error VCU code C1000 Err...

Page 110: ...ve pole red approx 12 6 V 2 negative pole black ground connection DIAGNOSTICS INSTRUMENT PARAMETERS Battery voltage Example value with key ON 12 0 V Example value with engine on 14 2 V In case of recovery this value is set by the control unit Battery voltage pre Recovery Example value with key ON 12 0 V Example value with engine on 14 2 V Value drawn from the signal read without taking into accoun...

Page 111: ...ness if OK check correct operation of the electrical alternator if not OK restore if OK check operation of the voltage regulator VCU ERRORS Battery tension too low or too high C1001 Error cause The battery tension is below 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 FUNCT...

Page 112: ...ce Troubleshooting Check speed sensor 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 decreases periodically Possible tone wheel fault due to deformations or dirt pos sible alterations on the wheel bearing surface In very rare cases abnormal to...

Page 113: ...yre 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 read ing the rear 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 DIAGRAM Level in wiring diagram ABS REMOVAL LOCATION O...

Page 114: ...r tone wheel Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If 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 ...

Page 115: ...e 130 20 Ohm Pin out 1 Negative signal 2 Positive signal CAUTION 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 DIAGNOSTICS INSTRUMENT STATUSES Synchronised panel No_under analysis_standby_Yes DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS CAUTION IF THE...

Page 116: ...ning and correct positioning of the sensor in its own housing if it is not replace it If it is OK replace the sensor Twistgrip position sensor Removal Remove the filter box Loosen the throttle cable nuts Unscrew and remove the two fixing screws Disconnect the two connections and remove the throttle grip position sen sor Remove the throttle cables See also Air box THROTTLE GRIP POSITION SENSOR Func...

Page 117: ...ntactless read the voltage of the 4 tracks by the diagnosis instrument MASTER connector blue A Track A supply B Track A ground C Track A signal D Track B supply E Track B ground F Track B signal SLAVE connector white A Track C supply B Track C ground C Track C signal D Track D supply E Track D ground F Track D signal DIAGNOSIS INSTRUMENT PARAMETERS Blue front connector throttle grip position senso...

Page 118: ..._choked_fully twisted Handle self learning carried out not carried out CAUTION 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 DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS Blue front connector throttle grip position sensor track A P0150 short circuit to...

Page 119: ...al to zero has been detected at PIN 13 of the ENGINE connector Troubleshooting short circuit to positive check the value shown by the parameter of the BLUE front connector Throttle Grip position Sensor track B disconnect the connector and read the value indicated by the diagnostics instrument if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor...

Page 120: ...rly if there is continuity replace the control unit if not restore the wiring White rear connector throttle grip position sensor track D P0153 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 11 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at ...

Page 121: ... sensor White rear connector throttle grip position tracks C D P0155 inconsistent signal Error cause Two illogical voltage signals have been detected at PIN 23 and 11 of the ENGINE connector tracks A B Troubleshooting Check the parameters of the white rear connector Throttle Grip Position Sensor tracks C and D if one of the two values clearly deviates from 600 1400 mV it means that this po tentiom...

Page 122: ...D THE WHITE BAND SHOULD BE PLACED AT THE BACK Intake pressure sensor Figure key A Rear B Front Function The pressure sensors one at the front one at the rear are fundamental for calculation of generated torque for calculation of ambient pressure and for correct ignition timing during start up Operation Operating principle Diaphragm sensor which translates the diaphragm position into electrical vol...

Page 123: ...itive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 24 If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 24 Troubleshooting If shorted to positive verify that the parameter of the front cylinder air Pressure Sensor on the diagnosis instrument is approx 1200 mbar disconnect the sensor connector ...

Page 124: ...here is continuity between the PIN 49 of the Marelli control unit and the sensor connector PIN 3 if there is no continuity restore the cable harness If there is continuity check the cable ground insulation if there is continuity to ground restore the cable harness if not with key set to ON check that the voltage on sensor connector PIN 1 is approx 5 V if not OK set the key to OFF and check continu...

Page 125: ... cable harness Replace the sensor if it is correct Error for unexpected air intake in the front cylinder manifold P0210 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 cleanlines...

Page 126: ...old and cleanliness of the hole for reading the pres sure there is an evident defect in the intake and pressure reading systems Pressure too low at front cylinder manifold error P0217 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 Troublesho...

Page 127: ...e at 60 575 kΩ 15 Ω Resistance at 90 230 kΩ 5 Ω Pin out 1 Yellow Brown 0 5 V signal 2 Green Pink Ground connection DIAGNOSIS INSTRUMENT PARAMETERS Engine temperature Example value with key ON 25 C Example value with engine on 75 C In case of recovery this value is set by the control unit if there is a malfunction after engine start up temperature decreases up to approximately 90 Engine temperature...

Page 128: ...it connector and with key set to key ON check the continuity between the sensor connector PIN 2 and the vehicle ground connection if OK it means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 12 and sensor PIN 1 if there is no continuity with the ground connection check the sensor connector and the Marelli control u...

Page 129: ...the intake air temperature in order to calculate oxygen presence so as to opti mise the petrol quantity necessary for correct com bustion Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in wiring diagram Temperature sensors Location sensor on filter box left side next to rear throttle body connector on the sensor Electrical characteristics ...

Page 130: ...s OK reconnect the control unit connector and with key set to key ON check the continuity between the sensor connector PIN 2 and the vehicle ground connection if OK it means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 37 and sensor PIN 1 check the sensor connector and the Marelli control unit connector If not OK ...

Page 131: ...ower supply white cable REAR CYLINDER LAMBDA PROBE Location on the vehicle exhaust end behind the rear head connector on the right side at the 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 Lamb...

Page 132: ...he status is Fault due to lean value Lambda check Open loop Closed loop Rich in closed loop Lean in closed loop enriched Closed loop indicates that the control unit is using the oxygen sensor 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 fr...

Page 133: ... instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting If shorted to positive disconnect the probe connector and check the correct 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 ...

Page 134: ... check the Red Brown cable continuity between the 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 chec...

Page 135: ... injectors 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 Electrical system ELE SYS 135 ...

Page 136: ...E GENERAL 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...

Page 137: ...e wiring is 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 clos...

Page 138: ...injector connector 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 res...

Page 139: ...not drop restore 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 ...

Page 140: ...gised for 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 ...

Page 141: ... head covers 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 ...

Page 142: ...nds and the 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 ...

Page 143: ... cable harness 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...

Page 144: ...tor if not 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 c...

Page 145: ...rol 4 potentiometer 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...

Page 146: ... 610 mV Rear 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...

Page 147: ...position CAUTION 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 ...

Page 148: ... between the 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 ci...

Page 149: ...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 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 be...

Page 150: ...nected check 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...

Page 151: ...le 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 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 Sig...

Page 152: ...and to compare 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 thr...

Page 153: ...key ON The 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 deterio...

Page 154: ...s hindering 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 ...

Page 155: ...at the throttle 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...

Page 156: ... Carried out 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 ...

Page 157: ...Location 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...

Page 158: ...estore the cable harness if it is not in voltage replace the sensor there is an interruption or shorted to positive of the Pink Black cable in the section from the sensor connector to the sensor or inside the sensor If shorted to negative disconnect the sensor connector and with key set to ON check Grey Black cable voltage if equal to zero restore the cable harness if equal to approx 5 V replace t...

Page 159: ...he sensor 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 APPLICA...

Page 160: ...onnector if 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 sen...

Page 161: ...ions relay 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 CAREF...

Page 162: ... circuit is 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 t...

Page 163: ... 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 connector a...

Page 164: ...et thresholds defined dur ing calibration it is completely open otherwise it is in an intermediate posi tion With bike stopped and in neutral the valve stays closed regardless of rpm Level in electrical circuit diagram Exhaust valve control unit Caponord 1200 VCU Vehicle Control Unit control unit Caponord 1200 Travel Pack Location On the vehicle The motor is placed in the front lower part of the e...

Page 165: ...htening 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 ZERO SEARCH OF THE DISCHARGE VALVE MOTOR PROCEDURE ENTAILS RESETTING THE EXISTING MECHANICAL STOPS AN ERROR FOR STOP SEARCH NOT CARRIED OUT IS THEN INDICATED WHICH REMAINS UNTIL THE SELF LEARNING OF THE DISCHARGE VALVE PROCEDURE IS P...

Page 166: ...ror cause If the circuit is open an interruption of the circuit has been detected If shorted to negative a null tension has been detected on PIN A1 or on PIN C1 EVC If shorted to positive or short circuit between both cables an excessive tension has been detected on PIN A1 or on PIN C1 EVC Troubleshooting If the circuit is open check the connector on the component and the EVC connector Dis connect...

Page 167: ...tput exhaust valve Status Flag active C1613 Error cause Overcurrent on exhaust valve the VCU goes in the recovery mode Troubleshooting Check the connector on the component and the VCU connector Disconnect the connector of the component and check its insulation from ground and supply system of PIN 4 and 5 also ensure that the two PINs are insulated between each other If all the above mentioned test...

Page 168: ...and PIN B4 VCU and restore the cable harness If the cable harness is not damaged replace the component Cruise Control Button IF APPLICABLE Function Cruise Control is an electronic system that makes it possible to set the desired speed and keep it constant also in case of driving uphill or downhill without using the gas control The system is deactivated automatically when the rider uses any of the ...

Page 169: ...he accelerator the Cruise Control will be deactivated back to ON sta tus the warning light starts flashing again The speed control is deactivated warning light starts flashing if you accelerate until the cruising speed is excee ded by more than 30 km h the clutch is activated one of the brake switches is activated the vehicle speed goes out of the speed range previously shown the button ON OFF Cru...

Page 170: ...F button open circuit C1402 Error cause An interruption of the circuit has been detected Troubleshooting Check the continuity of the two cables between the connector of the Cruise Control button and the VCU connector PIN A4 and PIN F4 Error Cruise Control ON OFF button indeterminate C1403 Error cause An interruption of the circuit or a shortcircuit on PIN A4 or on PIN F4 of the VCU connector has b...

Page 171: ...ectrical circuit diagram VCU Vehicle Control Unit control unit Location On the vehicle on the brake Connector on the component Connector 1 Switch front brake 2 Switch rear brake Pin out Gr N ground M Bi Brake released signal G Ro Pulled brake signal Pin out Gr N ground M V Brake released signal G Vi Pulled brake signal DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS VCU ERRORS Error switch front brake sh...

Page 172: ...has been detected Troubleshooting Check the insulation from ground and from supply system of the two cables of the button PIN E2 and PIN F2 VCU Error switch rear brake open circuit C1508 Error cause An interruption of the circuit has been detected Troubleshooting Check the correct operation of the contacts of the button on its two positions and the con tinuity of the cables between the button conn...

Page 173: ...as been detected on PIN A3 VCU Troubleshooting Disconnect the connector of the sensor and check its insulation from ground and supply system of PIN 4 if the insulation is not present restore the cabling otherwise replace the sensor Error pressure sensor open circuit C1408 Error cause An interruption of the circuit has been detected Troubleshooting Check the connector on the component and the VCU c...

Page 174: ...ot damaged replace the sensor Rotary sensor IF APPLICABLE Function Detect the position of the fork that is the angle be tween the fork and the frame Operation Operating principle The system by means of the VCU control unit Vehicle Control Unit measures in real time the energy transmitted to Caponord 1200 damping of the shock absorber from the roughness of the road surface and it adapts the calibra...

Page 175: ...ive or a null tension has been detected on PIN B3 VCU If the circuit is open an interruption has been detected Troubleshooting If shortcircuit disconnect the connector of the rotary sensor and check its insulation from ground and supply system of PIN 2 if the insulation is not present restore the cabling otherwise replace the sensor If the circuit is open Check the connector on the component and t...

Page 176: ...e preload of the rear single shock ab sorber in order to keep the optimal setup Operation Operating principle It is possible to adjust the preload of the spring of the rear shock absorber using an electrical device on 5 positions which are highlighted with specific icons on the digital instrument panel only rider only rider with luggage rider with passenger rider with passenger and luggage automat...

Page 177: ... travel positions Otherwise if you replace the VCU control unit with a new from spare parts the procedure is automatically performed the first time the engine is switched ON DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS VCU ERRORS Error preload motor Status Flag active C1619 Error cause Overcurrent on the preload motor Troubleshooting Check the connector on the component and the VCU connector Disconnec...

Page 178: ... Failed memorisation of the travel limit positions of the preload motor The error occurs if after 2 minutes from the start of the acquisition procedure the VCU cannot record the motor s travel limits possible interruption of the circuit Troubleshooting Check the connector on the component and the VCU connector Disconnect the two con nectors and check the continuity of the cable between the PIN 4 m...

Page 179: ...nectors and check the continuity of the cable between the PIN 1 motor PIN M2 VCU and between PIN 2 motor PIN M1 VCU If all the above mentioned tests have a positive out come 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 ba...

Page 180: ...ction C3 C4 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 Electrical system CAPONORD 1200 ELE SYS 180 ...

Page 181: ...ture sensor 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 CAPONORD 1200 Electri...

Page 182: ... 6 17 Cylinder 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 l...

Page 183: ...a heating 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 fr...

Page 184: ...t 5V tracks 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 Electrical sys...

Page 185: ...Dashboard Grey bodied instrument panel pinout key 1 Live supply CAPONORD 1200 Electrical system ELE SYS 185 ...

Page 186: ...P 9 Fuel reserve 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 Electrical system CAPONORD 1200 ELE SYS 186 ...

Page 187: ...onnection 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 CAPONORD 1200 Electrical system ELE SYS 187 ...

Page 188: ...a computer 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 t...

Page 189: ...ll the messages 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...

Page 190: ...t 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 panel DIAGNO...

Page 191: ...diagnostics instrument of Aprilia Traction Control not present update the control unit VCU ERRORS Failed CAN reception from motor ECU C1300 Error cause The VCU does not receive the signal from the motor control unit Troubleshooting Check the continuity of the cable between PIN K2 VCU PIN 66 VEHICLE motor control unit and between PIN J2 VCU PIN 80 VEHICLE motor control unit The error is automat ica...

Page 192: ... motor control unit Check also the insulation of the two cables between themselves from supply and ground Error Frame Counter ABS C1307 Error cause Failed synchronisation between VCU and ABS control unit on data packets sent received for each packet sent the VCU increases by 1 its internal counter and when it reaches 15 it resets itself Troubleshooting Possible contact or interruption of the cable...

Page 193: ...VCU PIN 26 instrument panel black connector Check also the insulation of the two cables between themselves from supply and ground CAPONORD 1200 Electrical system ELE SYS 193 ...

Page 194: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 195: ...lis to 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 Engine from vehicle ENG VE 195 ...

Page 196: ...ue Notes 1 Flanged nut fastening side panels to engine M12 3 80 Nm 59 lbf 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 ENG VE 196 ...

Page 197: ...t on gearbox 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 ...

Page 198: ... Slide 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 ENG VE 198 ...

Page 199: ...ust manifold 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 Engine from vehicle ENG VE 199 ...

Page 200: ...rews Remove 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 ENG VE 200 ...

Page 201: ...ctor Disconnect 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 Engine from vehicle ENG VE 201 ...

Page 202: ...ift lever 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 ENG VE 202 ...

Page 203: ... remove the 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 Engine from vehicle ENG VE 203 ...

Page 204: ...rear bottom 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 ENG VE 204 ...

Page 205: ...emove the 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 Engine from vehicle ENG VE 205 ...

Page 206: ...he throttle 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 ENG VE 206 ...

Page 207: ...ews slid ing 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 Engine from vehicle ENG VE 207 ...

Page 208: ...WERE BEFORE 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 requir...

Page 209: ...See also Vehicle preparation Adjusting CAPONORD 1200 Engine from vehicle ENG VE 209 ...

Page 210: ...INDEX OF TOPICS ENGINE ENG ...

Page 211: ...NE MOUNTING ARE STABLE AND EN SURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE Specific tooling 020710Y Engine plate AP8140187 Engine support stand 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 Engine ENG 211 ...

Page 212: ...ft 13 Fork 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 ENG 212 ...

Page 213: ...gear on secondary 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 bo...

Page 214: ...halves Slide off the desmodromic drum con trol Remove the three gear selection forks CAUTION THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE Engine CAPONORD 1200 ENG 214 ...

Page 215: ... Carefully rotate the engine support Carefully slide off the whole gear unit Repeat the removal operations but in reverse order CAPONORD 1200 Engine ENG 215 ...

Page 216: ... 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 Removing the gear selector Remove the clut...

Page 217: ...E REPLACE THE WASHER ON EVERY SERVICING Heat the screws of the gearbox selec tor mounting plate Unscrew and remove the three screws fastening the gearbox selector mount ing plate Remove the plate complete with selec tor CAPONORD 1200 Engine ENG 217 ...

Page 218: ...sure that 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 Engine CAPONORD 1200 ENG 218 ...

Page 219: ...the left hand 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 Gear con...

Page 220: ...Removing the starter motor Disconnect the starter motor power supply cable Unscrew and remove the two screws and remove the starter motor Engine CAPONORD 1200 ENG 220 ...

Page 221: ...55 in M12x1 25 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...

Page 222: ...lywheel cover inspection cap Unscrew and remove the ten screws Remove the flywheel cover using the specific tool Specific tooling 020712Y Handle for Flywheel cover removal Collect the gasket and the two dowel pins Engine CAPONORD 1200 ENG 222 ...

Page 223: ... SIMUL TANEOUSLY 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 Heat the magneto flywheel with the specific heater Lock the flywheel using the specific tool and loosen the screw Specific tooling 020713Y Flywheel extractor CAPONORD 1200 Engine ENG 223 ...

Page 224: ... special tool from the external body Unscrew the screw from the crankshaft Specific tooling 020713Y Flywheel extractor Remove the flywheel together with the freewheel 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 ove...

Page 225: ...move the 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 CAPONORD 1200 Engine ENG 225 ...

Page 226: ...haft Screw 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 Engine CAPONORD 1200 ENG 226 ...

Page 227: ... for Pump 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 ...

Page 228: ...4 79 lbf ft 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 Engine CAPONORD 1200 ENG 228 ...

Page 229: ...0 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 Unscrew and remove the six perimeter fastener screws Remove the clutch cover Remove the gasket CAPONORD 1200 Engine ENG 2...

Page 230: ...ows measure 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 To...

Page 231: ... operate in 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 CAPONORD 1200 Engine ENG 231 ...

Page 232: ...ch control rod Fasten the clutch housing using the specific tool Specific tooling 9100896 Clutch housing locking tool Unscrew and remove the clutch hub nut Remove the washer to be chamfered Engine CAPONORD 1200 ENG 232 ...

Page 233: ... Remove the clutch hub Collect the washer between the clutch hub and the housing Collect the clutch housing Collect the spacer and the needle bearings CAPONORD 1200 Engine ENG 233 ...

Page 234: ...fications 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...

Page 235: ...clutch bell for damage and wear that may result in clutch irregular operation Deburr the teeth or replace the bell MAIN DRIVEN GEAR CHECK Check the main driven gear for damage and wear and if necessary replace the main transmission driving gear and the clutch bell all together Make sure there is not excessive noise during operation if necessary replace the main transmission driving gear and the cl...

Page 236: ...amage and wear that may result in clutch irregular operation If neces sary replace the bell Checking the springs Check the springs for damage and if necessary replace the them 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 Engine CAPONORD 1200 ENG 236 ...

Page 237: ...bearing and 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 CAPONORD 1200 Engine ENG 237 ...

Page 238: ...kshaft to correctly 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 housing locking tool Tighten the nut and proceed to caulk CAUTION BE CAREFUL WITH THE CUPPED RING FITTING SIDE THE RING CONE SHALL BE DIRECTED TOWARDS THE ENGINE Engin...

Page 239: ...and alternate 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 g...

Page 240: ... in Prepare the following tools Specific tooling 020376Y Adapter handle 020362Y 12 mm guide 020891Y Adapter 25 mm 0 98 in 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 Engine...

Page 241: ...Notes 1 Special screw for fastening head cover M6 8 9 Nm 6 64 lbf ft 2 Special screw for fastening head cover M6 2 9 Nm 6 64 lbf 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 lbf ft CAPONORD 1200 Engine ENG 241 ...

Page 242: ... 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 lbf ft 8 Bleed union fastener screw M5 4 5 50 Nm 4 06 lbf ft Loctite dry loc 2040 Head cover remo...

Page 243: ...e features 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 CAPONORD 1200 Engine ENG 243 ...

Page 244: ...ecting 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 ...

Page 245: ...ing To refit 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 CAPONORD 1200 Engine ENG 245 ...

Page 246: ...t the washer and the internal spring Unscrew and remove the two screws Remove the chain tensioner and col lect the gasket Remove the camshafts with the gears See also Removing camshafts Disassembling the clutch Unscrew and remove the two chain slider screws Engine CAPONORD 1200 ENG 246 ...

Page 247: ...ve the mobile 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 CAPONORD 1200 Engine ENG 247 ...

Page 248: ...nd remove 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 Engine CAPONORD 1200 ENG 248 ...

Page 249: ...TED INSTRUMENT 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 ...

Page 250: ...oolant fitting 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 Engine CAPONORD 1200 ENG 250 ...

Page 251: ...place 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 CAPONORD 1200 Engine ENG 251 ...

Page 252: ...stall 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 Rear head removal Remove the magneto flywheel Unscrew and remove the screw and collect the washer and the internal spring Engine CAPONORD 1200 ENG 252 ...

Page 253: ...ct the gasket Remove the camshafts 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 CAPONORD 1200 Engine ENG 253 ...

Page 254: ...TE IT IS ADVISABLE 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 Engine CAPONORD 1200 ENG 254 ...

Page 255: ...he three bottom 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 CAPONORD 1200 Engine ENG 255 ...

Page 256: ...E 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 Valves Valve removal Remove the head Place the head on supporting surface N...

Page 257: ...ing compressing tool Specific tooling 020382Y Tool for removing valve cotters fitted with part 012 020896Y Bushing for valve removal Remove the cotters using a magnet Release the valve springs Remove the valve spring fittings and the springs CAPONORD 1200 Engine ENG 257 ...

Page 258: ... deviation 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 ...

Page 259: ...e head face and measure the eccentricity If the eccentricity exceeds the specified limit re place the valve Characteristic Valve head eccentricity 0 03 mm 0 0012 in Spring check Carry out a measurement and a visual inspection 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 l...

Page 260: ...ut M15x1 4 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 ENG 260 ...

Page 261: ...er head Fit 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 me...

Page 262: ...t tighten 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 ENG 2...

Page 263: ... THIS OPERATION WOULD IRRETRIEVABLY DAMAGE THE HEAD Locking torques N m Nut fixing camshaft gears M15x1 4 90 Nm 66 38 lb ft Repeat the fastening operations of the camshafts to the front head Release the crankshaft from the specific special tool Rotate the crankshaft in the riding direction until the rear cylinder piston reaches the top dead centre 270 Lock the crankshaft with the specific special ...

Page 264: ...ain 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 Removing the cylinder Remove the head Slide cylinder out of stud bolts collect ing the base gasket Engine CAPONORD 1200 ENG 264 ...

Page 265: ...ove the cylinder Take out the pin locking ring Lock the connecting rod using the spe cific tool Slide out the pin using the assembly tool pin and remove the piston Specific tooling 020716Y Connecting rod locking 020894Y Pin snap ring fitting tool CAPONORD 1200 Engine ENG 265 ...

Page 266: ...ASONS 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 Remove the top ring the intermediate ring and the three oil scraper rings Engine CAPONORD 1200 ENG 266 ...

Page 267: ...ng sur face the highest value should be considered to estimate wear limits Cylinder bore C 106 000 mm 4 1732 in C D1 or D2 max Replace the cylinder the piston and the piston ring all together if not complying with specifications Checking the piston Measure the piston skirt diameter P with a micrometer a 10 mm 0 39 in from the piston lower border Calculate the clearance between pis ton and cylinder...

Page 268: ... scraper ring 3rd slot with new engine 0 010 0 045 mm 0 0004 0 0018 in Wear limit 0 055 mm 0 0022 in Fit the piston ring to the cylinder Level the installed piston ring with the piston crown Measure piston ring port and replace it if 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 en...

Page 269: ...Limit 0 060 mm 0 0024 in CYLINDER PISTON COUPLING Name Initials Cylinder 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 ...

Page 270: ...tive to each other Fit a new retainer ring on the piston Insert piston in the cylinder using 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...

Page 271: ... Selecting 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 CAPONORD 1200 Engine ENG 271 ...

Page 272: ...ence between the two measurements using the chart be low identify the thickness of the cylin der base gasket to be used upon refitting By correctly identifying the cyl inder base gasket thickness an ade quate compression ratio can be main tained Remove the specific tool and the cyl inder Specific tooling 020720Y Timing tool BASE GASKET Specification Desc Quantity Measured protrusion 0 10 0 0 mm 0 ...

Page 273: ...ner 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 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 CAPONORD 1200 Engine ENG 273 ...

Page 274: ...4 Special calibrated screw for gearbox lubrication 1 18 Nm 13 28 lbf ft Splitting the crankcase halves 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 the water pump drive gear Specific tooling 020850Y Primary gear lock Remove the clutch Remove ...

Page 275: ...in the figure then remove the crankshaft gear with a commercially available extractor See also Disassembling the clutch Magneto flywheel removal Remove the head cylinder assem blies Remove the gear sensor loosening the two fixing screws CAPONORD 1200 Engine ENG 275 ...

Page 276: ...he cylinder Unscrew and remove the selector drum fastener screw Unscrew and remove the nine flywheel side M8 screws Unscrew and remove the eleven fly wheel side M6 screws Turn the engine into horizontal position Engine CAPONORD 1200 ENG 276 ...

Page 277: ...e support nuts Open the crankcase halves Removing the crankshaft CRANKSHAFT pos Description Type Quantity Torque Notes 1 Crankshaft primary gear fastener nut M24x1 5 1 300 Nm 221 27 lbf ft Anticlockwise nut CAPONORD 1200 Engine ENG 277 ...

Page 278: ...UTION TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE Check that both crankcase halves are not cracked or damaged Check that all threads are in proper conditions Check that all oil seals remaining in their position are not worn or damaged Check all ball bearings for clearance smoothness and potential distortions CAUTION LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CH...

Page 279: ...alves re move and thoroughly clean the nozzle that lubricates the piston crown REPLACE THE SPRAY NOZZLE O RING IF NECESSARY Replace the O Rings on oil ducts Before refitting UPON REFITTING THE CRANKSHAFT GREASE THE SHAFT BUSHING CONNECTING ROD COUPLING CAPONORD 1200 Engine ENG 279 ...

Page 280: ... Specific tooling 020714Y Dial gauge mounting Removal Mark the position of the original semi bushings on the crankcase To reduce the installation force neces sary score an incision approximately 0 5 mm 0 02 in deep without cutting into the steel shell in each semi bush ing in the area indicated in the figure Remove the bushings with the crank case cold using a press and the spe cific tool and push...

Page 281: ...he new bushings with the crank case cold using a press and the spe cific tool and pushing outward from the inside of the crankcase until the punch comes into contact with the crankcase surface Specific tooling 020727Y Punch for bushings Assembling the connecting rod CAUTION TO FIT THE CONNECTING RODS CHECK THE COUPLING TYPES INDICATED IN THE CRANK CASE CRANKSHAFT CONNECTING ROD SECTION IN THE CHAR...

Page 282: ...NSURE THAT THE ENGINE AND ENGINE MOUNTING ARE STA BLE AND ENSURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE Install the complete gearbox assembly and the gearbox lubrication diffuser pipe checking O ring conditions Apply black sealing paste Threebond on the left crankcase half CAUTION BE CAREFUL NOT TO APPLY THREEBOND IN EXCESS AS IT MAY BLOCK OIL DUCTS THROUGH THE CRANKCASE HALVES...

Page 283: ...support into vertical position Working on the left side place the elev en M6 screws fixing the 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 CAPONORD 1200 Engine ENG 283 ...

Page 284: ...wo screws fixing the se lector drum Fit a new O ring in the seat Position the gear sensor and screw the two fixing screws Refit both head cylinder assemblies Position the crankshaft gear Engine CAPONORD 1200 ENG 284 ...

Page 285: ...g 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 CAPONORD 1200 Engine ENG 285 ...

Page 286: ...tity Torque Notes 1 Fastening nipple to oil radiator M16x1 5 2 20 3 Nm 14 75 2 21 lb ft 2 Oil radiator tubes fastening M16x1 5 4 15 2 25 Nm 11 06 1 66 lb ft 3 Fastening nipple to engine M16x1 5 2 42 6 3 Nm 30 97 4 64 lb ft Engine CAPONORD 1200 ENG 286 ...

Page 287: ...r 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 Removin...

Page 288: ...y means of 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 Engine CAPONORD 1200 ENG 288 ...

Page 289: ... Remove the 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 CAPONORD 1200 Engine ENG 289 ...

Page 290: ...e cover Collect 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 Engine CAPONORD 1200 ENG 290 ...

Page 291: ... THE REFERENCES 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 CAPONORD 1200 Engine ENG 291 ...

Page 292: ... Fit the spacer Fit the gear Place the washer By means of a calliper spanner lock out gear rotation and tighten the retaining nut Engine CAPONORD 1200 ENG 292 ...

Page 293: ...leased into the atmosphere for environmental reasons Therefore there 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 4 CAPONORD 1200 Engine ENG ...

Page 294: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 295: ...Fuel pump Injection CAPONORD 1200 Power supply P SUPP 295 ...

Page 296: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 297: ...ption Type Quantity Torque Notes 1 Wheel axle 1 80 12 Nm 59 8 85 lb ft Removing the front wheel Hold the vehicle front part Unscrew the screws fixing the front pli ers and slide them off the disc CAPONORD 1200 Suspensions SUSP 297 ...

Page 298: ...p the wheel axle 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 During extraction support the wheel and then remove it Collect the spacer from the front wheel right side Suspensions CAPONORD 1200 SUSP 298 ...

Page 299: ...learance a minimum axial clearance is allowed Radial clearance none If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear ALWAYS REPLACE BOTH GASKETS ALWAYS REP...

Page 300: ...istic Maximum radial and axial eccentricity 2 mm 0 0079 in Handlebar HANDLEBAR pos Description Type Quantity Torque Notes 1 TCEI screw fastening counterweight to handlebar end M6x50 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 2...

Page 301: ...otes 1 TEFL screw fasten onto Fork Hubs M6x40 4 10 Nm 7 37 lb ft 2 Screw Pumping member pin fixing to the stem base 2 30 Nm 22 13 lb ft 3 Upper cover 2 20 Nm 14 75 lb ft 4 Upper cover locking nut 2 20 Nm 14 75 lb ft ADD Version CAPONORD 1200 Suspensions SUSP 301 ...

Page 302: ...tes 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 Pumping member pin fixing to the stem base 2 30 Nm 22 13 lb ft 4 Upper cover 2 20 Nm 14 75 lb ft Diagram Suspensions CAPONORD 1200 SUSP 302 ...

Page 303: ...rew fastening fork legs 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 locat...

Page 304: ... damage the cable itself At this point the stem can be removed from the plate WARNING USING APPROPRIATE EQUIPMENT ACCESS THE SPACE BETWEEN THE CABLE GUIDE AND THE CABLE THEN LEVERAGE MAKING SURE THAT YOU DO NOT DAMAGE THE CABLE Disassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Suspensions CAPONORD 1200 SUSP 304 ...

Page 305: ...y using the 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 Protection for fitting operations CAPONORD 1200 Suspens...

Page 306: ...pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Pliers for pre fill pipe Unscrew the cap and remove it Remove the spring preload pipe Remove the lock nut and the washer Suspensions CAPONORD 1200 SUSP 306 ...

Page 307: ...KE IT TO YOUR 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 CAPONO...

Page 308: ... 1 the movable 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 Pumping member ring nut locking spanner Suspensions CAPONORD 1200 SUSP 308 ...

Page 309: ... STEMS ARE DIFFERENT Specific tooling AP8140149 Protection for fitting 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 CAPONORD 1200 Suspensi...

Page 310: ... member pin 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 Suspensions CAPONORD 1200 SUSP 310 ...

Page 311: ...liding 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 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...

Page 312: ...ap from the pumping member and finally the spring Checking the components Stem Check the sliding surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION Suspensions CAPONORD 1200 SUSP ...

Page 313: ...here are no damages 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 piston If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE CAPONORD 1200 Suspensions SUSP 313 ...

Page 314: ...D FOR BOTH 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 Suspensions CAPONORD 1200 SUSP 314 ...

Page 315: ...d bushing Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight Insert the retainer ring in its position CAPONORD 1200 Suspensions SUSP 315 ...

Page 316: ...mping member pin in 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 Pumping member ring nut locking spanner Insert the spring guide and lock it by the appropriate seeger Place the fork vertically Insert the washer Suspensions CAPONORD 1200 SUSP 316 ...

Page 317: ...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 Pumping member stanchion support rod AP8140147 Spacer tool CAPONORD 1200 Suspensions SUSP 31...

Page 318: ... APPLIES TO 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 Suspensions CAPONORD 1200 SUSP 318 ...

Page 319: ...lly uncovered 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 CAPONORD 1200 Suspensions SUSP 319 ...

Page 320: ...on not to damage 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 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight Suspensions CAPONORD 1200 SUSP 320 ...

Page 321: ...e seat 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 shoes Compress the sleeve in the stem Place a support under the stem in...

Page 322: ... for fitting operations Oil level 135 mm 5 31 in from the sleeve edge without a spring and with preload pipe Characteristic Fork oil check also the correct air level in the stem 441 cm 26 91 cu in for each stanchion ADD Version Oil level LH stem 130 2mm 5 12 0 08 in from sleeve rim without spacer spring and to tal cap Oil level RH stem 120 2mm 4 72 0 08 in from sleeve rim without spacer spring and...

Page 323: ...Nm 18 44 lb ft 4 TCEI screw fastening U bolt onto fork yoke M10x60 2 50 Nm 36 88 lb ft 5 TCEI screw fastening fork legs to top yoke M8x30 2 25 Nm 18 44 lb ft 6 Headstock counter lock ring M25x1 1 Manually screw Adjusting play Place the vehicle so that the front wheel is off the ground Carry out a handlebar rotation test using a dynamometer at the hand grip external end The handlebar resistance to ...

Page 324: ...spill out Unscrew and remove the upper plug from steering yoke pin and collect the washer Operating from both sides loosen the screws fixing the stanchions to the up per plate Undo and remove the two screws fixing the instrument panel support to the fork upper plate Slide off the fork upper plate by moving it towards the instrument panel Suspensions CAPONORD 1200 SUSP 324 ...

Page 325: ...ening torque for the settlement of the steering package turn the steering completely from both sides for several times Loosen the ring nut completely carry out the final tightening of the ring nut to the indicated tightening torque STEERING RING NUT pos Description Type Qua ntit y Torque Notes 1 Headstock ring nut pre tightening M25x1 1 60 Nm 44 25 lb ft Unscrew after pre tightening 1 Headstock ri...

Page 326: ... screw fastening fork legs to bottom yoke M8x35 4 25 Nm 18 44 lb ft 4 TCEI screw fastening U bolt onto fork yoke M10x60 2 50 Nm 36 88 lb ft 5 TCEI screw fastening fork legs to top yoke M8x30 2 25 Nm 18 44 lb ft 6 Headstock counter lock ring M25x1 1 Manually screw Tighten the fixing screws of the upper plate to the prescribed tightening tor que When refitting the U bolt position the two referen ces...

Page 327: ...ing temperature range of 22 F to 284 F 30 C to 140 C drop point between 302ºF to 446 F 150 C to 230 C high corrosion protection qualities and good water and rust resistance Install the upper bearing on the steer ing yoke pin as shown in the figure with the conical part facing downward After inserting the bearing must slide freely on the steering pin till matching with the steering bearing conic in...

Page 328: ... Finish inserting until the stop with the teflon buffer and rubber hammer Pass with a brush on the seal ring to lay down potential grease storage Install dust gaiter 4 on frame head stock Place the tightening ring nut 5 with the indicated rim placed downwards Carry out the steering bearings clear ance adjustment See also Assembling Suspensions CAPONORD 1200 SUSP 328 ...

Page 329: ... Rear wheel axle 1 120 18 Nm 88 50 13 27 lb ft Removing the rear wheel 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 Suspensions SUSP 329 ...

Page 330: ...in from the sprocket Unscrew 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 Suspens...

Page 331: ...ng to the routine maintenance table See also Adjusting Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control...

Page 332: ...OTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS 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 ex...

Page 333: ... REAR SUSPENSION Pos Description Type Quantity Torque Notes 1 Upper TCEI 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 Suspensions SUSP 333 ...

Page 334: ...w M10x80 1 50 Nm 36 88 lb ft Removing 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 Unscrew and remove the shock ab sorber upper fixing screw Unscrew and remove the shock ab sorber lower fixing screw Suspensions CAPONORD 1200 SUSP 334 ...

Page 335: ... valve When removing the shock absorber pay attention to the electric motor it must be removed from the frame taking care not to damage it Revision Disconnect the cabling from the sup port bracket CAPONORD 1200 Suspensions SUSP 335 ...

Page 336: ... 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 Compress the shock absorber spring Remove the retainer ring Suspensions CAPONORD 1200 SUSP 336 ...

Page 337: ...e spring making sure not to damage the cable harness Remove the spring making sure not to damage the cable harness BLEEDING It is possible to carry out a bleeding and replace the oil in the suspension using a special pump Loosen the bleeding valve from sus pension CAPONORD 1200 Suspensions SUSP 337 ...

Page 338: ...bleeding filling to the joint Connect the tube for the oil 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 SUSP 338 ...

Page 339: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 340: ... 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 TBEI 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 ...

Page 341: ...EVER AFTER 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 CAPONORD 1200 Chassis CHAS 341 ...

Page 342: ...INGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN See also Removing the rear wheel Drive chain Adjusting The vehicle is fitted with 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 To check clearance Shut off the engine Rest the vehicle on its stand E...

Page 343: ...ster 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 Tighten the nut 1 Check chain clearance CAUTION TO ENSURE THAT THE WHEEL IS CORRECTLY CEN TRED THERE ARE FIXED REFERENCE MARKINGS 2 3 INSIDE THE CHAIN TENSIONER SLIDER SEATS ON THE SWINGARMS IN FRONT OF THE WHEEL AXLE CHECKING THE CHAIN THE PINION AND THE SPROCK...

Page 344: ... WITH UTMOST CAUTION CLEANING AND LUBRICATION Do not wash the chain with water jets steam jets high pressure water jets and highly flammable sol vents Wash the chain with fuel oil or kerosene Maintenance operations should be more frequent if there are signs of quick rust Lubricate the chain at the intervals specified on the routine maintenance table and whenever necessary Wash the chain allow to d...

Page 345: ...5 5 Nm 18 43 3 68 lb ft Loctite 243 Centre stand WHERE CONTEMPLATED Working on the left side unscrew and remove the central stand fixing screw Working on the left inside unscrew and remove the central stand fixing screw Working on the right side unscrew and remove the central stand fixing screw CAPONORD 1200 Chassis CHAS 345 ...

Page 346: ... Remove the centre stand Side stand Remove the gearshift lever first Disconnect the stand sensor Unscrew and remove the three fixing screws Remove the side stand Chassis CAPONORD 1200 CHAS 346 ...

Page 347: ...n Type Quantity Torque Notes 1 Fixing screw protection M6x16 3 5 1 Nm 3 68 0 74 lb ft Removing the tail pipe Unscrew and remove the two exhaust valve motor fixing screws Remove the exhaust valve motor CAPONORD 1200 Chassis CHAS 347 ...

Page 348: ...nscrew and remove the two fixing screws Remove the exhaust end 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 Chassis CAPONORD 1200 CHAS 348 ...

Page 349: ...e catalytic converter See also Removing the tail pipe Removing the exhaust manifold Disengage the spring Unscrew and remove the three nuts from the front and rear exhaust mani fold CAPONORD 1200 Chassis CHAS 349 ...

Page 350: ...ifold and the catalytic con verter Disconnect the front and rear lambda probe Remove the exhaust manifolds Removing the lambda sensor To remove the lambda probe refer to exhaust end removal See also Removing the tail pipe Chassis CAPONORD 1200 CHAS 350 ...

Page 351: ...ngine oil Remove both side fairings Working on the right side unscrew the two oil pipes Disconnect the horn connectors See also Side body panels Working on the left side unscrew and remove the screw from the front cylin der CAPONORD 1200 Chassis CHAS 351 ...

Page 352: ... Remove the seeger ring and slide off the pin Remove the oil radiator together with support and horn Chassis CAPONORD 1200 CHAS 352 ...

Page 353: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 354: ...ANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM ABS ABS SYSTEM pos Description Type Quantity Torque Notes ABS ECU fastener screw M6x25 1 10 Nm 7 37 lbf ft Loctite 243 ABS ECU fastener nut M6 2 10 Nm 7 37 lbf ft Braking system CAPONORD 1200 BRAK SYS 354 ...

Page 355: ...unit fuse 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 Braking system BRAK SYS 355 ...

Page 356: ...C2 Vehicle 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 BRAK SYS 356 ...

Page 357: ...Operating diagram ABS functional diagram key 1 Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit CAPONORD 1200 Braking system BRAK SYS 357 ...

Page 358: ...eed of the wheels in order to assess potential wheel slippage 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 Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coinci...

Page 359: ...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 sensor 3 on the tone wheel 2 forming an integral unit with the vehicle wheel reads the status of the vehicle wheel spotting any possible lock A control unit 1 signals this out and adjus...

Page 360: ... 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 various functions until the one regarding the ABS appears To activate or deactivate the system briefly press button A which will either activate or deactivate the system in cycles If the system is activated the ABS warning light will blink I...

Page 361: ...S 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 time according to the type of failure Error detection logic foresees that for the errors to be diagnosed one or more conditions mus...

Page 362: ...NO go to 8 7 CONTACT TECHNICAL SERVICE 8 PERFORM THESE CHECKS 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 ...

Page 363: ...onord 1200 pro 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 page shows the parameters meas ured by th...

Page 364: ...m the 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 re...

Page 365: ...nal works irregularly Faulty sensor or signal interference Rear speed sensor 5DA2 the signal decreases periodically Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing sur face In very rare cases abnormal tone wheel vibrations Rear speed sensor 5DA3 no signal or speed measured too low in rela tion to the front wheel Faulty sensor or missing sensor tone w...

Page 366: ...age is used to adjust some control unit parameters ADJUSTMENTS Characteristic Value example Unit of measure ment Notes Coding 1 Used for re coding the control unit or coding a new one 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 in the INFO ECU...

Page 367: ...ect con nector 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 Braking system BRAK SYS 367 ...

Page 368: ...ew fastening 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 CAPO...

Page 369: ...stems M10x1 25 4 50 Nm 36 88 lbf ft Loctite 270 Front brake pads Removal Remove the cotter pin Unscrew and remove the pin Collect the anti vibration springs Extract one pad 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 Rear brake pads CAPONORD 1200 Braking system BRAK SYS 369 ...

Page 370: ...KS Bleeding the braking system VEHICLE PREPARATION It is important to check that there is always enough brake fluid in the reservoir Using a bleed device facilitates these operations while in the meantime the Brake fluid replacement operations are performed In this case the bleed process must be accompanied by further pedal strokes and with the bleed device connected about 5 for each wheel circuit...

Page 371: ...ase the brake lever After releasing the lever wait two sec onds so that the brake fluid flows into the cylinder Repeat this procedure until the brake fluid is clear and has no air bubbles about 10 to 20 times NOTE CHECK BRAKE FLUID LEVEL IN THE RESERVOIR AND IF NECESSARY TOP UP CHECKING BRAKE PAD WEAR Bleed as previously described also on the bleed valve installed on the front brake pump Then perf...

Page 372: ...s 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 remove the bleed bottle Remove the damaged ABS control unit Note First of all detach the brake pipes that go from the ABS control unit to the brake pump 1 4 and immediately seal the opened unions of the ABS control un...

Page 373: ...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 screws again to the correct tightening torque BRAKE BLEEDING AFTER CALLIPER RE PLACEMENT VEHICLE PREPARATION The operations are described for the front system but they are al so valid for both ...

Page 374: ...GNOSTICS 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 BLEEDING PROCEDURE The pump starts rotating While the pump is perfor...

Page 375: ...ve the screw 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...

Page 376: ...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 BRAK SYS 376 ...

Page 377: ...lb ft Loctite 243 2 Microswitch fixing nuts M6 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 1 10 1 5 Nm 7 37 1 10 lb ft CAPONORD 1200 Braking system BRAK SYS 377 ...

Page 378: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS ...

Page 379: ...H 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 CAPONORD 1200 Clutch system CLU SYS 379 ...

Page 380: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 381: ...crew M4x45 6 3 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 Remove the radiator Tighten the three screws on radiator front side CAPONORD 1200 Cooling system COOL SYS 381 ...

Page 382: ...ecting the spacers From the front side collect the screws and dished washers See also Removing the radiator Coolant replacement Remove the right side fairing Place a container of suitable capacity Loosen the screw move the clamp and slide off the sleeve Remove the cap Cooling system CAPONORD 1200 COOL SYS 382 ...

Page 383: ...w M6 11 13 Nm 9 59 lbf ft 2 Fastener screw for Pump 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...

Page 384: ... remove the five water pump cover fixing screws Release the clamp See also Coolant replacement Remove the water pump cover PUMP ROTOR REMOVAL Remove the water pump cover H20 Unscrew and remove the anticlock wise screw Remove the rotor Cooling system CAPONORD 1200 COOL SYS 384 ...

Page 385: ...lide off the drive chain NOTE REPLACE THE O RINGS ON REASSEMBLY Removing the radiator Remove the fuel tank Slide out the connection pin with oil ra diator Drain the fluid from the system Slacken the clamp on the left side Slide off the pipe from the thermostatic valve See also Fuel tank CAPONORD 1200 Cooling system COOL SYS 385 ...

Page 386: ...ator NOTE UPON REFITTING ALWAYS REPLACE WITH A NEW CLAMP Operating from the right side unscrew and remove the radiator upper screw Disconnect the left electric fan Unscrew and remove the three fixing screws Remove the expansion tank Cooling system CAPONORD 1200 COOL SYS 386 ...

Page 387: ...ations explained above but in reverse order and re place all the clamps removed Restore the correct coolant level Thermostatic valve Traditional circuit three way thermostatic valve 1 Hot water inlet from the heads 2 Outlet towards the short circuit direct to the pump 3 Outlet towards the radiator CAPONORD 1200 Cooling system COOL SYS 387 ...

Page 388: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 389: ...e 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 FRONT FAIRING Pos Description Type Quantity Torque Notes 1 Deflector fixing screw M5x12 2 6 Nm 4 42 lb ft CAPONORD 1200 Bodywork BODYW 389 ...

Page 390: ...6x35 1 10 Nm 7 37 lb ft 3 Front with rear lug fixing screw 3 9x14 2 2 Nm 1 47 lb ft 4 Front mudguard fixing screw 4 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 TCEI screw M8 1 Tighten by hand Loct 243 Bo...

Page 391: ...on Type Quantity 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 Bodywork BODYW 391 ...

Page 392: ...iption Type 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 BODYW 392 ...

Page 393: ... fixing screw 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 Bodywork BODYW 393 ...

Page 394: ...escription 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 BODYW 394 ...

Page 395: ... wheel adjustment 1 10 2 Nm 7 37 1 47 lb ft Loctite 243 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 Bodywork BODYW 395 ...

Page 396: ...Type Quantity 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 BODYW 396 ...

Page 397: ...I screw fastening 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 10 3 Nm 2 21 lb ft 2 Cross head self tapping screw fas ten...

Page 398: ...tion Type Quantity Torque Notes 1 Plastic ring nut 1 20 3 Nm 14 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 1 3 0 45 Nm 2 21 0 33 lb ft Bodywork CAPONORD 1200 BODYW 398 ...

Page 399: ...Nm 2 21 0 44 lb ft INSTRUMENT SUPPORT Pos Description Type Quantity Torque Notes 1 Instrument panel to trellis fixing 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 CAPONORD 1200 Bodywork BODYW 399 ...

Page 400: ... Unscrew and remove the front saddle fixing screw Remove the front saddle Instrument panel Loosen the two fastening screws Remove the dashboard upper cover Bodywork CAPONORD 1200 BODYW 400 ...

Page 401: ...emove the cover Disconnect the connector Remove the instrument panel Headlight assy 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 CAPONORD 1200 Bodywork BODYW 401 ...

Page 402: ...ve the dashboard Unscrew and remove the two fixing screws of the central 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 Bodywork CAPONORD 1200 BODYW 402 ...

Page 403: ... of the light unit Remove the headlight assembly Taillight assy Remove the tail fairing and license plate holder first Unscrew and remove the two fixing screws Disconnect the connector then re move the rear light unit See also Tail guard License plate holder CAPONORD 1200 Bodywork BODYW 403 ...

Page 404: ...uter screws 2 Remove the right footrest Unscrew and remove both rear brake pump internal fixing screws LEFT FOOTREST Unscrew and remove the two external screws Loosen the gear shift lever rod screw Slide off the gear shift lever rod Remove the left footrest Bodywork CAPONORD 1200 BODYW 404 ...

Page 405: ...ngs The following procedure refers to one single fairing but is valid for both Remove the rear expansion cap Remove the front expansion cap Release the fairing from its fasteners CAPONORD 1200 Bodywork BODYW 405 ...

Page 406: ...he left side fairing the cable of the saddle lock must be removed License plate holder Unscrew and remove the two fixing screws Remove the access cap unscrew and remove the lower mounting screw Bodywork CAPONORD 1200 BODYW 406 ...

Page 407: ...sconnect the connectors and re move the license plate support Air box Remove the air filter box cover Remove the four screws Remove the two intake ducts See also Air filter CAPONORD 1200 Bodywork BODYW 407 ...

Page 408: ... Cut the ties Disconnect the air temperature sensor Remove the two clamps from the blow by system Remove the air filter box Bodywork CAPONORD 1200 BODYW 408 ...

Page 409: ...m both sides unscrew and remove the four fixing screws Remove the rear splash guard Fuel tank Before accessing the tank 1 the side covers 2 the central cover 3 and the tank cap 4 must be removed CAPONORD 1200 Bodywork BODYW 409 ...

Page 410: ... Unscrew and remove the rear fixing screw Unscrew and remove the front fixing screw Remove the three expansion caps on the inside of the fairing Bodywork CAPONORD 1200 BODYW 410 ...

Page 411: ...xpansion cap Undo and remove the front screw Remove the expansion cap placed on the side part of the fairing near the turn indicator Disconnect the turn indicator connec tor Remove the side plastic CAPONORD 1200 Bodywork BODYW 411 ...

Page 412: ... and remove the six fixing screws of the central cover of the tank Unscrew and remove the four fixing screws of the tank cap Remove the tank cap Remove the tank central cover Bodywork CAPONORD 1200 BODYW 412 ...

Page 413: ... Undo and remove the two mounting fixing screws Disconnect the level sensor Working from both sides disconnect both breather pipes CAPONORD 1200 Bodywork BODYW 413 ...

Page 414: ...ixing screws that connect the tank to the un derfairing Disconnect the fuel pump connector Disconnect the fuel pipe from the pump Remove the tank Rear Remove the lock and turn the key an ticlockwise Bodywork CAPONORD 1200 BODYW 414 ...

Page 415: ...e Repeat the operation for the case on the opposite side Rear grab rail Remove the plastic that covers the handgrip central fixing screw Unscrew and remove the five rear fix ing screws CAPONORD 1200 Bodywork BODYW 415 ...

Page 416: ...Unscrew and remove the two front fix ing screws Unscrew and remove the two central fixing screws Disconnect the saddle lock by undoing the two screws Remove the handgrip Bodywork CAPONORD 1200 BODYW 416 ...

Page 417: ...ield Instrument cluster 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 CAPONORD 1200 Bodywork BODYW 417 ...

Page 418: ...ansion tank 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 Bodywork CAPONORD 1200 BODYW 418 ...

Page 419: ...indicated 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 CAPONORD 1200 Bodywork BODYW 419 ...

Page 420: ...e left fairing 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 Bodywork CAPONORD 1200 BODYW 420 ...

Page 421: ...lower fixing 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 CAPONORD 1200 Bodywork BODYW 421 ...

Page 422: ...remove the 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 Bodywork CAPONORD 1200 BODYW 422 ...

Page 423: ... Undo and remove the stud bolt Disconnect the radiator pipe Remove the expansion caps Separate the two radiators and remove the radiator protection CAPONORD 1200 Bodywork BODYW 423 ...

Page 424: ...Battery Undo and remove the four fixing screws of the battery cover Remove the battery cover Disconnect the battery and remove it Bodywork CAPONORD 1200 BODYW 424 ...

Page 425: ...Tail guard Remove the side panniers support by unscrewing the two fastening screws Remove the two expansion caps Undo and remove the six fixing screws 1 CAPONORD 1200 Bodywork BODYW 425 ...

Page 426: ...li cense plate support Remove the tail fairing See also Rear grab rail License plate holder Side air deflectors Undo and remove the upper screw Unscrew and remove the front screw placed near the radiator Bodywork CAPONORD 1200 BODYW 426 ...

Page 427: ...the rear screw Remove the duct INSIDE FAIRING The following procedure refers to one single fair ing but is valid for both Cut and remove the clamp Remove the relay indicated in the fig ure CAPONORD 1200 Bodywork BODYW 427 ...

Page 428: ... Disconnect the voltage regulator Cut and remove the clamp Release the cables Bodywork CAPONORD 1200 BODYW 428 ...

Page 429: ... Remove the relay box Cut and remove the clamp Remove the inside fairing CAPONORD 1200 Bodywork BODYW 429 ...

Page 430: ...INDEX OF TOPICS ...

Page 431: ...PRE DELIVERY PRE DE ...

Page 432: ...fixing screws 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...

Page 433: ...LY COMES INTO 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 WH...

Page 434: ...ion Hydraulic 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...

Page 435: ...ch fastens 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 Pre delivery PRE DE 435 ...

Page 436: ... Place the hand guards fastening them on the sides using TCEI M6 X 50 screw being careful when inserting the bush ing Pre delivery CAPONORD 1200 PRE DE 436 ...

Page 437: ...40 246 275 288 293 379 Coil 141 Connecting rods Connectors 179 coolant 382 384 386 Coolant 382 384 386 Crankcase 49 214 247 254 273 274 278 282 Crankshaft 49 273 277 280 281 Cylinder 49 264 266 267 269 272 276 D Diagnostics 362 Drive chain 14 342 E ECU 182 362 Electric fan 161 381 Electrical system 14 76 432 Engine oil 67 197 351 Engine temperature sensor 127 Exhaust 163 347 349 Exhaust manifold 3...

Page 438: ...l 223 225 253 275 Maintenance 9 63 Maintenance Table Mudguard O Oil filter 68 Oil pressure sensor 156 R Radiator 197 382 385 418 Rear head 249 252 256 265 Rear wheel 329 331 342 Recommended products 54 Run Stop switch 162 S Saddle Shock absorbers 333 Side fairings 405 Side stand 158 346 Side stand sensor 158 Spark plug 64 Spark plugs Speed sensor 111 Stand 158 344 346 Start up 94 Starter motor 219...

Page 439: ...Tyres 15 W Warning lights Water pump 383 Wiring diagram 79 ...

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