APRILIA DORSODURO 1200 ABS - ATC Service Station Manual Download

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5. Engine control unit

6. Headlamp

7. Start-up relay

8. Coils

9. Spark plugs

10.Starter motor

11.Taillight

12.Auxiliary fuses

13.Main fuses and ABS fuses

14.Throttle grip position sensor

15.Neutral / gear sensor

16.Engine speed sensor - pick up

17.Engine temperature sensor

18.Battery

19.Lambda probe

20.fall sensor

21.Main injection relay

22.Rear speed / ABS sensor

23.Voltage regulator

24.ABS control unit / Modulator

25.Front speed / ABS sensor

CAUTION

A RELAY CANNOT BE IDENTIFIED BASED ONLY ON THE FOLLOWING INDICATIONS: THIS
SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES.

RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE

LIGHT LOGIC RELAY

•

Location on the wiring diagram: 8

•

Location on the vehicle: under the fuel tank, left side, rear relay box, second relay starting

from the front.

START-UP RELAY

•

Location on the wiring diagram: 31

•

Location on the vehicle: under the saddle, right side, next to main fuses.

MAIN INJECTION RELAY

•

Location on the wiring diagram: 17

•

Location on the vehicle: under the left fairing, left side, next to auxiliary fuses.

AUXILIARY INJECTION RELAY

•

Location on the wiring diagram: 35

DORSODURO 1200 ABS - ATC

Electrical system

ELE SYS - 89

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: [email protected]

Summary of Contents for DORSODURO 1200 ABS - ATC

Page 1: ...SERVICE STATION MANUAL 897263 DORSODURO 1200 ABS ATC Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 2: ...l Aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Aprilia reserves the right at any time and without being required to update this publication beforehand to make any changes...

Page 3: ...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 prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle NOTE Provid...

Page 4: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 5: ...M 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 6: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 8: ...T 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 Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant contains ethylene glycol which under certain conditio...

Page 9: ...TION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO 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 OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATT...

Page 10: ...ines Lubricate parts whenever possible before 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 ...

Page 11: ... OR COMPROMISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Engine run in is essential to ensure engine long life and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your riding speed during the running in period In this way you allow for the work of components to be loaded and then unl...

Page 12: ...sion 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 hand side of the headstock Chassis No Dimensions and mass DIMENSIONS Specification Desc Quantity Max length 2248 mm 88 19 in Max w...

Page 13: ...chanical 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 ratio 24 25 secondary Final drive gear ratio 16 40 Capacities CAPACITY Specif...

Page 14: ...tion Desc Quantity High beam light LED Right turn indicator LED Left turn indicator LED General warning LED Gear in neutral LED Side stand down LED Fuel reserve LED ABS LED BULBS Specification Desc Quantity High beam light 12 V 60 W H4 Low beam light 12 V 50 W H4 Front daylight running light 12V 6W H6 Turn indicator light 12V 10W Rear daylight running light stop light LED License plate light 12V 5...

Page 15: ... Ø 32 mm 1 26 in pistons and two calliper pads Rear 240 mm 9 45 in diam disc brake with 34 mm 1 34 in diam single piston calliper Wheels and tyres WHEEL RIMS Specification Desc Quantity Type Light alloy rims with extractable bolt Front 3 50 x 17 Rear 6 00 x 17 TYRES Specification Desc Quantity Tyre type standard PIRELLI CORSA III DUNLOP SPORTMAX QUALIFIER Front tyre 120 70 ZR17 58W Front tyre pres...

Page 16: ... side COOLING SYSTEM pos Description Type Quantity Torque Notes 1 Electric fan fastener screw M4x45 6 3 Nm 2 21 lbf ft 2 Flanged TE screw fastening left Ra diator to trellis M6x25 1 10 Nm 7 37 lbf ft 3 Flanged TE screw fastening expan sion tank M6x20 1 10 Nm 7 37 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded ...

Page 17: ...astening oil radiator M6x25 1 10 Nm 7 37 lbf ft 2 TEFL screw fastening oil radiator mounting M6x12 1 10 Nm 7 37 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 18: ...5 lbf ft Unscrew after pre tightening 1 Headstock ring nut tightening M25x1 1 50 Nm 36 88 lbf ft 2 Headstock cap M22x1 1 100 Nm 73 75 lbf ft 3 TCEI screw fastening fork legs to bottom yoke M8x35 4 25 Nm 18 44 lbf ft 4 TCEI screw fastening U bolt onto fork yoke M10x60 2 50 Nm 36 88 lbf ft 5 TCEI screw fastening fork legs to top yoke M8x30 2 25 Nm 18 44 lbf ft 6 Headstock counter lock ring M25x1 1 T...

Page 19: ...rument panel mounting to fork yoke M6x20 2 10 Nm 7 37 lbf ft 2 Screw fixing instrument panel to plate 5x14 3 2 6 Nm 1 92 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 19 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 20: ... 1 Nm 0 74 lbf ft 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 Characteristics DORSODURO 1200 ABS ATC CHAR 20 Manuals by Motomatrix www motomatrix co uk T...

Page 21: ...utch pump on handle bar 2 10 Nm 7 37 lbf ft 4 Screw fastening clutch control mounting on flywheel side crankcase half M6 1 10 Nm 7 37 lbf ft 5 TBEI tank fixing screw M5x10 1 6 Nm 4 42 lbf ft 6 TBEI screw M6x16 1 12 Nm 8 85 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 21 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 22: ... 2 10 Nm 7 37 lbf ft 3 TBEI screw fastening the brake tank to the plate M6x20 1 10 Nm 7 37 lbf ft 4 TBEI screw M6x16 1 12 Nm 8 85 lbf ft 5 Screw fastening the brake pipe to steering base M6x25 1 10 Nm 7 37 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 22 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 23: ...I screw fastening headlamp mounting to fork yoke M6 1 10 Nm 7 37 lbf ft 4 TCEI fixing screw of headlight to in strument panel support M6x35 1 10 Nm 7 37 lbf ft 5 TEFL screw fixing headlight mount ing to steering base M6x25 1 10 Nm 7 37 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 23 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 24: ... M6x16 2 10 Nm 7 37 lbf ft 3 TBEI screw fastening ignition block cover to spacer M5x9 1 6 Nm 4 42 lbf ft 4 TEFL screw fastening tank protec tion M6x12 2 10 Nm 7 37 lbf ft 5 TEFL screw fastening tank to frame M6x30 2 10 Nm 7 37 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 24 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ...le nut 1 80 Nm 59 lbf ft 2 TE flanged screw fastening front disc M8x20 12 30 Nm 22 13 lbf ft Loctite 243 DORSODURO 1200 ABS ATC Characteristics CHAR 25 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 26: ...10x30 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 Loctite 243 Ch...

Page 27: ... Torque Notes 1 Flanged nut fastening side panels to engine M12 3 80 Nm 59 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 27 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 28: ...4 Footrest rubber fastener narrow nut M5 4 6 Nm 4 42 lbf ft 5 TCEI screw fastening rider footrest mounting M6x16 6 10 Nm 7 37 lbf ft STAND ASSEMBLY pos Description Type Quantity Torque Notes 1 Stand bolt M10x1 25 1 10 Nm 7 37 lbf ft 2 Thin nut M10x1 25 1 25 Nm 18 44 lbf ft Loctite 243 3 Spring fixing pin 1 7 5 Nm 5 53 lbf ft 4 TCEI screw fastening stand switch M5x16 2 6 Nm 4 42 lbf ft Loctite 243 ...

Page 29: ...t 2 Rear TE screw fastening tank M6x90 1 10 Nm 7 37 lbf ft 3 Saddle front retaining pin 1 3 Nm 2 21 lbf ft 4 Hose tail fitting 2 6 Nm 4 42 lbf ft Loctite 518 DORSODURO 1200 ABS ATC Characteristics CHAR 29 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 30: ...R 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 lbf ft 2 Cross head self tapping screw fas tening blow by tank M5x20 2 3 Nm 2 21 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 30 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 31: ...ll joint M6 1 10 Nm 7 37 lbf ft 5 RH ball joint on gearbox control lever M6 1 10 Nm 7 37 lbf ft 6 Pinion protector fixing screw M6x12 2 10 Nm 7 37 lbf ft 7 LH ball joint on gearbox control lever 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 DORSODURO 1200 ABS ATC Characteristics CHAR 31 Manuals...

Page 32: ...tening de mand sensor mounting to demand sensor 5x14 3 4 Nm 2 35 lbf ft 6 TBEI screw fastening relay support to demand sensor mounting M6x16 4 10 Nm 7 37 lbf ft 7 TEFL screw fastening cableway to demand sensor mounting M6x12 1 10 Nm 7 37 lbf ft 8 TEFL horn fixing screw M6x12 1 10 Nm 7 37 lbf ft TBEI starter relay fixing screw M6x10 2 10 Nm 7 37 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 32...

Page 33: ...anual 2 TE screw fastening saddle lock bat tery compartment to saddle mount ing M6x25 2 10 Nm 7 37 lbf ft To reuse Loctite 243 DORSODURO 1200 ABS ATC Characteristics CHAR 33 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 34: ...y Torque Notes 1 Upper LH TCEI screw fastening sad dle mounting to frame M8x55 1 25 Nm 18 44 lbf ft 2 Upper RH TCEI screw fastening sad dle mounting to frame M8x60 1 25 Nm 18 44 lbf ft 3 Lower TCEI screw fastening Saddle mounting to frame M8x40 2 25 Nm 18 44 lbf ft Loctite 243 4 TCEI tank cross member fixing screw M5x16 4 6 Nm 4 42 lbf ft 5 TBEI screw fastening saddle strap M6x20 2 10 Nm 7 37 lbf ...

Page 35: ...Loctite 243 6 TBEI screw fastening rear mudguard to swingarm M5x9 2 6 Nm 4 42 lbf ft Loctite 243 7 TBEI screw fastening chain guard to rear mudguard M5x9 1 4 Nm 2 95 lbf ft 8 TBEI screw fastening chain guide to swingarm M5x9 2 6 Nm 4 42 lbf ft Loctite 243 9 Wheel axle nut M25x1 5 1 120 Nm 88 5 lbf ft 10 Flanged TBEI screw fastening chain slider M5x9 2 6 Nm 4 42 lbf ft DORSODURO 1200 ABS ATC Charac...

Page 36: ...r TCEI mounting screw M10x50 1 50 Nm 36 88 lbf ft 2 Lower TCEI mounting screw M10x80 1 50 Nm 36 88 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 36 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 37: ...mpart ment protection M8x12 2 22 Nm 16 23 lbf ft 5 Flanged TE screw fastening silencer M8x35 2 25 Nm 18 44 lbf ft REAR WHEEL pos Description Type Quantity Torque Notes 1 Lower self locking nut fastening sprocket to sprocket carrier M10 5 50 Nm 36 88 lbf ft 2 TCEI screw fastening flexible cou pling mounting on wheel M10x30 5 50 Nm 36 88 lbf ft Loctite 270 DORSODURO 1200 ABS ATC Characteristics CHAR...

Page 38: ...elf 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 Characteristics DORSODURO 1200 ABS ATC CHAR 38 Manuals by Motomatrix www motomatrix co uk...

Page 39: ...w M5x25 1 6 Nm 4 42 lbf ft 2 TCEI rear turn indicator fixing screw M6 2 3 Nm 2 21 lbf ft 3 Reflector fastener M5 1 6 Nm 4 42 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 39 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 40: ...pos Description Type Quantity Torque Notes 1 TBEI screw fastening LH RH covers to silencer M6x20 4 10 Nm 7 37 lbf ft 2 TBEI screw fastening tail fairing to saddle mounting M5x9 2 6 Nm 4 42 lbf ft 3 Screw fastening tail fairing to battery compartment 5x14 3 2 6 Nm 1 92 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 40 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 41: ... 3 Screw fastening license plate mount ing cover to license plate mounting 3 9x14 3 0 8 Nm 0 59 lbf ft 4 TEFL screw fastening taillight to li cense plate mounting support M6x45 3 10 Nm 7 37 lbf ft 5 Flanged TBEI screw fastening li cense plate bracket to mounting M5x12 2 6 Nm 4 42 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 41 Manuals by Motomatrix www motomatrix co uk The Solution For Lost ...

Page 42: ...astener screw M6x25 1 10 Nm 7 37 lbf ft Loctite 243 ABS ECU fastener nut M6 2 10 Nm 7 37 lbf ft Engine Characteristics DORSODURO 1200 ABS ATC CHAR 42 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 43: ... pre tightening M10x1 25 8 10 Nm 7 38 lbf ft Lubricate the threads before tight ening 3 Head stud bolt fastener nut tighten ing M10x1 25 8 13 Nm 9 59 lbf ft 90 90 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 lb...

Page 44: ...3 Nm 9 59 lbf ft 2 Cylinder plate fastener screw M6 4 13 Nm 9 59 lbf ft 3 Chain tensioner adjustment screw M6 2 5 50 Nm 4 06 lbf ft Characteristics DORSODURO 1200 ABS ATC CHAR 44 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 45: ... 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 DORSODURO 1200 ABS ATC Characteristics CHAR 45 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk...

Page 46: ... 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 DORSODURO 1200 ABS ATC CHAR 46 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 47: ...ator valve M18x1 5 1 42 Nm 30 98 lbf ft 6 Oil pump fastener screw M6 2 12 Nm 8 85 lbf ft 3M SCOTCH GRIP 2353 7 Rose pipe fastener 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 DORSODURO 1200 ABS ATC Characteristics CHAR 47 Manua...

Page 48: ...fastening Desmodromic se lector drum Selector sprocket M8 1 20 Nm 14 75 lbf ft 3M SCOTCH GRIP 2353 4 Gear sensor fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 270 5 Selector pin fastener onto clutch side crankcase half M10x1 5 1 16 Nm 11 80 lbf ft Loctite 242 Characteristics DORSODURO 1200 ABS ATC CHAR 48 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys emai...

Page 49: ...ening 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 13 Nm 9 59 lbf ft DORSODURO 1200 ABS ATC Characteristics CHAR 49 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatr...

Page 50: ... 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 DORSODURO 1200 ABS ATC CHAR 50 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 51: ...Quantity Torque Notes 1 Spark plug 4 11 Nm 8 11 lbf ft 2 Freewheel Ring fastener screw M6 6 14 Nm 10 33 lbf ft 3M SCOTCH GRIP 2353 3 Screw fastening Rotor Crankshaft M12x1 25 1 130 Nm 95 88 lbf ft 4 Screw fastening Stator Flywheel Cover M6 3 9 Nm 6 64 lbf ft 5 Screw fastening pick up Flywheel cover M5 2 3 50 Nm 2 58 lbf ft Loctite 270 6 Flywheel cover fastener screw M6 10 13 Nm 9 59 lbf ft 7 Screw...

Page 52: ...te 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 DORSODURO 1200 ABS ATC CHAR 52 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 53: ...ce A A Type A A 105 990 105 997 mm 4 1728 4 1731 in 105 928 105 935 mm 4 1704 4 1707 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance B B Type B B 105 997 106 004 mm 4 1731 4 1734 in 105 935 105 942 mm 4 1707 4 1709 in 0 055 0 069 mm 0 0022 0 0027 in Cylinder piston clear ance C C Type C C 106 004 106 011 mm 4 1734 4 1736 in 105 942 105 949 mm 4 1709 4 1712 in 0 055 0 069 mm 0 0022 0 ...

Page 54: ...case 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 and in the gearbox control mechanism area on clutch side crankc...

Page 55: ...ss 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 bushing type B blue Semi bushing type C yellow Class 9 main journ...

Page 56: ...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 different pinion classes A or B are available selected in relation to ...

Page 57: ...f 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 significant weight classes are available refer to the follo...

Page 58: ... bearings with an operating temperature range of 30 C to 140 C 22 F to 284 F a drop point between 150 C and 230 C 302 F and 446 F high corrosion pro tection qualities and good water and rust resistance AGIP CHAIN GREASE SPRAY Recommended CHAIN oil Grease AGIP BRAKE 4 BRAKE 5 1 Recommended BRAKE FLUID AGIP BRAKE 4 BRAKE 5 1 Recommended CLUTCH FLUID AGIP PERMANENT SPEZIAL Recommended ENGINE COOLANT ...

Page 59: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 60: ...8140187 Engine support stand 020850Y Primary gear lock 020712Y Handle for Flywheel cover removal 020713Y Flywheel extractor Special tools DORSODURO 1200 ABS ATC S TOOLS 60 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 61: ...tool 020716Y Connecting rod locking 020894Y Pin snap ring fitting tool 020895Y Piston installation ring 020719Y Timing pin DORSODURO 1200 ABS ATC Special tools S TOOLS 61 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 62: ...g for valve removal 020720Y Timing tool 020376Y Adapter handle 020891Y Adapter 25 mm 0 98 in 020362Y 12 mm guide Special tools DORSODURO 1200 ABS ATC S TOOLS 62 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 63: ...020727Y Punch for bushings 020884Y 46 mm wrench for steering ring nut 020193Y Gauge for oil pressure check AP8140612 Fuel pressure gauge DORSODURO 1200 ABS ATC Special tools S TOOLS 63 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 64: ...888Y Pliers for pre fill pipe 020889Y Pumping member ring nut locking span ner 020890Y Pumping member stanchion support rod AP8140149 Protection for fitting operations Special tools DORSODURO 1200 ABS ATC S TOOLS 64 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 65: ...89 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight DORSODURO 1200 ABS ATC Special tools S TOOLS 65 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 66: ...INDEX OF TOPICS MAINTENANCE MAIN Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 67: ...FF ROAD OR FOR TRACK USE I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Check and clean adjust or replace if necessary every 1 000 km 2 Replace every 2 years 3 Replace every 4 years 4 At each engine start 5 Check every month 6 Check each time the rear tyre is replaced 7 Lubricate if you are riding in the rain on wet roads or after the vehicle ...

Page 68: ...egular 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 fairings In order to reach the spark plugs CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE FRONT SPARK P...

Page 69: ...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 See also Fuel tank DORSODURO 1200 ABS ATC Maintenance MAIN 69 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 70: ...YPE OF SPARK PLUG OTHERWISE THE ENGINE DURATION AND PERFORMANCE COULD BE COMPROMISED See also Engine Engine oil Check Check the engine oil level frequently 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 ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM IF YOU CHECK LEVEL WHEN THE...

Page 71: ...8 07 cu in CAUTION DO NOT EXCEED THE MAXIMUM LEVEL CAUTION THE VEHICLE MUST BE UNLOADED Replacement Check the engine oil level frequently To change the oil CAUTION HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY IDEAL TEMPERATURE IS REACHED AFTER THE ENGINE HAS RUN FOR ABOUT TWENTY MINUTES OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT BE CAREFUL NOT TO GET BURNED WHEN CARRYING OU...

Page 72: ... engine oil See also Engine oil filter Check Engine oil filter Remove the fairing lug Working from both sides unscrew and remove the two ABS control unit mounting screws Move the frame complete with ABS control unit Drain the engine oil Unscrew and remove the filter Fit a new engine oil filter Add engine oil up to the correct level NOTE NEVER REUSE AN OLD FILTER Maintenance DORSODURO 1200 ABS ATC ...

Page 73: ... 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 WEAR OF THE PISTON RINGS AND THE CYLINDER CAN BE CAUSED BY A MALFUNCTIONING OR MISPLACED FIL TERING ELEMENT DORSODURO 1200 ABS ATC Maintenance MAIN 73 Manuals by Motomatrix www motomatrix co uk The...

Page 74: ... 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 in Remove one camshaft at a time Leave the other camshaft ass...

Page 75: ...d 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 Calibrated pad 2 45 21 Calibrated pad 2 40 CAUTION BEFORE REFITTING ...

Page 76: ...along the gasket housing Apply THREEBOND on the head in the areas indicated in the figure Maintenance DORSODURO 1200 ABS ATC MAIN 76 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 77: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 78: ...FORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 7 READ THE ACTIVATION PROCEDURE FOR A NEW CONTROL UNIT ON THE ELEC TRICA...

Page 79: ...GINE TEMPERATURE 65 c FRONT THROTTLE CORRECTION OR REAR THROTTLE CORRECTION WITH ENGINE AT IDLE ARE THE PARAMETERS INCLUDED WITHIN 0 8 0 8 INTERVAL AND IN THE SAME SCREEN PAGE ARE THE FRONT THROT POT 1 DEGREES AND REAR THROT POT 1 DEGREES WITH EN GINE AT IDLE OR A 0 5 CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT CYLINDER MUST NOT BE 1 YES go to 16 NO note D 1...

Page 80: ...RUMENT COMMUNICATES WITH THE CONTROL UNIT THAT IS AFTER SELECTING FUEL INJECTION AND FOLLOWING THE INSTRUCTION WITH KEY SET TO ON THE PARAMETERS STATUSES ETC ARE READ YES go to 4 NO go to DIAGNOSIS INSTRUMENT CONNECTION CHECK 4 WITH DIAGNOSIS INSTRUMENT DEVICES ACTIVATION SCREEN PAGE INJEC TOR ICON CARRY OUT ACTIVATION OF AN INJECTOR IT IS ADVISED TO DISCON NECT THE BLACK FUEL PUMP 4 PIN CONNECTOR...

Page 81: ... SENSOR IN VERTICAL POSITION YES go to 13 NO go to 14 13 REFER TO THE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSOR INDICATION ON DIAGNOSIS INSTRUMENT ALWAYS TIP OVER END 14 SET THE SENSOR TO THE CORRECT POSITION END 15 REFER TO THE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS RUN STOP SWITCH INDICATION ON DIAGNOSIS INSTRUMENT ALWAYS STOP END 16 CHECK OPERATION OF FUEL CIRCUIT PRESSUR...

Page 82: ... FROM THE PIN 40 TO THE MAIN IN JECTION RELAY 17 If there is continuity go to MAIN INJECTION RELAY 17 CHECK if there is not continuity restore cable harness END See also Electrical system installation CHECK FUEL PUMP 1 WITH KEY SET TO ON DISCONNECT THE CONNECTOR AND CHECK THAT THERE IS BATTERY VOLTAGE ON PIN 1 YES go to 2 NO go to 4 2 CHECK FUEL PUMP CONNECTOR AND CHECK THAT AT PIN 2 THERE IS GROU...

Page 83: ...E HARNESS SIDE YES go to 3 NO go to 6 3 WITH KEY SET TO ON IS THERE VOLTAGE ON ORANGE CABLE OF THE RELAY CONNECTOR ON THE CABLE HARNESS SIDE YES go to 4 NO go to 7 4 CHECK CORRECT OPERATION OF THE RELAY THAT IS PROVIDING VOLTAGE ON THE CORRESPONDING PIN TO THE RED BROWN CABLE AND GROUND ON SPE CIFIC PIN TO THE BROWN BLACK CABLE IS THERE CONTINUITY BETWEEN THE OTHER TWO RELAY PINS YES go to 5 NO re...

Page 84: ...NNECTOR AND RE LAY CONNECTOR If there is continuity go to 5 if there is not continuity restore cable harness END 5 WITH KEY SET TO OFF CHECK IF THERE IS VOLTAGE ON RED WHITE CABLE ON THE KEY SWITCH CONNECTOR YES go to 6 NO restore the cable harness END 6 WITH KEY SET TO ON AND CONNECTOR DISCONNECTED CHECK ON THE SWITCH SIDE IF THERE IS LACK OF CONTINUITY BETWEEN THE TWO PINS COR RESPONDING TO THE ...

Page 85: ...ETWEEN SWITCH CONNECTOR AND PIN 58 OF THE CONTROL UNIT YES go to 4 NO restore the cable harness END 6 CHECK CONTINUITY OF PINK BLACK CABLE BETWEEN SWITCH CONNECTOR AND PIN 4 OF THE CONTROL UNIT YES go to 4 NO restore the cable harness END 7 REPLACE THE STARTER BUTTON COMPONENT END DORSODURO 1200 ABS ATC Troubleshooting TROUBL 85 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 86: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 87: ...ning de mand sensor mounting to demand sensor 5x14 3 4 Nm 2 35 lbf ft 6 TBEI screw fastening relay support to demand sensor mounting M6x16 4 10 Nm 7 37 lbf ft 7 TEFL screw fastening cableway to demand sensor mounting M6x12 1 10 Nm 7 37 lbf ft 8 TEFL horn fixing screw M6x12 1 10 Nm 7 37 lbf ft TBEI starter relay fixing screw M6x10 2 10 Nm 7 37 lbf ft DORSODURO 1200 ABS ATC Electrical system ELE SYS...

Page 88: ...r 2 Intake air pressure sensor 3 Intake air temperature sensor 4 Instrument panel Electrical system DORSODURO 1200 ABS ATC ELE SYS 88 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 89: ...IDENTIFYING THE COLOUR OF THE RELAY CABLES RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the wiring diagram 8 Location on the vehicle under the fuel tank left side rear relay box second relay starting from the front START UP RELAY Location on the wiring diagram 31 Location on the vehicle under the saddle right side next to main fuses MAIN INJECTION RELAY Locat...

Page 90: ...esses how they are fixed to the motorcycle and potential problems are defined on the following sections in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harness 1 Taillight Cable harness 1 License Plate Light Cable Harness 1 Injection Main Relay 1 Relay Mounting...

Page 91: ...the following connec tors 1 Secondary Lock Connector 2 Instrument panel connector FRONT SECTION TABLE B1 3 Throttle grip position sensor connectors CENTRAL SECTION TABLE A2 4 Pick up connector 5 Side Stand Switch Connector CENTRAL SECTION TABLES V1 V2 V3 6 Regulator Connector CENTRAL SECTION TABLE N 7 Front cylinder coil and rear cylinder coil connectors CENTRAL SECTION TABLES I1 I2 as sembly diag...

Page 92: ...f connectors is also important and essential for the correct operation of the vehicle Front side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A AUXILIARY FUSES VIEW WHEN BIKE IS FINIS...

Page 93: ...tle cables and brake pipes 4 5x290 mm 0 18x11 42 in Clamps TABLE B2 TABLE B3 TABLES C FRONT PIPE ARRANGEMENT TABLE C1 Rubber clamps DORSODURO 1200 ABS ATC Electrical system ELE SYS 93 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 94: ...0 mm 0 18x11 42 in Clamps TABLE E Front speed ABS sensor cable 2 5x160 mm 0 01x6 30 in Clamps Electrical system DORSODURO 1200 ABS ATC ELE SYS 94 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 95: ... screw TABLE G Front speed ABS sensor cable 4 Cable grommet TABLE H Front speed ABS sensor cable 5 2 5x160 mm 0 01x6 30 in Clamps DORSODURO 1200 ABS ATC Electrical system ELE SYS 95 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 96: ...ORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLES A NOTES FOR INSTALLING THE MAIN CABLE HARNESS TABLE A1 Complete main cable harness Electrical system DORSODURO 1200 ABS ATC ELE SYS 96 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomat...

Page 97: ...mps must be removed after reassembly to engine TABLE A4 5 Screw 6 M5 Clip 7 Short screws 8 Screws TABLE A5 Mounting for the AMP SuperSeal connector DORSODURO 1200 ABS ATC Electrical system ELE SYS 97 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 98: ...rews TABLE A8 View of the engine left side with cable harness as sembled TABLE A9 View of the engine right side with cable harness assembled Electrical system DORSODURO 1200 ABS ATC ELE SYS 98 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 99: ...C WATER TEMPERATURE BULB Water temperature bulb and connection at the base and inside the front cylinder TABLES D OVERVIEW OF THE VARIOUS COMPONENTS POSITION TABLE D1 Rear cylinder coil connectors po sition and fastening DORSODURO 1200 ABS ATC Electrical system ELE SYS 99 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 100: ...tion 17 4 5x180 mm 0 18x7 08 in Clamps TABLE F 18 Screws 19 Bushes TABLE G 2 5x160 mm 0 01x6 30 in Clamps Electrical system DORSODURO 1200 ABS ATC ELE SYS 100 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 101: ...AND FASTENING TABLE I1 20 Mounting for the AMP SuperSeal connector 21 MTA mounting for the Bosch connector TABLE I2 TABLE I3 DORSODURO 1200 ABS ATC Electrical system ELE SYS 101 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 102: ...E K1 OVERVIEW WITH FILTER BOX BASE INSTALLED TABLE K2 22 Gasket 23 Screws 24 Air temperature sensor Electrical system DORSODURO 1200 ABS ATC ELE SYS 102 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 103: ...01x6 30 in Clamps TABLES M FUEL PUMP CONNECTION POSI TION TABLE M1 TABLE M2 TABLE M3 DORSODURO 1200 ABS ATC Electrical system ELE SYS 103 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 104: ...O 27 Polarised relay 28 Cap TABLE P OVERVIEW OF THE LEFT SIDE TABLE P1 TABLE P2 Electrical system DORSODURO 1200 ABS ATC ELE SYS 104 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 105: ...tal cable grommet TABLE R2 4 5x290 mm 0 18x11 42 in Clamps TABLE R3 The ABS branch must act as a trap to help keep water out of the gaiter Frame seal and 4 5x180mm 0 18x7 08 in clamps DORSODURO 1200 ABS ATC Electrical system ELE SYS 105 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 106: ...erproof grease 32 Chassis seal TABLE T 4 5x290 mm 0 18x11 42 in Clamps TABLES U TABLE U1 Cable guide TABLE U2 33 Cable guide 34 Screw Electrical system DORSODURO 1200 ABS ATC ELE SYS 106 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 107: ...E V3 2 5x98 mm 0 02x3 86 in Clamps TABLE W GROUND POINT The ground point is on the engine right side and holds together only the two eyelets already present on main cable harness through the flanged screw DORSODURO 1200 ABS ATC Electrical system ELE SYS 107 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 108: ... cable arrangement TABLE Z OVERVIEW LEFT SIDE TABLES AA TABLE AA1 Cable grommet Electrical system DORSODURO 1200 ABS ATC ELE SYS 108 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 109: ...correct installation TABLE AA4 35 Screw 36 Cable grommet TABLE AA5 Lambda probe cable arrangement DORSODURO 1200 ABS ATC Electrical system ELE SYS 109 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 110: ...S INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLES A TABLE A1 1 Start up relay 2 30A fuses 3 Black cable guide TABLE A2 BATTERY Electrical system DORSODURO 1200 ABS ATC ELE SYS 110 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 111: ...LE B2 4 2 5x160 mm 0 01x6 30 in Clamps 5 Cable grommet 4 5x180 mm 0 18x7 08 in Clamps TABLE B3 Cable guide TABLE B4 5 Cable grommet DORSODURO 1200 ABS ATC Electrical system ELE SYS 111 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 112: ...SS TABLE C1 7 4 5x290 mm 0 18x11 42 in Clamp 8 Chassis seal 9 License Plate Light Cable Harness Electrical system DORSODURO 1200 ABS ATC ELE SYS 112 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 113: ...ess TABLE C3 4 2 5x160 mm 0 01x6 30 in Clamp 11 Pipe clamp TABLE C4 2 5x160 mm 0 01x6 30 in Clamp DORSODURO 1200 ABS ATC Electrical system ELE SYS 113 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 114: ...RS 2 FRONT RIGHT TURN INDICATOR 3 COMPLETE HEADLAMP 4 FRONT LEFT TURN INDICATOR Electrical system DORSODURO 1200 ABS ATC ELE SYS 114 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 115: ...HT BULB 22 TAILLIGHT ASSEMBLY 23 RECOVERY LOGIC RELAY 24 Secondary fuses 25 ABS CONTROL UNIT 26 FRONT ABS SENSOR 27 REAR ABS SENSOR 28 Voltage regulator 29 ALTERNATOR 30 STARTER MOTOR 31 START UP RELAY 32 ABS CONTROL UNIT FUSE 33 MAIN FUSE 34 BATTERY 35 AUXILIARY INJECTION RELAY 36 OIL PRESSURE SENSOR 37 FAN 38 FAN CONTROL RELAY 39 Right light switch 40 41 FUEL RESERVE SENSOR PIC 42 FUEL PUMP DORS...

Page 116: ...ENSOR 56 ENGINE SPEED SENSOR 57 FRONT CYLINDER COIL 58 REAR CYLINDER COIL 59 FRONT CYLINDER COIL 60 REAR CYLINDER COIL 61 SPARK PLUG 62 FRONT CYLINDER INJECTOR 63 REAR CYLINDER INJECTOR 64 LAMBDA PROBE Colour key Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red Ro Pink V Green Vi Purple Electrical system DORSODURO 1200 ABS ATC ELE SYS 116 Manuals by Motomatrix www motom...

Page 117: ...nt etc For connec tors whose terminals are not visible e g Marelli control unit use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector CAUTION IN CASE OF TEMPORAL MALFUNCTIONING CARRY OUT ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED 3 Pulling the cables slightly f...

Page 118: ... Check goal this control is to check if a cable is energised i e if it receives power supply from the battery or the control unit Tester set the tester on the direct current symbol and place the tester red probe on the cable being inspected and the black probe on the vehicle ground connection or on the battery terminal CAUTION IN CASE OF TEMPORAL MALFUNCTIONING CARRY OUT ALL DUE CHECKS LOOKING FOR...

Page 119: ...n electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting Check the sensor connector on the cable harness and the instrument panel connector If not OK restore if OK check electrical characteristics and aerial circuit continuity from the instrument panel connector on PIN 24 and 34 if not OK restore cable harness if OK check circuit ground insulat...

Page 120: ... of 4 total keys or the procedure will be interrupted after 20 seconds At this stage the instrument panel turns on as usual 2 Deleting the errors stored by the instrument panel select Menu and then Diagnosis An access code is required to enter this menu 98789 Then select the option Delete errors NOTE DELETE THE ERROR CAUSED BY THE LACK OF MEMORY OF KEY CODES 3 Connect to the vehicle with the diagn...

Page 121: ...errors in the immobilizer and the sensors connected to it DSB 01 Immobilizer fault key code read but not recognised DSB 02 Immobilizer fault key code not read key not present or transponder not working DSB 03 Immobilizer fault aerial not working open or short circuited DSB 04 Internal controller fault DSB 05 DSB 06 Error cause An oil sensor fault is signalled when it is detected that the sensor ci...

Page 122: ...strument panel again This screen page shows the software version currently loaded the LCD reads INSTRUMENT PANEL DISCONNECTED NOW CONNECT THE DIAGNOSIS INSTRU MENT The instrument panel will restart to work normally after the key is inserted extracted Modify Keys With this function the instrument panel can update the keys Up to 4 keys can be stored The user code is first requested to be entered ENT...

Page 123: ... up the engine Operation Operating principle Press the start up button to close the specific cir cuit taking the PIN 58 of the control unit to a voltage equal to zero ground closing Level in electrical circuit diagram Start up signal Location on the vehicle right light switch connector between filter box and wa ter radiator at the centre Electrical characteristics key released the circuit is open ...

Page 124: ... ERRORS Starter switch P0169 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 Front headlamp Characteristic Front daylight running light 12V 6W H6 Low beam light 12 V 50 W H4 High beam light 12 V 60 W H4 Rear light Char...

Page 125: ...Low beam high beam light logic 15 A 7 Fans 15 A Spare fuses 7 5 10 15 A MAIN FUSES ABS ATC version under the saddle remove the battery protection A Spare fuses 30 A 20 A B Battery recharge fan relay live positive lamb da probe ABS ATC live positive 30 A C Permanent ABS ATC positive 20 A Control unit Remove the fuel tank Unscrew and remove the two screws DORSODURO 1200 ABS ATC Electrical system ELE...

Page 126: ...LIDES MUST MOVE FREELY TO THE END OF STROKE WHICH HELPS WITH THE INSERTION OF THE CONNECTOR YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE See also Fuel tank Air box Electrical system DORSODURO 1200 ABS ATC ELE SYS 126 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 127: ...en page screen example value with key set to ON Drawing number Marelli spare part code IAW7SMHW430 Hardware number 00 Mapping Software version number 0000 Type approval Code ISO Code Marelli software code Control unit series number NIP 7SMPRA119 Identifies the single control unit Person in charge for last program ming Indicates the series number of the diagnosis instrument that has car ried out th...

Page 128: ...page on the DIAGNOSIS section of the instrument panel Start up enabling yes no Indicates whether the control unit will enable start up when requested in case the safety measures are not respected side stand neutral sensor and clutch in correct position or the fall sensor is inverted or if the immobilizer does not send the start up consent to the control unit the status is NO DIAGNOSIS INSTRUMENT A...

Page 129: ...el does not indicate the presence of this error even in the ATT status ROM Error P0605 circuit not operational Error cause Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status A D converter P0607 circuit not operational Error cause Replace injection ECU Safety relay error P0610 short circuit to positive short circuit to negative open circui...

Page 130: ...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 indicate the presence of this error even in the ATT status Troubleshooting Continue fault search for the other errors detected Safety Engine Stop P0609 Error cause Since the safety system has detected a serious fault the control unit has sh...

Page 131: ... If front and rear throttle automatic self acquisition indicate Not carried out go to phase 1 if indicate Carried out go to phase 2 Phase 1 current errors have probably been detected by the control unit solve these malfunctions and check the two statuses Throttle Self learning can also be checked from the Parameter adjustment screwdriver and hammer screen page Stage 2 Carry out the Handle Self lea...

Page 132: ...42 If too low too low a voltage has been detected at PIN 42 The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting If too high check correct operation of the voltage regulator If too low check voltage regulator connectors engine vehicle cable harness connector and the control unit connector paying special attention to possible oxidation if not OK r...

Page 133: ...y are OK check continuity of the white brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor on the cable harness side with the sensor disconnected and key set to ON must have 12V voltage approximately if there is no voltage check PIN 2 for continuity with the vehicle gro...

Page 134: ... distance between the sensor and the tone wheel 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 If it is not OK replace the tone wheel and if it is OK replace the...

Page 135: ...N 1 of the sensor on the cable harness side and PIN 12 of the ABS control unit connector If this is not OK restore the cable harness If it is OK replace the sensor LOGIC ERRORS Speed sensor 5DA1 the signal works irregularly faulty sensor or signal interference 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 fix...

Page 136: ...teeth or wrong tyre size 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 If it is not OK replace the tone wheel and if it is OK check that the tyre size is the co...

Page 137: ...OK REPLACE THE SENSOR IF OK CHECK THAT THERE IS CONTINUITY ON BOTH CABLES SUPPLY INSULATION AND GROUND INSULATION CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR IF NOT OK RE STORE THE CABLE HARNESS REPLACE THE SENSOR IF OK PERFORM THE TEST FROM PIN 20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR DIAGNOSIS INSTRUMENT LOGIC ERRORS Engine speed sensor P0336 signal not valid Error ...

Page 138: ... control unit Operation Operating principle The two throttle cables opening and closing ac tuate on a scroll mounted on a shaft which is sent back to its home position by a return spring On the shaft covers there are 2 double track potentiome ters 4 control tracks by means of which the tor que demand is read and checked The 4 potentiometers are tinned and magnetically con trolled contactless they ...

Page 139: ...107 mV Example value with engine on Voltage value of the front potentiometer track A Blue front connector throttle grip position sensor track B Example value with key ON 1070 mV Example value with engine on Voltage value times 2 of the front potentiometer track B White rear connector throttle grip position sensor track C Example value with key ON 3560 mV Example value with engine on Voltage value ...

Page 140: ...it is open shorted to negative voltage equal to zero has been detected at PIN 39 of the ENGINE connector Troubleshooting shorted to positive check the value shown by the parameter of the BLUE front connector Throttle Grip Position Sensor track A disconnect the connector and read the value indi cated by the diagnosis instrument if the voltage does not vary there is a short circuit in the cable wiri...

Page 141: ... and with the switch key set to ON check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is continuity replace the control unit if not restore the wiring DIAGNOSIS INSTRUMENT ELECTRICAL ERRORS White rear connector throt...

Page 142: ...check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable ground insulation from the throttle grip sensor connector or the control unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the switch key set ...

Page 143: ...p position P0156 incongruent signal Error cause The value of the front side sensor tracks A B does not coincide with the value of the rear sensor tracks C D Troubleshooting Replace the throttle grip sensor DIAGNOSIS INSTRUMENT ADJUSTABLE PARAMETERS Handle self learning RESET PROCEDURE If Marelli control unit or its mapping are replaced or if you carry out control unit EEPROM zero setting or if you...

Page 144: ...ottle body right side front cylin der sensor on front throttle body left side connector on the sensor Electrical specifications Pin out 1 Power supply 5V 2 Ground connection 3 Output signal DIAGNOSIS INSTRUMENT PARAMETERS Front Cylinder Intake Pressure Example value with key ON 1004 mbar Example value with engine on 715 mbar NOTE pressure read by the front sensor Rear Cylinder Intake Pressure Exam...

Page 145: ...is shorted between the control unit connector and the sensor connector restore the cable harness Replace the sensor if the value varies If the circuit is open shorted to negative check the Marelli control unit connector and the sensor connector if not OK restore If everything is OK with key set to OFF check if there is continuity between the PIN 24 of the Marelli control unit and the sensor connec...

Page 146: ...ot OK restore the cable harness if OK replace the control unit if there is 5V voltage at PIN 1 and with key set to ON check the continuity to ground of the sensor connector PIN 3 if not OK restore the cable harness if OK replace the sensor DIAGNOSIS INSTRUMENT LOGIC ERRORS front cylinder air pressure sensor P0107 signal not valid Error cause According to the engine operation data rpm throttle etc ...

Page 147: ... manifold P0211 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is higher than the estimated one intake manifold condi tions Troubleshooting Check the conditions of the intake manifold and cleanliness of the hole for pressure reading Estimation error for front cylinder intake manifold pressure P0215 to...

Page 148: ...for pressure reading Pressure too low at rear cylinder manifold error P0218 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the conditions of the intake manifold and cleanliness of the hole for pressure reading Engine te...

Page 149: ...n 40 C Value drawn from the signal read without taking into account any recovery the value in the example refers to an open circuit Engine temperature at start up Example value with key ON 40 C Example value with engine on 25 C The temperature value is stored during engine start up With key ON value 40 C is read CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHO...

Page 150: ...nnector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If shorted to negative check sensor correct resistance if resistance is null replace the sen sor if resistance is correct it means that the Yellow Brown cable has ground connection restore the cable harness DIAGNOSIS IN...

Page 151: ...INSTRUMENT PARAMETERS Air temperature Example value with key ON 45 C 113 F In case of recovery this value is set by the control unit Air temperature pre Recovery Example value with key ON 40 C 40 0 F Value drawn from the signal read without taking into account any recovery the value in the exam ple refers to an open circuit CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL...

Page 152: ...ctor and the Marelli control unit connector If not OK restore the cable harness If OK check continuity between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If shorted to negative check sensor correct resistance if ...

Page 153: ...ue with key ON 1 00 mV Example value with engine on 0 90 1 10mV In closed loop the value must be close to 1 00 values not within the 0 90 1 10 interval indicate a fault for example value 0 75 corresponds to 25 with respect to the reference injection time 1 25 corresponds to 25 In an open circuit the lambda probe signal is too low Therefore the con trol unit takes it as a lean combustion condition ...

Page 154: ...on DIAGNOSIS INSTRUMENT ELECTRICAL ERRORS lambda probe P0130 shorted to positive Error cause Excessive voltage battery voltage has been detected at PIN 10 and 22 of the ENGINE connector Caution the lambda probe parameter is not the real value that is read a re covery value is displayed instead The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting ...

Page 155: ... OK with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if it is not OK check the Red Brown cable continuity between the probe connector and the auxiliary injection relay No 35 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 in...

Page 156: ...OBE READS LEAN COMBUSTION CONDITIONS AND THE CONTROL UNIT INCREASES INJECTION TIME CAUSES CHECK FOR INCORRECT AIR INTAKE LITTLE PET ROL RUSTY TERMINAL CONTACTS DEFECTIVE PROBE IF 1 1 THE PROBE READS RICH COMBUSTION CONDITIONS AND THE CONTROL UNIT RE DUCES INJECTION TIME CAUSES LITTLE AIR EXCESSIVE PETROL DEFECTIVE PROBE Injector Injectors key 1 Front injector 2 Rear injector INJECTOR Function To s...

Page 157: ...uxiliary injection relay No 35 in the wiring diagram placed in the front relay box left side CHECK however the identification of the relay with the colour of the cables is ener gised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuit...

Page 158: ...ed to positive disconnect the injector connector set key to ON activate the compo nent with the diagnosis instrument and check the voltage on the White Black cable on the injector connector if there is voltage if there is voltage restore the filter box cable harness If there is no voltage replace the sensor If shorted to negative disconnect the injector connector set the key to ON and check if the...

Page 159: ...ORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT ACTIVATION Fuel pump NOTE The auxiliary injection relay No 35 in the wiring diagram positioned in the front relay box left side CHECK however the identification of the relay with the ...

Page 160: ...ore if OK check continuity of cable harness Brown Black cable Coil Function Spark generation Operation Operating principle Inductive discharge system Level in electrical circuit diagram coils and injectors Location on the vehicle on the 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 shor...

Page 161: ...ification of the relay with the colour of the cables is energised for 5 seconds 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 Th...

Page 162: ...ck the ground insulation of the cable from coil connector or control unit connector if not OK restore 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...

Page 163: ...rness Rear cylinder side coil P0354 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 1 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 1 of the ENGINE connector Troubleshooting If shorted to positive disconnect the coil connector set the key to ON act...

Page 164: ... connection DIAGNOSIS INSTRUMENT PARAMETERS Front cylinder throttle correction Example value with key ON 0 0 Example value with engine at idle 0 5 The system reading the intake pressure tries to balance the intake pressures between the front cylinder and the rear one working on the throttle position an acceptable value should be between 0 8º and 0 8º Rear cylinder throttle correction Example value...

Page 165: ...th key ON 746 mV Example value with engine on 605 mV Front throttle Potentiometer 2 degrees Example value with key ON 5 5 Example value with engine on 2 5 With key set to ON the throttle is kept in position by the springs around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal to 0 5 When the gear is not engaged at approx 6000 rpm throttles...

Page 166: ...ULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Front throttle automatic self acquisition ice interrupted carried out limp home closed throttle stop springs check limp home self ac quisition initialise Indicates if self acquisition carried out by control unit has ...

Page 167: ... if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body potentiometer 2 sensor front throttle position P0122 short circuit to positive open circuit short circuit to negative Error...

Page 168: ...is connected to ground If both are correct replace the throttle body potentiometer 2 sensor rear throttle position P0127 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 21 If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 21 Troubleshooting If shorted to positive c...

Page 169: ...t connector between PIN 29 and 41 is within 1 and 2 5 Ohm if it is not replace the throttle body if it is check that the throttle body is not mechanically blocked if blocked solve the problem and replace the body if it is not replace the control unit Rear throttle control circuit P0186 short circuit to positive short circuit to negative open circuit overvoltage excessive internal temperature circu...

Page 170: ...ntrol unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor front throttle position P0123 signal not valid Error cause Signal not within the expected value drawn according to the value...

Page 171: ...e Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN 36 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor rear throttle position P0128 signal not valid Error cause Signal not w...

Page 172: ...this error even in the ATT status Troubleshooting Check if the throttle body and the intake duct are clean If OK replace the throttle body Front throttle mechanical springs self acquisition P0161 failed test Error cause Return time of the throttle kept in position by the springs not within the expected limits the causes can be a deterioration of the performance of the springs or excessive throttle...

Page 173: ...or P0167 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body Rear throttle Limp Home self acquisition P0180 failed test Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Tro...

Page 174: ...ensation in the intake duct If OK replace the throttle body Rear throttle supply voltage during self acquisition P0184 low power supply voltage Error cause The throttle power supply voltage is too low to carry out the self acquisition test correctly at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Delete errors hindering thrott...

Page 175: ...the statuses are Carried out If necessary carry out Throttle self learning process on the adjustable parameters screen page screwdriver and hammer and check again that the Throttle self learning with diagnostics instrument status indicates Carried out and that the Front throttle automatic self acquisition or Rear throttle automatic self acquisition indicate car ried out Engine oil pressure sensor ...

Page 176: ... pressure is low with the specific gauge Neutral sensor Function It tells the gear position to the control unit from the 1st gear to the 6th gear and if the gear is neutral or riding Operation Operating principle The sensor has 2 circuits one to indicate the en gaged gear whose resistance varies according to the gear engaged in this way the injection ECU according to detected electric voltage iden...

Page 177: ... detected with gear engaged only Check the sensor connector and the VEHICLE connector of the control unit if not OK restore if they are OK check the continuity of the grey black cable between the two connectors if not OK restore if they are OK with key set to ON and control unit connector disconnected check from the control unit side if the cable is in voltage if it is in voltage disconnect the se...

Page 178: ... CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Clutch Indefinite_Released_Pulled WARNING The statuses regularly viewed are Released and Pulled Indication on Navigator always released check the sensor connector and the control unit connector special attention to PIN56 if not OK restore cable harness if OK disconnect both terminals from the sensor and check with key ...

Page 179: ... ity Side Stand Down open circuit infinite resistance CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Side stand sensor up down Indication on Navigator always down check the connector if not OK restore if it is ...

Page 180: ... circuit con tinuity Pin out 1 Ground connection 2 Voltage 5V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Fall sensor Normal Tip over Indication on Navigator always Normal even when the sensor is inverted di...

Page 181: ...ic fan circuit Function Radiator fan and coolant Operation Operation Operating principle When the control unit detects a temperature of ap prox 102 C it closes the fan control relay pickup circuit to ground Level in electrical circuit diagram electric fan Location sensor relay located inside the rear re lay box the one toward motorcycle rear end also CHECK relay identifica tion with the colour of ...

Page 182: ...e harness Brown cable If shorted to negative check the relay electrical specifications are correct by disconnecting it from the cable harness If not OK replace the relay if OK restore the cable harness Brown cable If the 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 VEHIC...

Page 183: ...there is voltage on Yellow Red cable if there is no voltage restore the cable harness if there is check the Yellow Red cable ground insulation If there is continuity with ground connection restore the cable harness if OK set the key to OFF and check the VEHICLE connector and the engine vehicle cable harness connector if it is not OK restore if it is OK check the continuity of the Yellow Red cable ...

Page 184: ...nnection 1 PIN 5 Analogue ground connection 1 PIN 6 17 Lambda sensor input PIN 10 Track D throttle grip input PIN 11 Water temp sensor input PIN 12 Track B throttle grip input PIN 13 Serial line K for diagnosis PIN 14 Rear throttle motor output PIN 15 Electrical system DORSODURO 1200 ABS ATC ELE SYS 184 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email in...

Page 185: ...PIN 28 Front throttle motor output PIN 29 SAFETY relay control output PIN 31 Lambda 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 Track A throttle grip input PIN 39 Key input PIN 40 42 Front throttle motor output PIN 41 Input for front throttle potentiometer 1 signal PIN 48 Rear cylinder inta...

Page 186: ...ut PIN 64 Fall sensor input PIN 65 CAN L line high speed PIN 66 Rear cylinder 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 engine stop input PIN 78 Vehicle speed input PIN 79 CAN H line high speed PIN 80 Electrical system DORSODURO 1200 ABS ATC ELE SYS 186 Manuals by Motomatrix www motomatrix...

Page 187: ... 9 Low fuel sensor 10 Not used 11 Battery 12 Left turn indicator control 13 Not used 14 Not used 15 Not used 16 Indicator reset 17 Oil sensor input 18 Dorsoduro 750 Dorsoduro 1200 selection 19 Not used 20 K line DORSODURO 1200 ABS ATC Electrical system ELE SYS 187 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 188: ...ed 30 Sensors ground connection 31 Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation 34 Aerial 1 35 Low beam light relay activation 36 Not used 37 Not used 38 Ground connection 39 Ground connection 40 Ground connection Electrical system DORSODURO 1200 ABS ATC ELE SYS 188 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys emai...

Page 189: ...cation protocol is CSMA CD Carrier Sense Multiple Access w Collision Detection In order to transmit every nod must first check that the BUS the connection among all devices is free before attempting to send a message with BUS Carrier Sense If during this period there is no activity on BUS every nod has the same chance to send a message Multiple Access If two nodes start transmitting simultaneously...

Page 190: ...ation on CAN line PIN 66 and or PIN 80 problem on the whole network for example battery cut off or short circuited or shorted to ground Troubleshooting Check the Marelli control unit VEHICLE connector if not OK restore if OK check the ground insulation of the two CAN lines from PIN 66 and PIN 80 of the VEHICLE connector if not OK restore cable harness if OK check the continuity of the two CAN line...

Page 191: ...he Marelli control unit If not OK restore If OK check pins 5 and 6 and the ABS control unit connector If not OK restore If OK check overall operation of the Marelli control unit and ABS control unit replace the affected component if you find any fault NAVIGATOR LOGIC ERRORS CAN line towards ABS control unit U1711 No signal Configuration error Error cause If there is no signal no signal is received...

Page 192: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 193: ...rew 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 DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 193 Manuals by Motomatrix www motomatrix co uk The Solution For Lost ...

Page 194: ...0 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 243 Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 194 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 195: ...trol 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 Unscrew and remove the two screws Cut the clamps and remove the chas sis cover See also Fuel tank Removing th...

Page 196: ...r ABS version Move the ABS con trol unit and disconnect control unit connector Slide out bushing and O ring from gearbox secondary shaft Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 196 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 197: ...ng joining central exhaust manifold to exhaust end Disengage the spring joining the cen tral exhaust manifold to the rear ex haust manifold DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 197 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 198: ...e nuts from the rear exhaust manifold Remove the exhaust manifold Unscrew and remove the three screws Remove the clutch control cylinder Lock the plunger using a clamp Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 198 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 199: ...case Unscrew and remove the two clutch support screws Disconnect the side stand sensor con nector DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 199 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 200: ...cer Slide off the pinion from the chain and remove Loosen the screw and slide off the gear transmission connecting rod keeping it linked to the gear shift lever through the rod Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 200 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 201: ...nd hoist Working on the left side unscrew and remove the three nuts See also Vehicle preparation Unscrew and remove the rear coil fix ing screws Slide out the rear coils DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 201 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 202: ...o spacers The thinner spacer is on the right Slide off the rear bottom pin and collect the washer Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 202 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 203: ...t the washer Remove the bottom spacer on the right side Unscrew and remove the screw Release the ground points DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 203 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 204: ...e the ECU aside but keep it connected to the wiring harness Loosen the two clamps Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 204 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 205: ...Disconnect the engine temperature sensor from the front cylinder Disconnect the alternator connectors DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 205 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 206: ...hat the rear attachments on the chassis are aligned Working on the right side insert the three bolts with their washers Working on the right side place the spacers on the three bolts between the engine block and the chassis CAUTION THE SPACERS HAVE DIFFERENT SIZES REFIT THEM IN THE SAME WAY THEY WERE BEFORE BEING REMOVED Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 206 Manuals by Motomatrix w...

Page 207: ...ctric connections and clamp the cable harnesses Carry out the vehicle preparation oper ations but in reverse order restore the correct level of all fluids and carry out the adjustments that may be required DORSODURO 1200 ABS ATC Engine from vehicle ENG VE 207 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 208: ... also Vehicle preparation Adjusting Engine from vehicle DORSODURO 1200 ABS ATC ENG VE 208 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 209: ...INDEX OF TOPICS ENGINE ENG Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 210: ... 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 Engine DORSODURO 1200 ABS ATC ENG 210 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 211: ... selector drum 18 M8x1 25 threaded pin 19 Selector locking plate 20 Complete main gear shaft 21 TE flanged screw M6x15 22 Complete index lever 23 Spring Gearbox shafts Gearbox shafts diagram key DORSODURO 1200 ABS ATC Engine ENG 211 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 212: ...0 15 4th gear on secondary Z 28 16 5th gear on secondary Z 26 17 6th gear on secondary Z 25 18 Thrust washer 19 Circlip 20 Thrust washer 21 Thrust washer 22 Thrust washer 23 Floating bushing 24 Floating bushing 25 Floating bushing Disassembling the gearbox Open the crankcase halves Slide off the gearbox lubrication diffus er pipe Remove the two bolts of the forks Engine DORSODURO 1200 ABS ATC ENG ...

Page 213: ...e 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 DORSODURO 1200 ABS ATC Engine ENG 213 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 214: ...refully slide off the whole gear unit Repeat the removal operations but in reverse order Engine DORSODURO 1200 ABS ATC ENG 214 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 215: ...ctor sprocket M8 1 20 Nm 14 75 lbf ft 3M SCOTCH GRIP 2353 4 Gear sensor fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 270 5 Selector pin fastener onto clutch side crankcase half M10x1 5 1 16 Nm 11 80 lbf ft Loctite 242 Removing the gear selector Remove the clutch Remove the selector shaft See also Disassembling the clutch DORSODURO 1200 ABS ATC Engine ENG 215 Manuals by Motomatrix www motomatrix...

Page 216: ...ec tor mounting plate Unscrew and remove the three screws fastening the gearbox selector mount ing plate Remove the plate complete with selec tor Engine DORSODURO 1200 ABS ATC ENG 216 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 217: ...orresponding teeth Pawl Make 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 DORSODURO 1200 ABS ATC Engine ENG 217 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 218: ... 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 control rod roller cage punch Starter motor Engine DORSODURO 1200...

Page 219: ...arter motor power supply cable Unscrew and remove the two screws and remove the starter motor DORSODURO 1200 ABS ATC Engine ENG 219 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 220: ...lywheel cover M5 2 3 50 Nm 2 58 lbf ft Loctite 270 6 Flywheel cover fastener screw M6 10 13 Nm 9 59 lbf ft 7 Screw fastening starter motor brack et to motor and crankcase M6 4 13 Nm 9 59 lbf ft 8 Crankshaft access cap 1 4 Nm 2 95 lbf ft 9 Retainer plate fastener screw M6 1 8 Nm 5 90 lbf ft 3M SCOTCH GRIP 2353 Removing the flywheel cover Remove the flywheel cover inspection cap Engine DORSODURO 120...

Page 221: ...pins Removing the flywheel cover components Remove the two pick up fixing screws Remove the three stator fixing screws CAUTION THE PICK UP AND STATOR SHALL BE REMOVED SIMUL TANEOUSLY AS THEY ARE PART OF THE SAME ELEC TRICAL BRANCH DORSODURO 1200 ABS ATC Engine ENG 221 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 222: ... on the external body Keeping the external body blocked and gripping the key screw the anticlock wise bolt so as to remove the flywheel from the crankshaft Specific tooling 020713Y Flywheel extractor Unscrew and remove the anticlockwise bolt of the special tool from the external body Unscrew the screw from the crankshaft Specific tooling 020713Y Flywheel extractor Engine DORSODURO 1200 ABS ATC ENG...

Page 223: ...both supports In case of malfunction the start up transmission gear cannot be over hauled Therefore the complete trans mission gear should be replaced Collect the crankshaft woodruff key Freewheel removal Remove the flywheel Remove the freewheel gear DORSODURO 1200 ABS ATC Engine ENG 223 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 224: ...gneto flywheel See also Magneto flywheel removal Installing the flywheel Insert the woodruff key on the crank shaft Insert the start up transmission gear after applying a layer of grease Engine DORSODURO 1200 ABS ATC ENG 224 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 225: ...e specific tool tighten the screw on the crankshaft Remove the special tool Specific tooling 020713Y Flywheel extractor Locking torques N m Screw fixing Rotor Crankshaft M12x1 25 1 130 Nm 95 88 lbf ft Place the retention plate Tighten the screw DORSODURO 1200 ABS ATC Engine ENG 225 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 226: ...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 6 Nm 4 42 lbf ft 7 Water pump support fixing screw M6 3 12 Nm 8 85 lbf ft 8 Water pump support plug M6x10 1 6 5 Nm 4 79 lbf ft 3M SCOTCH GRIP 2353 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 on...

Page 227: ... clamp retaining water pump pipe Collect the gasket Removing the clutch cover DORSODURO 1200 ABS ATC Engine ENG 227 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 228: ...utch cover alone is only recom mended when replacing the clutch plates When removing the entire clutch assembly removing the clutch side cover is recommended However removing the entire clutch assembly is possible by removing the clutch cover alone In this case proceed as follows measure the projection of the clutch housing from the crankcase before dis assembling when refitting check that the pro...

Page 229: ...crew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate the plates and belleville washer DORSODURO 1200 ABS ATC Engine ENG 229 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 230: ... comes out on the other side Remove the clutch control rod Fasten the clutch housing using the specific tool Specific tooling 9100896 Clutch housing locking tool Engine DORSODURO 1200 ABS ATC ENG 230 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 231: ...sher to be chamfered Remove the clutch hub Collect the washer between the clutch hub and the housing DORSODURO 1200 ABS ATC Engine ENG 231 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 232: ...cs on a level surface and check them for cracks and potential distortions Maximum distortion allowed 0 20 mm 0 0079 in Measure the driving plate thickness at four positions replace them all if not complying with specifications CAUTION Engine DORSODURO 1200 ABS ATC ENG 232 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 233: ... 95 mm 0 077 in MUSHROOM VALVE CHECK Check if the valve slides freely without jamming Blow compressed air into the valve and check that the lubricating oil passage holes open Checking the clutch housing Remove the clutch bell Remove the seeger ring Remove the oil pump control gear UPON REFITTING THE GEAR COLLAR MUST ALWAYS BE FACING THE CLUTCH BELL DORSODURO 1200 ABS ATC Engine ENG 233 Manuals by ...

Page 234: ...ake sure there is not excessive noise during operation if necessary replace the main transmission driving gear and the clutch bell all together Checking the pusher plate Check the thrust plate and the bearing for damage and wear If necessary replace the parts Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation If neces sary replace the bel...

Page 235: ...h when unloaded 69 2 5 mm 2 72 0 2 in Assembling the clutch Fit the shim washer Fit the needle 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 DORSODURO 1200 ABS ATC Engine ENG 235 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 236: ...he projection has changed rotate the crankshaft 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 Engine DORSODURO 1200 ABS ATC ENG 236 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mo...

Page 237: ...e nitrided steel disc 3 Fit the clutch plates Start with the fric tion material discs 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 DORSODURO 1200 ABS ATC Engine ENG 237 Manual...

Page 238: ...utside diameter of 20 mm 0 79 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 Engi...

Page 239: ...6 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 DORSODURO 1200 ABS ATC Engine ENG 239 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 240: ... 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 removal The operations described below are valid for both heads Uns...

Page 241: ...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 DORSODURO 1200 ABS ATC Engine ENG 241 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 242: ...amshaft gear works properly if it is damaged or does not move smoothly replace the timing chain and the camshaft gear CAMSHAFT LOBES Check that they do not show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Remove the exhaust camshaft Position the camshaft on a vice featur ing protective shoes Unscrew and remove the screw and collect the washer Engine DORSODURO 1...

Page 243: ...d 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 DORSODURO 1200 ABS ATC Engine ENG 243 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 244: ...o 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 DORSODURO 1200 ABS ATC ENG 244 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 245: ...he 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 DORSODURO 1200 ABS ATC Engine ENG 245 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcy...

Page 246: ...remove the three bottom head fixing nuts Unscrew and remove the four nuts proceeding in stages and in a diagonal pattern Engine DORSODURO 1200 ABS ATC ENG 246 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 247: ...THREADS OR THE VALVE SEATS Check that cylinder head is not damaged or scratched replace it if necessary Check that there are no mineral deposits or rust in the cylinder head water cooled jacket remove them if necessary Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn replace the defective part s Rear head DORSODURO 1200 ABS ATC Engine ENG 247 Manuals by Mot...

Page 248: ... 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 DORSODURO 1200 ABS ATC ENG 248 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 249: ...eck 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 DORSODURO 1200 ABS ATC Engine ENG 249 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle...

Page 250: ...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 DORSODURO 1200 ABS ATC ENG 250 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 251: ...oving 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 DORSODURO 1200 ABS ATC Engine ENG 251 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 252: ...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 DORSODURO 1200 ABS ATC ENG 252 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 253: ...uts proceeding in stages and in a diagonal pattern Slide head off the stud bolts Remove the gasket between the head and the cylinder DORSODURO 1200 ABS ATC Engine ENG 253 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 254: ...ched replace it if necessary Check that there are no mineral deposits or rust in the cylinder head water cooled jacket remove them if necessary Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn replace the defective part s Valves Valve removal Remove the head Place the head on supporting surface Number the valves and their bucket tappets in order to position...

Page 255: ...g 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 DORSODURO 1200 ABS ATC Engine ENG 255 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 256: ...or the guide must be replaced Characteristic Valve stem distortion 0 25 mm 0 0098 in If the valve stem when measured with a micro meter is worn to its limit and the clearance ex ceeds the specified limit replace the valve If the valve stem lies within the specific limit re place the valve guide Recheck the clearance after replacing the valve or the guide Characteristic Intake valve stem diameter 5...

Page 257: ...xceeds 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 limit 2 36 7 mm 1 445 in DORSODURO 1200 ABS ATC Engine ENG 257 ...

Page 258: ...ew 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 DORSODURO 1200 ABS ATC ENG 258 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 259: ...rmediate gear Remove the screw and collect the washer and the spring Fit the chain tensioner body on the cyl inder and insert a new paper gasket Tighten the two screws to the prescri bed torque Insert the spring and tighten the screw together with the washer Cam timing Timing Remove the flywheel Install the timing chains on the inter mediate gears Install special tool flange on flywheel side crank...

Page 260: ... 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 DORSODURO 1200 ABS ATC ENG 260 Manuals by Motomatrix www motomatrix co uk The Sol...

Page 261: ...rques N m Nut fixing camshaft gears M15x1 4 90 Nm 66 38 lbf 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 tool Carry out the timing operations performed on the front c...

Page 262: ...nder plate fastener screw M6 4 13 Nm 9 59 lbf ft 3 Chain tensioner adjustment screw M6 2 5 50 Nm 4 06 lbf ft Removing the cylinder Remove the head Slide cylinder out of stud bolts collect ing the base gasket Engine DORSODURO 1200 ABS ATC ENG 262 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 263: ...ting 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 DORSODURO 1200 ABS ATC Engine ENG 263 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 264: ... 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 DORSODURO 1200 ABS ATC ENG 264 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 265: ... 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 as follows Piston diameter P 106 000 mm 4 1732 in Piston cyli...

Page 266: ... 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 engine 0 35 0 60 mm 0 0138 0 0236 in Wear limit 0 80 mm 0 032 in...

Page 267: ...s 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 in 10...

Page 268: ...t 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 assembled on the stud bolts aligning pin with connecting rod ...

Page 269: ...nder on the stud bolts Selecting the base gasket Temporarily fit the piston to the cylinder without base or head gasket DORSODURO 1200 ABS ATC Engine ENG 269 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 270: ...ify 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 0039 0 0000 in Gasket 0 4 mm 0 0157 in Measured protrusion 0 0...

Page 271: ...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 DORSODURO 1200 ABS ATC Engine ENG 271 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 272: ...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 the complete flywheel Remove the selector Remove the starter m...

Page 273: ...lly 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 DORSODURO 1200 ABS ATC Engine ENG 273 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 274: ...w 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 DORSODURO 1200 ABS ATC ENG 274 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 275: ...ft CRANKSHAFT pos Description Type Quantity Torque Notes 1 Crankshaft primary gear fastener nut M24x1 5 1 300 Nm 221 27 lbf ft Anticlockwise nut DORSODURO 1200 ABS ATC Engine ENG 275 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 276: ...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 CHECKING If the internal ring does not rotate smoothly and silen...

Page 277: ...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 DORSODURO 1200 ABS ATC Engine ENG 277 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 278: ... 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 pushing inward from the outside of the crankcase Specific tooling ...

Page 279: ... 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 CHARACTERISTICS CHAPTER OF THE WORKSHOP MANUAL Installing the cran...

Page 280: ...RE 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 Place the right crankcase half with the aid of a rubber hamme...

Page 281: ...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 DORSODURO 1200 ABS ATC Engine ENG 281 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 282: ...at Position the gear sensor and screw the two fixing screws Refit both head cylinder assemblies Position the crankshaft gear Engine DORSODURO 1200 ABS ATC ENG 282 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 283: ...ic tooling 020850Y Primary gear lock Position the water pump drive gear the washer and crankshaft fastener nut and tighten it to the specified torque DORSODURO 1200 ABS ATC Engine ENG 283 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 284: ...FL screw fastening oil radiator M6x25 1 10 Nm 7 37 lbf ft 2 TEFL screw fastening oil radiator mounting M6x12 1 10 Nm 7 37 lbf ft Engine DORSODURO 1200 ABS ATC ENG 284 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 285: ... 1 42 Nm 30 98 lbf ft 6 Oil pump fastener screw M6 2 12 Nm 8 85 lbf ft 3M SCOTCH GRIP 2353 7 Rose pipe fastener screw M6 2 12 Nm 8 85 lbf ft 8 Oil pump driven gear fastener nut M6 1 11 Nm 8 11 lbf ft 9 By Pass plate fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 242 10 Oil cooling radiator nipple M16x1 5 2 42 5 Nm 31 35 lbf ft Removing Remove the clutch Bend the chamfering tongue DORSODURO 1200 A...

Page 286: ...n the nut to re move it See also Disassembling the clutch Collect the washer Collect the gear Collect the spacer Engine DORSODURO 1200 ABS ATC ENG 286 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 287: ... 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 DORSODURO 1200 ABS ATC Engine ENG 287 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 288: ...p 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 DORSODURO 1200 ABS ATC ENG 288 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 289: ...HECK 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 DORSODURO 1200 ABS ATC Engine ENG 289 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 290: ...asher By means of a calliper spanner lock out gear rotation and tighten the retaining nut Engine DORSODURO 1200 ABS ATC ENG 290 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 291: ...mfering tongue Refit the clutch See also Assembling the clutch DORSODURO 1200 ABS ATC Engine ENG 291 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 292: ...INDEX OF TOPICS POWER SUPPLY P SUPP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 293: ...0 Nm 7 37 lbf ft Removing CAUTION PAY ATTENTION DURING THE REMOVAL AND INSTALLATION PHASES OF THE FUEL PUMP SINCE TI COULD GET DAMAGED The fuel pump includes 1 Fuel pump 2 Fuel level probe bracket 3 Fuel level probe DORSODURO 1200 ABS ATC Power supply P SUPP 293 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 294: ...uel pump as shown Progressively turn the fuel pump while sliding it out to avoid damaging it Turn and fully take out the fuel pump Injection Power supply DORSODURO 1200 ABS ATC P SUPP 294 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 295: ... mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit Therefore there is a Throttle map to which the control unit refers in order to decide the position at which the throttle valves should be and at what speed they should reach the pre set position The main parameters which influence the throttle map are Throttle ...

Page 296: ...r the controlled minimum opening position DC electrical motor Tinned double throttle position sensors with magnetic control contactless The throttle bodies do not require any maintenance and cannot be overhauled In case of electric or mechanic malfunction replace the whole unit Pressure sensors The pressure sensors one per cylinder are fundamental not only for the injection map at low and stabilis...

Page 297: ...oved The engine may shut off during the operation if it is running at idle speed and the gear is in neutral D the malfunction may affect riding in safety the warning light turns on the message Urgent Service is displayed the engine stops running Operating logic Those riding motorbikes do not require a specific throttle valve opening from their engines but actually a specific torque The Ride by Wir...

Page 298: ...he filter support Remove both bodies UPON REFITTING REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE Remove the air pressure sensors re taining screw Remove the air pressure sensors Power supply DORSODURO 1200 ABS ATC P SUPP 298 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 299: ...ee also Removing the engine from the vehicle Working on the body in question re move the injector slide off the clip and the injector itself CAUTION NEVER UNDO THE SCREWS IN THE FIGURE See also Removing the engine from the vehicle DORSODURO 1200 ABS ATC Power supply P SUPP 299 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 300: ...com in the search section Parameters Navigator The same parameters status errors etc divided according to components they refer to are avail able in the Electrical system chapter Checks and controls Power supply DORSODURO 1200 ABS ATC P SUPP 300 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 301: ...INDEX OF TOPICS SUSPENSIONS SUSP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 302: ...t disc M8x20 12 30 Nm 22 13 lbf ft Loctite 243 Removing the front wheel Hold the vehicle front part Unscrew the screws fixing the front pli ers and slide them off the disc Suspensions DORSODURO 1200 ABS ATC SUSP 302 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 303: ...e 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 DORSODURO 1200 ABS ATC Suspensions SUSP 303 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 304: ... 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 REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE WHEEL AXLE Use a...

Page 305: ...dlebar 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 20 Nm 14 75 lbf ft 5 TBEI screw M6x16 2 12 Nm 8 85 lbf ft DORSO...

Page 306: ...7 37 lbf ft 2 Screw Pumping member pin fixing to the stem base 2 30 Nm 22 13 lbf ft 3 Upper cover 2 20 Nm 14 75 lbf ft 4 Upper cover locking nut 2 20 Nm 14 75 lbf ft Suspensions DORSODURO 1200 ABS ATC SUSP 306 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 307: ...4 lbf ft 4 TCEI screw fastening U bolt onto fork yoke M10x60 2 50 Nm 36 88 lbf ft 5 TCEI screw fastening fork legs to top yoke M8x30 2 25 Nm 18 44 lbf ft 6 Headstock counter lock ring M25x1 1 Tighten by hand 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 DORSODURO 1200 ABS ATC Suspensions SUSP 307...

Page 308: ...in the vice Specific tooling AP8140149 Protection for fitting operations Operating on the upper screw unload the spring Loosen the cover without unscrewing it completely Suspensions DORSODURO 1200 ABS ATC SUSP 308 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 309: ...fic tool fixed to the pre loading 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 DORSODURO 1200 ABS ATC Suspensions SUSP 309 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 310: ...A SEALED CONTAINER AND TAKE 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 Suspensions DORSODURO 1200 ABS ATC SUSP 310 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle ...

Page 311: ... sleeve from the stem using the stem as a hammer puller Remove the fixed bushing 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 DORSODURO 1200 ABS ATC Suspensions SUSP 311 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 312: ...e stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in go...

Page 313: ...amage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE Replace the following components with new ones seal ring DORSODURO 1200 ABS ATC Suspensions SUSP 313 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 314: ...nd 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 Fit the ring the movable bushing and after removing the tape fit the fixed bushing Suspensions DORSODURO 1200 ABS ATC SUSP 314 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 315: ...n orifices AP8140146 Weight Insert the retainer ring in its position Fit the dust gaiter with the specific tool Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight DORSODURO 1200 ABS ATC Suspensions SUSP 315 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 316: ...ing 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 Refill the fork with oil according to the prescribed quantity Suspensions DORSODURO 1200 ABS ATC SUSP 316 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 317: ...d 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 Tighten the nut as much as possible Insert the cover and tighten until it stops DORSODURO 1200 ABS ATC Suspensions SUSP 317 Manuals by Motomatrix www motomatrix co uk...

Page 318: ...mes Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Specific tooling AP8140149 Protection 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...

Page 319: ...0 2 50 Nm 36 88 lbf ft 5 TCEI screw fastening fork legs to top yoke M8x30 2 25 Nm 18 44 lbf ft 6 Headstock counter lock ring M25x1 1 Tighten by hand 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 rotation must be of 400 150 g 0 88 0 33 lb in both directions ...

Page 320: ... 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 DORSODURO 1200 ABS ATC SUSP 320 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Co...

Page 321: ...n 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 lbf ft Unscrew after pre tightening 1 Headstock ring nut tightening M25x1 1 50 Nm 36 88 lbf ft Install the r...

Page 322: ...f ft 4 TCEI screw fastening U bolt onto fork yoke M10x60 2 50 Nm 36 88 lbf ft 5 TCEI screw fastening fork legs to top yoke M8x30 2 25 Nm 18 44 lbf ft 6 Headstock counter lock ring M25x1 1 Tighten by hand Tighten the fixing screws of the upper plate to the prescribed tightening tor que When refitting the U bolt position the two referen ces facing the front part of the vehicle Suspensions DORSODURO ...

Page 323: ...t 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 the frame Ensure the bearing mating in its seat using a teflo...

Page 324: ...bber 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 DORSODURO 1200 ABS ATC SUSP 324 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Ke...

Page 325: ...M10x30 5 50 Nm 36 88 lbf ft Loctite 270 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 DORSODURO 1200 ABS ATC Suspensions SUSP 325 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 326: ...he right side hit the wheel axle lightly so as to take out the head from its housing Working on the left side slide off the wheel axle together with the chain guide slider Remove the wheel by freeing the disc from the brake calliper Collect the spacer from the rear wheel right side Suspensions DORSODURO 1200 ABS ATC SUSP 326 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcyc...

Page 327: ...l 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 parameters DORSODURO 1200 ABS ATC Suspensions SUSP 327 Manuals by Motomatrix...

Page 328: ... TYPE REAR wheel axle Use a dial gauge to check the wheel axle eccentricity 1 Replace the wheel axle if the eccentricity exceeds the limit value 1 Characteristic Maximum eccentricity 0 25 mm 0 0098 in REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bear...

Page 329: ...ional under sump and rear wheel service stands Unscrew and remove the upper screw and collect the washer Loosen the under sump optional serv ice stand to lower the engine Unscrew and remove the lower screw and retrieve the nut Remove the shock absorber DORSODURO 1200 ABS ATC Suspensions SUSP 329 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 330: ...INDEX OF TOPICS CHASSIS CHAS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 331: ...f ft Loctite 243 7 TBEI screw fastening chain guard to rear mudguard M5x9 1 4 Nm 2 95 lbf ft 8 TBEI screw fastening chain guide to swingarm M5x9 2 6 Nm 4 42 lbf ft Loctite 243 9 Wheel axle nut M25x1 5 1 120 Nm 88 5 lbf ft 10 Flanged TBEI screw fastening chain slider M5x9 2 6 Nm 4 42 lbf ft Removing Remove the exhaust system Support the vehicle by means of the engine service stand and a hoist with ...

Page 332: ...KE FLUID LEAKAGE Unscrew and remove the two lower swingarm screws Remove the cable guide Unscrew and remove the shock ab sorber lower screw and collect the nut Fasten the shock absorber to the chas sis With the specific box spanner un screw and remove the locking ring nut Chassis DORSODURO 1200 ABS ATC CHAS 332 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ...

Page 333: ...moving 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 Engage neutral gear Check that the vertical oscillation at a po...

Page 334: ... 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 SPROCKET FOR WEAR Furthermore check the following parts and make sur...

Page 335: ...h 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 dry and lubricate with spray grease for sealed chains Stand STAND ASSEMB...

Page 336: ...ction M4x6 4 3 4 Nm 2 21 2 95 lbf ft 3 Silencer Clamp between central manifold and silencer M6 2 7 Nm 5 16 lbf ft 4 Screw fastening saddle compart ment protection M8x12 2 22 Nm 16 23 lbf ft 5 Flanged TE screw fastening silencer M8x35 2 25 Nm 18 44 lbf ft Removing the tail pipe Remove the tail fairing Remove the central manifold Remove the clamp Chassis DORSODURO 1200 ABS ATC CHAS 336 Manuals by Mo...

Page 337: ...ust end fixing screw Loosen the clip and remove one ex haust end Remove the other exhaust end togeth er with manifold sliding it out of the rubber blocks DORSODURO 1200 ABS ATC Chassis CHAS 337 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 338: ...ve the three nuts from the front exhaust manifold Disengage the spring joining central exhaust manifold to exhaust end See also Engine oil cooler Chassis DORSODURO 1200 ABS ATC CHAS 338 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 339: ...ld moving the central exhaust manifold Remove the central exhaust manifold Unscrew and remove the three nuts from the rear exhaust manifold Remove the exhaust manifold DORSODURO 1200 ABS ATC Chassis CHAS 339 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 340: ... Remove the fairing lug Drain the engine oil Remove both side fairings Working on the right side unscrew the two oil pipes Disconnect the horn connectors See also Side body panels Chassis DORSODURO 1200 ABS ATC CHAS 340 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 341: ...ont cylin der Remove the seeger ring and slide off the pin Remove the oil radiator together with support and horn DORSODURO 1200 ABS ATC Chassis CHAS 341 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 342: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 343: ...M 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 DORSODURO 1200 ABS ATC Braking system BRAK SYS 343 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 344: ...und 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 Braking system DORSODURO 1200 ABS ATC BRAK SYS 344 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mo...

Page 345: ...e 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 DORSODURO 1200 ABS ATC Braking system BRAK SYS 345 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 346: ... Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit Braking system DORSODURO 1200 ABS ATC BRAK SYS 346 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 347: ...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 coincides with danger recognition wheel slippage above threshold the...

Page 348: ...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 adjusts the pressure in the braking circuit accordingly CAUTION WHEN TH...

Page 349: ...ing when the speed is under 5 km h 3 1 mph If the ABS warning light remains on when the vehicle is running it means that a fault has been detected and the ABS system has been automatically deactivated IN CASE OF FAILURE OR WITH ABS DISCONNECTED THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS SYSTEM ABS enable disable Push the MODE control briefly to the left or right to scroll through the TRIP1 or...

Page 350: ...SYSTEM WILL BE ACTIVE NOTE WHEN THE BIKE S PANEL IS OFF AND WHEN TURNING IT ON THE NEXT TIME THE ABS SYSTEM IS STILL ACTIVE REGARDLESS OF WHAT WAS SET PREVIOUSLY Riding with a deactivated ABS system The warning light 5 turns on permanently the system was deactivated Riding with a deactivated ABS system The warning light 5 turns on permanently the system was deactivated 20 A fuse ABS Main fuse 6 Pr...

Page 351: ... that for the errors to be diagnosed one or more conditions must persist within a given time If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no longer able to diagnose the error The ABS system is still inactive Example error code 5D93 requires some minutes before it is diagnosed during the given time A The EFI warning light kee...

Page 352: ...ECKS AND TESTS SPEED SENSOR Using Navigator for the abs Abs screen pages ECU INFO screen page This screen page shows general data regarding the control unit for example software type map ping control unit programming date INFO ECU SCREEN PAGE Characteristic Value example Unit of measure ment Notes Vehicle manufacturing date Chassis number Software version Vehicle code Dorsoduro 1200 The vehicle co...

Page 353: ...all motorcycles equipped with ABS control units connected via CAN line PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc PARAMETERS Characteristic Value example Unit of measure ment Notes Front wheel speed 0 km h With stopped wheel 0 Km h is displayed...

Page 354: ...voltage Speed Ambient parameter error reading 2 Number of error detections number of times the error has been detected by the control unit Ambient parameter error reading 3 for example if it indicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Ambient parameter error reading 4 Operation cycles from ...

Page 355: ...ensor 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 wheel or ex cessive distance between the sensor and the tone wheel or to...

Page 356: ...teristic 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 screen page in the line Vehicle code NOTE the X in the table identif...

Page 357: ...ake 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 DORSODURO 1200 ABS ATC Braking system BRAK SYS 357 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 358: ...langed 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 DORSODURO 1200 ABS ATC BRAK SYS 358 Manuals by Motomatrix www moto...

Page 359: ...per to fork stems M10x1 25 4 50 Nm 36 88 lbf ft Loctite 270 Front brake pads Removal Turn the pins and remove both split pins Remove both pins Collect the anti vibration springs Extract one pad at a time CAUTION DORSODURO 1200 ABS ATC Braking system BRAK SYS 359 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 360: ...LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS 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 Braking system DORSODURO 1200 ABS ATC BRAK SYS 360 Manu...

Page 361: ...rocedure 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 Then perform the same procedure for the rear brake calliper acting only on the valve in stalled on that calliper Fill the reservoir until it reaches the reference MAX and refit the cap check pad wear Detach the bleed hoses...

Page 362: ...3 that go from the ABS control unit to the brakes and also seal these unions with protective caps Install the new ABS control unit previ ously filled up So that the brake fluid remains in the ABS control unit first remove the pro tective caps of the braking circuit un ions and connect the respective pipes Once all the braking circuits have been con nected remove the protective caps from the brakin...

Page 363: ...fluid flowing out from the open system Close the bleed screws of the front cal liper and remove the bleed bottle Replace the damaged calliper with a new one Unlock the brake lever Remove the cap of the reservoir and fill it with the new DOT 4 brake fluid up to the reference MAX Refit the cap BRAKING SYSTEM BLEEDING only the new calliper CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEED AS DESCRIBED...

Page 364: ...RM THE REGULAR BRAKING SYSTEM BLEED AS DESCRIBED AT THE BEGINNING OF THE CHAPTER Changing the brake fluid BRAKE FLUID REPLACEMENT VEHICLE PREPARATION Connect the bleeding unit to the reser voir of the braking system Max filling pressure to be applied to the sys tem 3 bar 300 kPa 43 51 PSI PURGING PROCESS TO CHANGE THE BRAK ING SYSTEM FLUID Connect the bleed bottle to the bleed screw of the front c...

Page 365: ...r as described Detach the bleed hoses and close the bleed screws again to the correct tightening torque Front brake pump FRONT BRAKE PUMP pos Description Type Quantity Torque Notes 1 Pipe union fastening brake pipe to pump M10x1 1 25 Nm 18 44 lbf ft 2 Fastener for front brake pump on handlebar 2 10 Nm 7 37 lbf ft 3 TBEI screw fastening the brake tank to the plate M6x20 1 10 Nm 7 37 lbf ft 4 TBEI s...

Page 366: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 367: ...tch pump on handle bar 2 10 Nm 7 37 lbf ft 4 Screw fastening clutch control mounting on flywheel side crankcase half M6 1 10 Nm 7 37 lbf ft 5 TBEI tank fixing screw M5x10 1 6 Nm 4 42 lbf ft 6 TBEI screw M6x16 1 12 Nm 8 85 lbf ft DORSODURO 1200 ABS ATC Clutch system CLU SYS 367 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 368: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 369: ...Ra diator to trellis M6x25 1 10 Nm 7 37 lbf ft 3 Flanged TE screw fastening expan sion tank M6x20 1 10 Nm 7 37 lbf ft Electric fan Remove the radiator Tighten the three screws on radiator front side DORSODURO 1200 ABS ATC Cooling system COOL SYS 369 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 370: ...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 DORSODURO 1200 ABS ATC COOL SYS 370 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 371: ...se 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 6 Nm 4 42 lbf ft 7 Water pump support fixing screw M6 3 12 Nm 8 85 lbf ft 8 Water pump support plug M6x10 1 6 5 Nm 4 79 lbf ft 3M SCOTCH GRIP 2353 DORSODURO 1200 ABS ATC Cooling system COOL SYS 371...

Page 372: ...amp 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 DORSODURO 1200 ABS ATC COOL SYS 372 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 373: ...Y 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 DORSODURO 1200 ABS ATC Cooling system COOL SYS 373 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 374: ...AMP Operating from the right side unscrew and remove the radiator upper screw Disconnect the left electric fan Unscrew and remove the screw of the expansion tank Cooling system DORSODURO 1200 ABS ATC COOL SYS 374 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 375: ...he 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 DORSODURO 1200 ABS ATC Cooling system COOL SYS 375 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co ...

Page 376: ...INDEX OF TOPICS BODYWORK BODYW Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 377: ...strument panel mounting to fork yoke M6x20 2 10 Nm 7 37 lbf ft 2 Screw fixing instrument panel to plate 5x14 3 2 6 Nm 1 92 lbf ft DORSODURO 1200 ABS ATC Bodywork BODYW 377 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 378: ...que Notes 1 TBEI screw fastening front side pan els to tank M5x9 4 6 Nm 4 42 lbf ft 2 TBEI screw fastening front side pan els and duct to radiator M6x16 2 10 Nm 7 37 lbf ft 3 TBEI screw fastening ignition block cover to spacer M5x9 1 6 Nm 4 42 lbf ft 4 TEFL screw fastening tank protec tion M6x12 2 10 Nm 7 37 lbf ft 5 TEFL screw fastening tank to frame M6x30 2 10 Nm 7 37 lbf ft Bodywork DORSODURO 1...

Page 379: ...over to compartment 5x14 3 2 6 Nm 1 92 lbf ft 2 TBEI screw fastening battery com partment to saddle mounting M5x9 2 6 Nm 4 42 lbf ft DORSODURO 1200 ABS ATC Bodywork BODYW 379 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 380: ...nting to mounting M5x12 1 6 Nm 4 42 lbf ft 2 Fastener for license plate mounting frame assembly to gusset plate saddle lock M6x12 4 10 Nm 7 37 lbf ft 3 Screw fastening license plate mount ing cover to license plate mounting 3 9x14 3 0 8 Nm 0 59 lbf ft 4 TEFL screw fastening taillight to li cense plate mounting support M6x45 3 10 Nm 7 37 lbf ft 5 Flanged TBEI screw fastening li cense plate bracket ...

Page 381: ... M8x60 1 25 Nm 18 44 lbf ft 3 Lower TCEI screw fastening Saddle mounting to frame M8x40 2 25 Nm 18 44 lbf ft Loctite 243 4 TCEI tank cross member fixing screw M5x16 4 6 Nm 4 42 lbf ft 5 TBEI screw fastening saddle strap M6x20 2 10 Nm 7 37 lbf ft DORSODURO 1200 ABS ATC Bodywork BODYW 381 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co ...

Page 382: ...o fork yoke M6 1 10 Nm 7 37 lbf ft 4 TCEI fixing screw of headlight to in strument panel support M6x35 1 10 Nm 7 37 lbf ft 5 TEFL screw fixing headlight mount ing to steering base M6x25 1 10 Nm 7 37 lbf ft Operating from both sides unscrew and remove the front frame fixing screw and collect the nut Bodywork DORSODURO 1200 ABS ATC BODYW 382 Manuals by Motomatrix www motomatrix co uk The Solution Fo...

Page 383: ...rom the right side Disconnect the front turn indicator ca ble harness Disconnect the headlamp connector and remove the headlamp assembly See also Instrument cluster support DORSODURO 1200 ABS ATC Bodywork BODYW 383 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 384: ...head screw 1 Manual 2 TE screw fastening saddle lock bat tery compartment to saddle mount ing M6x25 2 10 Nm 7 37 lbf ft To reuse Loctite 243 Bodywork DORSODURO 1200 ABS ATC BODYW 384 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 385: ...cator fixing screw M6 2 3 Nm 2 21 lbf ft 3 Reflector fastener M5 1 6 Nm 4 42 lbf ft Remove the screws fastening the li cense plate support taillight Unscrew the saddle release block fas tener screws DORSODURO 1200 ABS ATC Bodywork BODYW 385 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 386: ...te holder to be able to disconnect the tail light connector See also Tail guard Slide out the saddle opening cable from the taillight Remove the taillight See also Tail guard Bodywork DORSODURO 1200 ABS ATC BODYW 386 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 387: ...3 3 TCEI screw fastening rider footrest mounting to frame M8x35 4 30 Nm 22 12 lbf ft Loct 243 4 Footrest rubber fastener narrow nut M5 4 6 Nm 4 42 lbf ft 5 TCEI screw fastening rider footrest mounting M6x16 6 10 Nm 7 37 lbf ft RIGHT FOOTREST Unscrew and remove the upper screw 1 Unscrew and remove the two outer screws 2 DORSODURO 1200 ABS ATC Bodywork BODYW 387 Manuals by Motomatrix www motomatrix ...

Page 388: ...ernal screws Loosen the gear shift lever rod screw Slide off the gear shift lever rod Remove the left footrest Side body panels Remove the saddle Unscrew and remove the rear screw Bodywork DORSODURO 1200 ABS ATC BODYW 388 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 389: ...e saddle Remove the tail fairing Unscrew and remove the three screws Disconnect the taillight connector Release the taillight cable harness from the clamps DORSODURO 1200 ABS ATC Bodywork BODYW 389 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 390: ...Slide off the license plate holder to wards the back See also Seat Tail guard Air box Bodywork DORSODURO 1200 ABS ATC BODYW 390 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 391: ...ross head self tapping screw fas tening blow by tank M5x20 2 3 Nm 2 21 lbf ft Remove the air filter box cover Remove the four screws Remove the two intake ducts See also Air filter Cut the ties DORSODURO 1200 ABS ATC Bodywork BODYW 391 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 392: ...ir temperature sensor Remove the two clamps from the blow by system Remove the air filter box Bodywork DORSODURO 1200 ABS ATC BODYW 392 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 393: ...2 lbf ft 2 Rear TE screw fastening tank M6x90 1 10 Nm 7 37 lbf ft 3 Saddle front retaining pin 1 3 Nm 2 21 lbf ft 4 Hose tail fitting 2 6 Nm 4 42 lbf ft Loctite 518 DORSODURO 1200 ABS ATC Bodywork BODYW 393 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 394: ...ve the rubber ring on the ignition switch assembly Unscrew and remove the screw Remove the cover of the ignition switch assembly See also Side body panels Unscrew and remove the two front screws retaining the fuel tank collect ing the corresponding bushings Bodywork DORSODURO 1200 ABS ATC BODYW 394 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mo...

Page 395: ...N DURING FUEL TANK LIFTING AND REPOSITIONING BE CAREFUL SO AS NOT TO CRUSH BEND OR SLIDE OFF TANK BREATHERS FROM THE CORRESPONDING TUBE GUIDES Lift the fuel tank DORSODURO 1200 ABS ATC Bodywork BODYW 395 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 396: ...and screws and remove everything Disconnect the connectors of arrow in dicators headlamps ignition switch assembly and relay Remove the three screws that fix the instrument panel Bodywork DORSODURO 1200 ABS ATC BODYW 396 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 397: ...ddle Remove the rear passenger grab han dle if present Working from both sides unscrew and remove the external screw Unscrew and remove the three screws Slide off the tail fairing backwards DORSODURO 1200 ABS ATC Bodywork BODYW 397 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 398: ...INDEX OF TOPICS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 399: ...PRE DELIVERY PRE DE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 400: ...m lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Electric starter Engine stop via emergency stop switch a...

Page 401: ...R AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHIL...

Page 402: ... if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION CHECK AND ADJU...

Page 403: ... hand guards Position and fasten the top screw en suring to insert the bushing between the hand guard and the handlebar fas tening point DORSODURO 1200 ABS ATC Pre delivery PRE DE 403 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 404: ...n the sides using TCEI M6 X 50 screw being careful when inserting the bush ing Pre delivery DORSODURO 1200 ABS ATC PRE DE 404 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 405: ... 370 372 374 Crankcase 53 213 245 252 271 272 276 280 Crankshaft 53 271 275 278 279 Cylinder 53 262 264 265 267 270 274 D Drive chain 14 333 E ECU 184 352 Electric fan 181 369 Electrical system 14 82 87 90 400 Engine oil 70 195 338 340 Engine temperature sensor 148 Exhaust 120 336 338 Exhaust manifold 337 338 F Filter box Fork 306 308 314 Front head 241 244 247 263 Front wheel 302 304 Fuel 69 126 ...

Page 406: ... 370 373 Rear head 247 250 254 263 Rear wheel 325 327 333 Recommended products 58 Ride by wire 295 Run Stop switch 81 182 S Saddle Saddle mounting Shock absorbers 329 Side stand 81 179 Side stand sensor 81 179 Spark plug 68 Spark plugs Speed sensor 133 Stand 81 179 335 Start up 123 Starter motor 218 219 T Tank 69 126 195 373 393 Throttle body 164 298 Transmission 13 Tyres 15 W Warning lights Manua...

Page 407: ...Water pump 371 Wiring diagram 114 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 408: ......

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