APRILIA DORSODURO 2007 Service Station Manual Download Page 4

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INDEX OF TOPICS

HARACTERISTICS

CHAR

PECIAL

TOOLS

S-TOOLS

AINTENANCE

MAIN

ROUBLESHOOTING

TROUBL

LECTRICAL

SYSTEM

ELE SYS

NGINE

FROM

VEHICLE

ENG VE

NGINE

ENG

OWER

SUPPLY

P SUPP

USPENSIONS

SUSP

HASSIS

CHAS

RAKING

SYSTEM

BRAK SYS

LUTCH

SYSTEM

CLU SYS

OOLING

SYSTEM

COOL SYS

ODYWORK

BODYW

DELIVERY

PRE DE

Summary of Contents for DORSODURO 2007

Page 1: ...SERVICE STATION MANUAL 854202 DORSODURO ...

Page 2: ...ted during the vehicle design stage All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and duration The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this manual remain unchanged aprilia reserves the right at any time and without being required to update this pu...

Page 3: ... to prevent injuries to the repairer Personal safety Failure to completely observe these instructions will result in serious risk of personal injury Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to t...

Page 4: ... MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS COOLING SYSTEM COOL SYS BODYWORK BODYW PRE DELIVERY PRE DE ...

Page 5: ......

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ... EXPLODE DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut 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 C...

Page 8: ... KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELEC TROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IF THE ELECTRO LYTIC FLUID COMES INTO CONTACT WITH THE SKIN RINSE WELL WITH ABUNDANT FRESH WATER IT IS PARTICULARL...

Page 9: ... Only use ORIGINAL APRILIA SPARE PARTS Comply with lubricant and consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start from the ones with the largest section or from the internal ones moving diagonally Tighten nuts and screws in successive steps before ap plying the tightening torque Always replace self locking nuts washers seal...

Page 10: ...ONE OF THESE COMPONENTS TO GET LOOSE AND EVEN DETACHED THUS BLOCKING A WHEEL OR OTHERWISE COMPROMISE VEHICLE HANDLING THIS CAN LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Running the engine in is essential to ensure engine durability and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your riding speed when runni...

Page 11: ...X KEY ZD4 WMI World manufacturer identifier code SM model 000 version variation 0 digit free Y year of manufacture S production plant S Scorzè XXXXXX progressive number 6 digits ENGINE NUMBER The engine number is printed on the base of the left side engine crankcase Engine No CHASSIS NUMBER The chassis number is stamped on the right side of the headstock Chassis No Dimensions and mass DIMENSIONS S...

Page 12: ...d GEARBOX Specification Desc Quantity Type Mechanical 6 speeds with foot lever on the left hand side of the engine Transmission GEAR RATIOS Specification Desc Quantity Gear ratio Gear primary drive 38 71 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 driv...

Page 13: ...sc Quantity High beam light 12 V 60 W H4 Low beam light 12 V 50 W H4 Front tail light 12V 6W H6 Turn indicator lights 12V 10W Rear tail light stop light LED License plate light 12V 5W Rpm indicator lighting LED Multifunction display lighting LED WARNING LIGHTS Specification Desc Quantity High beam light LED Right turn indicator LED Left turn indicator LED General warning LED Gear in neutral LED Si...

Page 14: ... four plungers two of them Ø 27 mm 1 06 in the other two Ø 32 03 1 26 in and 4 pads Rear 240 mm 9 45 in disc brake with 35 mm 1 38 in 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 DUNLOP SPORTMAX QUALIFIER Front tyre 120 70 ZR17 Front tyre...

Page 15: ...fixing screw M8x45 1 25 Nm 18 44 lbf ft Loctite 243 FOOTREST UNIT Name Torque in Nm Upper screw fixing passenger footrest to chassis fairings M8x35 2 25 Nm 18 44 lbf ft TCEI lower screw fixing passenger footrest to rider footrest support M8x35 2 25 Nm 18 44 lbf ft TCEI screw fixing rider footrest to chassis M8x35 4 28 Nm 20 65 lbf ft Loctite 243 STAND UNIT Name Torque in Nm Screw for Stand M10x1 2...

Page 16: ... ft Primary Clamp between front rear manifolds and central mani fold M6 2 7 Nm 5 16 lbf ft Silencer Clamp between central manifold and silencer M6 1 7 Nm 5 16 lbf ft Self tapping TE screw fixing Muffler holding Bracket to saddle pillar M8x20 2 25 Nm 18 44 lbf ft Self tapping TE screw fixing Silencer front attachment to muf fler holding bracket M8x35 2 35 Nm 25 81 lbf ft COOLING SYSTEM UNIT Name To...

Page 17: ...xing screw M5x16 2 7 Nm 5 16 lbf ft TE screw fixing regulator to chassis M6x30 2 10 Nm 7 37 lbf ft Screw fixing control unit to filter casing base 4 2 5 Nm 1 47 lbf ft SWP Self tapping screw fixing Demand Support to Demand M5x14 4 3 Nm 2 21 lbf ft Self tapping TE screw fixing Demand sensor to chassis M6x20 3 10 Nm 7 37 lbf ft Start up relay retainer 2 4 Nm 2 95 lbf ft Positive on engine retainer 1...

Page 18: ... Name Torque in Nm TCEI screw fixing passenger grab handles to saddle pillar M8x80 4 30 Nm 22 13 lbf ft TCEI screw M8x40 1 25 Nm 18 44 lbf ft Switch shear head screw retainer 1 Manual Self tapping TE screw M6x25 2 10 Nm 7 37 lbf ft COMPLETE HEAD Name Torque in Nm Cam cap head fixing screws M6 16 Pre tightening 4 90 6 86 Nm 3 61 5 06 lbf ft Tightening 9 81 12 75 Nm 7 24 9 40 lbf ft Map sensor fitti...

Page 19: ...or M5 2 5 50 Nm 4 06 lbf ft Loctite 243 872432 Screw fixing Revolution sensor M6 1 5 50 Nm 4 06 lbf ft Loctite 243 874555 Screw fixing Revolution sensor M6 1 5 50 Nm 4 06 lbf ft loctite 243 Tone Wheel tightening on Secondary Transmission Shaft M16x1 1 43 Nm 31 72 lbf ft Loctite 270 Oil pressure adjustment valve 3 4 Unf 16 1 43 Nm 31 72 lbf ft Oil Pump fixing screw M6 2 5 50 Nm 4 06 lbf ft Loctite ...

Page 20: ...M6 6 12 Nm 8 85 lbf ft 874549 Screw fixing Clutch Cover Clutch side Cover M6 6 12 Nm 8 85 lbf ft Screw fixing split clutch cover gasket retainer M4 steel A2 6 3 Nm 2 21 lbf ft Screw fixing Plate Clutch Control Support M5 3 5 50 Nm 4 06 lbf ft Screw fixing Clutch Control Support flywheel side crankcase half M6 1 12 Nm 8 85 lbf ft 872421 Screw fixing Clutch Control Support flywheel side crankcase ha...

Page 21: ... 6217 3 6197 in Piston cylinder coupling Type B Cylinder 91 997 92 004 mm 3 6219 3 6222 in Piston 91 940 91 947 mm 3 6197 3 6199 in Piston cylinder coupling Type C Cylinder 92 004 92 011 mm 3 6222 3 6225 in Piston 91 947 91 954 mm 3 6199 3 6202 in Piston cylinder coupling Type D Cylinder 92 011 92 018 mm 3 6225 3 6227 in Piston 91 954 91 961 mm 3 6202 3 6205 in Fitting clearance 0 050 0 064 mm 0 0...

Page 22: ...676 1 9679 in Crankshaft type 5 8 Main journals diameter 49 972 49 978 mm 1 9674 1 9676 in Once the categories below are checked crankcase flywheel side main journal clutch side main journal choose the bushings to be used for coupling according to the following table MAIN BUSHINGS Specification Desc Quantity Main journal type 4 flywheel side crankcase type 1 half bushings A red Main journal type 4...

Page 23: ...rimary category Pinion can be selected from two types A or B ac cording to the centre to centre distance between the primary reduction gears The category can be checked out on the pinion it self Crankshaft category Shaft can be selected from two types 1 or 2 ac cording to the crank pin diameter Shaft can be selected from seven types E1 E2 according to connecting rod weight CRANKSHAFT SELECTION TYP...

Page 24: ... MUST BE THE SAME COLOUR AND HAVE THE SAME TYPE OF COUPLING AS THE CRANKSHAFT UPON REFITTING MAKE SURE THAT THE HALF BUSHINGS ARE OF THE SAME TYPE See also Removing the clutch cover Removing the flywheel cover Recommended products chart RECOMMENDED PRODUCTS Product Description Specifications AGIP TEC 4T SAE 15W 50 Engine oil Use top branded oils that meet or exceed the requirements of API SJ CCMC ...

Page 25: ...DORSODURO Characteristics CHAR 25 ...

Page 26: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 27: ...ode Description 020709Y Engine support 020710Y Engine plate AP8140187 Engine support stand 020711Y Engine pinion locking 020712Y Handle for Flywheel cover removal 020713Y Flywheel extractor DORSODURO Special tools S TOOLS 27 ...

Page 28: ...tor support 020715Y Tone wheel removal 9100896 Clutch bell locking tool 020716Y Connecting rod locking 020717Y Piston ring driver AP8140302 tool for sealing ring fitting 020718Y Camshaft gear alignment pin Special tools DORSODURO S TOOLS 28 ...

Page 29: ...ion 020719Y Timing pin 020720Y Timing tool AP8140179 Valve spring compressor 020721Y Adaptor for valve removal 020722Y Guide for oil seal 020376Y Adapter handle 020629Y 8 mm 0 31 in guide DORSODURO Special tools S TOOLS 29 ...

Page 30: ...ription 020412Y 15 mm Oil seal guide 020439Y 17 mm guide for oil seal 020263Y Sheath for fitting the driven pulley 020365Y 22 mm 0 87 in guide 020364Y 25 mm Guide 020483Y 30 mm guide Special tools DORSODURO S TOOLS 30 ...

Page 31: ...iption 020441Y Oil seal punch 020358Y 37 x 40 mm adaptor 020357Y 32 x 35 mm adaptor 020359Y 42 x 47 mm adaptor 020360Y 52 x 55 mm adaptor 020723Y Template for timing overhead camshafts DORSODURO Special tools S TOOLS 31 ...

Page 32: ...r cage punch 020725Y Punch for water pump overall sealing 020726Y Extractor for bushings 020727Y Punch for bushings AP8140180 Extractor for bushings 8140181 manometer for fuel oil compression pressure AP8140199 Tool panel Special tools DORSODURO S TOOLS 32 ...

Page 33: ...Stores code Description 8202222 Generic adhesive film for panel 8140426 Hooks for panel DORSODURO Special tools S TOOLS 33 ...

Page 34: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 35: ...THE MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VE HICLE IS USED IN WET OR DUSTY AREAS OFF ROAD OR FOR SPORTS APPLICATIONS I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE Check and clean adjust or replace if necessary every 1000 km Replace every 2 years Replace every 4 years At every start up Check monthly ROUTINE MAINTENANCE TABLE ...

Page 36: ... off any carbon deposits or replace as required CAUTION ALWAYS REPLACE BOTH SPARK PLUGS EVEN IF ONLY ONE NEEDS REPLACING Remove the saddle Remove the lower air deflector Remove the side fairings In order to gain access to the spark plugs CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE FRONT SPARK PLUG Work...

Page 37: ... Turn the radiator forwards and lower it to act on the coil Undo and remove the screw Slide off the front coil Unscrew and remove the front spark plug REAR SPARK PLUG DORSODURO Maintenance MAIN 37 ...

Page 38: ...nd slide off the rear spark plug Check the gap between the electrodes with a feeler thickness gauge CAUTION DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP The electrode gap should be between 0 6 0 7 mm 0 023 0 027 in Otherwise replace the spark plug Make sure the washer is in good con ditions Installation Maintenance DORSODURO MAIN 38 ...

Page 39: ...NANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VE HICLE IS USED IN WET OR DUSTY AREAS OFF ROAD OR FOR SPORTS APPLICATIONS ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM IF YOU CHECK LEVEL WHEN THE ENGINE IS COLD OIL LEVEL COULD TEMPORARILY DROP BELOW THE MIN MARK THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDED THAT THE ALARM WARNING LIGHT AND THE ENGINE OIL PRESSURE ICON ON THE DIS...

Page 40: ...NE HAS RUN FOR ABOUT TWENTY MINUTES OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW Use a cloth to wipe off any mud deposit on the area next to the filler plug 1 Place a container with 4000 cm 244 cu in capacity under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler plug 1 Drain the oi...

Page 41: ... oil See also Engine oil filter Check Engine oil filter Drain off the engine oil Remove the oil filter Fit a new engine oil filter Add engine oil up to the correct level CAUTION NEVER REUSE AN OLD FILTER See also Replacement Air filter Remove the fuel tank Disconnect the air temperature sensor Undo and remove the nine screws DORSODURO Maintenance MAIN 41 ...

Page 42: ...G THE FILTER CASING COVER MAKE SURE NEITHER THE CLOTH NOR ANY OTHER OBJECT HAS BEEN LEFT IN SIDE THE FILTER CASING MAKE SURE THE FILTERING ELEMENT IS CORRECTLY PLACED SO THAT UNFIL TERED AIR DOES NOT FLOW IN DO NOT FORGET THAT EARLY WEAR OF THE PISTON RINGS AND THE CYLIN DER CAN BE CAUSED BY A MALFUNCTIONING OR MIS PLACED FILTERING ELEMENT REFITTING Upon refitting pay attention when inserting inta...

Page 43: ...st as follows Take the engine to the TDC Lock the camshafts by using the cor responding timing pins Specific tooling 020719Y Timing pin Characteristic Intake valve clearance 0 11 0 18 mm 0 0043 0 0071 in Outlet valve clearance 0 16 0 23 mm 0 0063 0 0091 in Remove one camshaft at a time Leave the other camshaft assembled and blocked by means of the timing pin CAUTION IF BOTH CAMSHAFTS ARE REMOVED T...

Page 44: ...librated 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 HEAD COVERS CLEAN HEAD AND COVER SURFACES CAREFULLY Apply T...

Page 45: ... Apply THREEBOND on the head in the areas indicated in the figure See also Removing the head cover DORSODURO Maintenance MAIN 45 ...

Page 46: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 47: ... WINDOW IS SELECTED AND IS DISPLAYED PRESS THE KEY TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 7...

Page 48: ...go to 15 NO note C 15 IN THE ENGINE PARAMETER READING SCREEN PAGE AND WITH ENGINE AT IDLE ARE FRONT THROTTLE CORRECTION PARAMETERS OR REAR THROTTLE CORRECTION WITHIN THE 0 4 0 4 RANGE AND IN THE SAME SCREEN PAGE ARE THE FRONT THROT POT 1 DEGREES AND REAR THROT POT 1 DE GREES PARAMETERS OR TO 0 5 WITH ENGINE AT IDLE CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT...

Page 49: ... WITH THE CONTROL UNIT YES go to 3 NO go to 4 3 ACTIVATE ONE INJECTOR BY MEANS OF AXONE DEVICES ACTIVATION SCREEN PAGE INJECTOR ICON IS THE INJECTOR ACTIVATED YES go to 17 NO go to 12 4 WITH THE KEY TURNED TO OFF CHECK IF THERE IS VOLTAGE ON THE ORANGE RED CABLE OF THE MAIN INJECTION RELAY POLARISED 41 YES go to 6 NO go to 5 5 INSPECT IF THERE IS AN INTERRUPTION IN THE ORANGE RED CABLE FROM THE MA...

Page 50: ... NO go to 19 18 WHEN THE KEY IS TURNED TO OFF CHECK CONTINUITY AND GROUND IN SULATION OF THE YELLOW PURPLE CABLE FROM THE RELAY TO PIN 62 VEHICLE CONNECTOR YES go to 22 NO go to 21 19 RESTORE THE CABLE HARNESS 20 CHECK THERE IS GROUND INSULATION FOR THE BLUE CABLE OF THE PUMP CONNECTOR OK go to 24 NOT OK go to 23 21 RESTORE THE CABLE HARNESS END 22 CHECK THE VEHICLE CONNECTOR OK go to 25 NOT OK go...

Page 51: ...THE PINK BLACK CABLE OF THE RETENTION RELAY START UP LOGIC 39 TO PIN 14 VEHICLE CONNECTOR OK go to 38 NOT OK go to 39 37 REPLACE THE RETENTION RELAY START UP LOGIC 39 38 CHECK THE VEHICLE CONNECTOR PIN 14 OK go to 40 NOT OK go to 41 39 RESTORE THE CABLE HARNESS 40 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS ENGINE REVOLUTION SENSOR FOLLOW THE TROUBLESHOOTING STEPS IN THE SECTION ...

Page 52: ... 40 OK go to 52 NOT OK go to 53 51 REPLACE THE RELAY END 52 PRESSING THE STARTER BUTTON CHECK IF THERE IS VOLTAGE TO THE YEL LOW RED CABLE OF THE START UP RELAY OK go to 54 NOT OK go to 55 53 REPLACE THE RELAY END 54 CHECK IF THE BLUE CABLE OF THE START UP RELAY 36 IS GROUNDED OK go to 56 NOT OK go to 57 55 RESTORE THE CABLE HARNESS END 56 WITH THE KEY TURNED TO OFF CHECK IF THERE IS VOLTAGE TO TH...

Page 53: ...TE ANY DEVICE AND CHECK THE SUITA BLE INDICATION ON THE DEVICE STATUS ICON 0 1 SCREEN PAGE If MALFUNCTION is shown go to 71 If CORRECT OPERATION is shown go to 72 67 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSOR INDICATION ON AXONE ALWAYS STOP END 68 IS THE SENSOR VERTICAL YES go to 69 NO go to 70 69 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SEN...

Page 54: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 55: ...Components arrangement Key 1 Revolution sensor 2 Intake air pressure sensor 3 Intake air temperature sensor DORSODURO Electrical system ELE SYS 55 ...

Page 56: ...IAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the wiring diagram 7 Location on the vehicle under the fuel tank left side second relay starting from the front START UP RELAY Location on the wiring diagram 34 Location on the vehicle under the fuel tank right side fifth relay starting from the front below in relation to the line of the other relays RETENTION RELAY Location on the wiring dia...

Page 57: ...ODUCTION Scope and applicability The position of the cable harnesses 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 Filter Casing Cable Harness 1 Rear l...

Page 58: ...using Connectors 8 ECU and Ground Lead Connectors for the filter casing CENTRAL SECTION TABLE C 9 Fuel Pump Connector 10 Key Connector Right Light Switch Connectors Left Light Switch Connectors Connectors inside the housing behind the radiator FRONT SECTION TABLE B THE CONNECTORS LISTED ARE CONSIDERED CRITICAL IN COMPARISON WITH ANY OTHER BECAUSE THE VEHICLE WILL STOP IF THEY ARE ACCIDENTALLY DIS ...

Page 59: ...STENING SWITCH CABLE HARNESSES Fasten switch cable harnesses with a rubber retainer TABLE C FASTENING GROUND LEAD START UP CABLE The cable must be laid oriented as shown in the photograph Before fitting the cable push the sheath towards the panel end so as to hide the red cable DORSODURO Electrical system ELE SYS 59 ...

Page 60: ...l part 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 MAIN CABLE HARNESS LAYING View of main cable harness laying without airbox Electrical system DORSODURO ELE SYS 60 ...

Page 61: ...the cable harness TABLE C1 CABLE HARNESS LAYING Components described in tables C1 C2 of this page must be laid under the airbox 1 To lay the auxiliary fuse box under the airbox slide off the protection cover then reinsert it re specting the correct poles 2 Control unit connectors 3 Side stand switch 4 Gear in neutral switch 5 Horn DORSODURO Electrical system ELE SYS 61 ...

Page 62: ... LAYING The cable going out from the generator must be laid behind the thermostatic valve TABLE D FASTENING THE CABLE HARNESS Fasten the cable harness with clamps as shown in the figure Electrical system DORSODURO ELE SYS 62 ...

Page 63: ...ONT CYLINDER COIL 1 Cable guide that fastens the secondary fuses and front cylinder coil cable harnesses Fasten the cable harness with retaining straps as shown in the figure TABLE G HANDGRIP SENSOR CONNECTOR 1 Fitting the connector in the handgrip sensor 2 Closing the connector block 3 During step 1 move the hook 3 forwards DORSODURO Electrical system ELE SYS 63 ...

Page 64: ...SES CABLE HARNESS Cable guide that fastens the secondary fuses and front cylinder coil cable harnesses TABLE I FASTENING THE CABLE HARNESS Fasten the cable harness with a retaining strap Electrical system DORSODURO ELE SYS 64 ...

Page 65: ...module 2 Main injection relay 3 12V 30A relay TABLE K BATTERY ENGINE EARTHING CA BLE HARNESS PATH TABLE L LAMBDA PROBE Place two clamps to fasten the cable harness to the chassis as indicated 1 medium clamp 2 small clamp DORSODURO Electrical system ELE SYS 65 ...

Page 66: ...alve position sen sors TABLE M2 SENSORS Place the two sensors TABLE M3 CLAMPS Fasten cable harnesses with clamps TABLE M4 FILTER HOUSING Insert the throttle body with the cable harness correctly fixed in the filter cas ing Electrical system DORSODURO ELE SYS 66 ...

Page 67: ...bber cap that hosts light switch and key switch connectors 3 Demand 1 Master Connector First connect the light switch and the key switch connectors inside the rubber cap 2 and position it as shown in the figure then connect the Demand Master connector BLUE tape 3 and the Regulator connector 1 DORSODURO Electrical system ELE SYS 67 ...

Page 68: ...ng strap TABLE Q RIGHT SIDE Fasten the cable harness with retaining straps TABLE R MAIN CABLE HARNESS BATTERY EARTHING Two retaining straps that clasp the main cable harness and the battery engine earthing cable harness Electrical system DORSODURO ELE SYS 68 ...

Page 69: ...BLE GUIDES TABLE T GROUND LEADS The cables fastened to the engine earthing must face downwards 1 Main cable harness engine earthing on the left 2 Battery ground lead on the right DORSODURO Electrical system ELE SYS 69 ...

Page 70: ...D UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A LAMBDA PROBE REAR STOP SWITCH CABLE HARNESS 1 Plastic cable guide that clasps the lambda probe branch and the rear stop switch branch 2 Clamp TABLE B REAR STOP SWITCH CABLE HAR NESS Retaining strap that clasps the rear stop switch cable harness to the brake pipe Electrical...

Page 71: ...REATHER TUBES FASTENING Two cable guides and a clamp that fasten the breather pipe TABLE C LICENSE PLATE HOLDER CABLE HARNESS Retaining strap that fastens the cable harness DORSODURO Electrical system ELE SYS 71 ...

Page 72: ...General wiring diagram Key 1 MULTIPLE CONNECTORS 2 RIGHT FRONT TURN INDICATOR 3 COMPLETE FRONT HEADLAMP 4 TAIL LIGHT BULB Electrical system DORSODURO ELE SYS 72 ...

Page 73: ... TURN INDICATOR 21 LICENSE PLATE LIGHT BULB 22 REAR TWIN LIGHT STOP LIGHT BULB 23 REAR LIGHT ASSEMBLY 24 REAR STOP SWITCH 25 FRONT STOP SWITCH 26 SPEED SENSOR 27 FALL SENSOR 28 NEUTRAL SENSOR 29 TIMING SENSOR OPTIONAL 30 AUXILIARY FUSES 31 FLYWHEEL 32 VOLTAGE REGULATOR 33 STARTER MOTOR 34 START UP RELAY 35 MAIN FUSE 36 BATTERY 37 RETENTION RELAY START UP LOGIC 38 CONTROL RELAY START UP LOGIC 39 MA...

Page 74: ...OR 54 FRONT CYLINDER PRESSURE SENSOR 55 REAR CYLINDER INJECTOR 56 FRONT CYLINDER INJECTOR 57 EFG 1X THROTTLE CONTROL UNIT 58 REAR CYLINDER THROTTLE 59 FRONT CYLINDER THROTTLE 60 DEMAND CONTROL UNIT 61 PICK UP 62 ECU 63 HAZARD BUTTON LIGHTING 64 HIGH BEAM LIGHT RELAY 65 RECOVERY LOGIC RELAY 66 PROTECTION RESISTANCES Colour key Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R...

Page 75: ...nd terminal integrity i e that termi nals are not loose open bent 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 FAILURES BY MOVING SLIGHTLY...

Page 76: ...e 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 FAILURES BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED Dashboard In case the EFI warning light turns on and the words SERVICE or URGENT SERVICE are shown on the display due to an error detected in the injection ECU ...

Page 77: ... immobilizer and the sensors connec ted to it Instrument panel errors In this mode a chart is displayed showing potential errors in the immobilizer and the sensors connected to it DSB 01 Immobilizer failure key code read but not recognised DSB 02 Immobilizer failure key code not read key not present or transponder not working DSB 03 Immobilizer failure aerial not working open or short circuited DS...

Page 78: ...st 200 km 124 mi of the vehicle provided this has not been done by the Quality Check UPDATE This function is used to program the instrument 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 CHANGE KEYS With t...

Page 79: ...IAGNOSIS section See also Diagnosis level indicators Fuel reserve sensor Check proper operation of the sensor by adding a 2W bulb in series to the sensor Place a bulb between the battery power supply cable and the connector terminal and connect the negative terminal to the ground connection if the sensor is submerged in petrol sensor high electrical resistance approx 5 7 kOhm the bulb should remai...

Page 80: ... and EFG 1x control unit 15 A E Permanent positive ECU power supply 3A F Oxygen sensor heater Coils Start up logic Fan and injection relay Fuel pump Purge valve Injectors ECU Start up logic 20A G Spare fuses 10 15 20 A MAIN FUSES H Spare fuses 30 A I Battery charging fan relay live positive 30 A Control unit MARELLI CONTROL UNIT Function It controls the Ride by wire system the injection ignition t...

Page 81: ...ed the consent by the instrument panel regarding the im mobilizer coded key or user code entered manually Potential errors will be shown on the Instrument Panel Errors screen page on the DIAGNOSIS section of the instrument panel Start up signal Example value yes no Indicates whether the control unit will enable start up when requested in case the safety measures are not respected side stand neutra...

Page 82: ...t lines error P0610 circuit not operational Error cause Problems on the reset lines PINS 55 and 56 of the VEHICLE connector of the throttle motors lines used to interrupt motor functioning for safety reasons Troubleshooting Check the VEHICLE connector of the Marelli control unit the filter housing large connector and the throttle control unit connector if not OK restore If OK check continuity betw...

Page 83: ... learning can also be checked from the Pa rameter adjustment screwdriver and hammer screen page Stage 2 Carry out the Throttle Self learning from the Parameter adjustment screwdriver and hammer screen page and check that Throttle Self learning status is Carried out If it is not correct or the voltage detected on the throttle is out of scale check with Axone or if current errors are probably detect...

Page 84: ...RAMETERS Speed sensor Vehicle speed km h AXONE LOGIC ERRORS Sensor vehicle speed signal P0500 over maximum limit signal not valid Error cause If over the maximum limit excessive signal frequency has been detected at PIN 49 VEHI CLE If signal is not valid a fault in the signal no signal short circuit to positive open or earthed circuit defective sensor open circuit defective measuring cam etc has b...

Page 85: ...able harness if there is 5V voltage set the key to OFF and check that there is continuity between the VEHICLE PIN 49 and the sensor PIN 2 if there is no continuity restore the cable harness If there is continuity check that the cam that reads the signal is in good conditions if it is not replace it If it is OK replace the sensor SENSOR REMOVAL Remove the rear shock absorber Undo and remove the scr...

Page 86: ...AUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL CON CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE PARAMETERS Engine rpm AXONE STATUSES Synchronised panel Example value Start up_Lean_Rich_Fault due to rich value_Fault due to lean value If the probe connector is removed voltage almost equ...

Page 87: ...ition sensor THROTTLE GRIP POSITION SENSOR Function The throttle grip is the part to which the throttle control cables arrive its task is to translate the rider s power request Demand into an electrical signal to be sent to the electronic control unit Operation Operating principle The two throttle cables opening and closing actuate on a scroll mounted on a shaft which is sent back to its home posi...

Page 88: ...ck A Left side throttle grip position sensor track B Example value 1107 mV Voltage value times 2 of the left potentiometer track B Right side throttle grip position sensor track C 3560 mV Voltage value of the left potentiometer track C Right side throttle grip position sensor track D 3555 mV Voltage value times 2 of the left potentiometer track D Throttle grip position sensor 1107 mV Voltage corre...

Page 89: ...ector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable earth insulation from the throttle grip sensor connector or the control unit connector if the cable is not earth insulated restore the wiring If it is earth insulated and with the key set to ON check that there is power supply for the potentiometer PIN A and that PIN C is ...

Page 90: ... displayed by the Axone if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open short circuit to negative 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 ...

Page 91: ...ubleshooting Check the parameters of the left Throttle Grip Position Sensor tracks A and B if one of the two values clearly deviates from 600 1400 mV it means that this potentiometer is defective Check the throttle grip sensor connector and the control unit connector if not OK restore If OK check that cable resistance between the throttle grip sensor connector and the control unit is a few tenths ...

Page 92: ...ors which get to the throttle grip sensor are the same but they should NEVER be inverted Mark or check the connector marking before removing them blue stamp blue band REMOVAL When required disconnect the corre sponding connectors undo and re move the two screws and remove the throttle grip position sensor Intake pressure sensor INTAKE AIR PRESSURE SENSOR Function The pressure sensors one per cylin...

Page 93: ...003 mbar Pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure Example value 1004 mbar Pressure estimated by the control unit according to the throttle position AXONE ELECTRICAL ERRORS Front cylinder air pressure sensor P0105 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive volt...

Page 94: ...ON check that the voltage on sensor con nector PIN 1 is approx 5 V if this is not correct set the key to OFF and check continuity between the ENGINE connector PIN 15 and the sensor connector PIN 1 If not OK restore the cable harness if it is 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 rest...

Page 95: ...iven percentage this error is activa ted The most frequent causes can be abnormal resistance in the sensor circuit for example rusted terminals or sensor with poor performance Troubleshooting Check the filter casing large connector the Marelli control unit connector and the sensor connector if not OK restore If everything is OK check that cable resistance between VE HICLE connector PIN 34 and sens...

Page 96: ...r and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Estimation error for front cylinder intake manifold pressure P0215 pressure too high pressure too low Error cause A substantial difference between the estimated pressure and the measured pressure has been detected for example the pipe between sensor and...

Page 97: ...sure 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 pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the inta...

Page 98: ...ers to an open circuit AXONE ELECTRICAL ERRORS engine temperature sensor P0115 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 45 of the ENGINE connector If shorted to negative voltage equal to zero has been detected at PIN 45 of the ENGINE connector If the circuit is open shorted to positive che...

Page 99: ...ensor P0116 signal not valid Error cause An excessive temperature variation has been detected for example the cause may be a contact resistance between the terminals Troubleshooting Check the sensor connector and the ENGINE connector of the Marelli control unit NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check th...

Page 100: ...PIN 63 of the ENGINE connector If shorted to negative voltage equal to zero has been detected at PIN 63 of the ENGINE connector Troubleshooting If the circuit is open shorted to positive check the sensor connector and the Marelli control unit connector If they are OK check sensor continuity replace the sensor if not OK if it is OK check continuity between the ENGINE connector PIN 63 and the sensor...

Page 101: ...s OK check the sensor connector and the Marelli control unit connector Lambda sensor LAMBDA PROBE Function It tells the control unit whether combustion is lean or rich Operation Operating principle The Marelli injection control unit reads and inter prets a voltage generated by the difference in oxy gen content between the exhaust fumes and the ambient It does not require an external supply source ...

Page 102: ...s to 25 In an open circuit the lambda probe signal is too low Therefore the control unit takes it as a lean combustion condition and will try to enrich it The value read will be 0 75 once this correction has been tried the value shifts to 1 00 fixed and the Lambda probe error is signalled AXONE STATUSES Lambda Example value Start up_Lean_Rich_Fault due to rich value_Fault due to lean value If the ...

Page 103: ...negative check the continuity from probe connector PIN 3 and 4 towards the probe if not OK replace the probe if it is correct check the sensor connector and the Marelli control unit connector If not OK restore If OK and with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if not ok check the red black cable between the probe connector and the auxiliary in...

Page 104: ...ITTLE AIR EXCESSIVE PETROL DEFECTIVE PROBE Injector INJECTOR Function To supply the correct amount of petrol at the right timing Operation Operating principle Injector coil is excited for the petrol passage to open Level in wiring diagram Coils and injectors Location on the vehicle inside the filter casing connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C 68 F Pin out 1 Supply 2 ...

Page 105: ...itive disconnect the injector connector set key to ON activate the compo nent with Axone and check the voltage on the grey green cable on the filter casing small connector towards the Marelli control unit if there is voltage restore the cable harness be tween the filter casing connector and the Marelli control unit If there is no voltage reconnect the connector and check if there is voltage at PIN...

Page 106: ...n the grey red cable if there is restore the cable harness between the filter casing connector and the Marelli control unit if there is not reconnect the connector and disconnect the injector connector and check if there is a ground connection on PIN if there is voltage restore the filter casing cable harness If there is no voltage replace the injector the circuit is open check the component corre...

Page 107: ... 5 seconds and the sky blue orange cable of the coil 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 dis played in case of lack of activation Rear coil The auxiliary injection relay No 40 in the wiring diagram placed ...

Page 108: ... coil connector or control unit connector If not OK restore the cable harness Rear coil P0352 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 19 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 19 of the ENGINE connector Troubleshooting If shorted to ...

Page 109: ...orced to activation If start up is attempted during this activation which requires 3 seconds the engine will not start Level in wiring diagram throttle control unit Location on the vehicle inside the filter casing connector on the throttle body Pin out 1 potentiometer signal 1 2 supply voltage 5V 3 throttle valve control 4 potentiometer signal 2 5 throttle valve control 6 ground connection CAUTION...

Page 110: ... manifold the pressure read is different from the pressure estimated by the control unit and the system tries to reach an estimated situation by opening the throttle a little bit more therefore this parameter takes a value different from zero an acceptable value should be between 0 7º and 0 7º Front cylinder Limp home position Rear cylinder Limp home position Example value 800 mV 780 mV Voltage st...

Page 111: ...alue short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN A5 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN A5 of the throttle control unit Troubleshooting if shorted to positive check the value shown by the parameter of the front throttl...

Page 112: ...ition P0127 Example value short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN B5 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN B5 of the throttle control unit Troubleshooting if shorted to positive check the value shown by the parameter...

Page 113: ...nnector set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection if it is there is a short circuit in the cable ground connection if it is not replace the throttle body open circuit overcurrent excessive inside temperature check the throttle body connector and the throttle control unit connector If not OK restore If everything is OK disconnect the throttle body conn...

Page 114: ...e the throttle body open circuit overvoltage excessive inside temperature check the throttle body connector and the throttle control unit connector If not OK restore If everything is OK disconnect the throttle body connector PIN 3 and the throttle control unit connector C8 and check the circuit continuity between the two terminals if there is no continuity restore the cable har ness If there is co...

Page 115: ...n one of the two circuits Troubleshooting Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 1 and the throttle control unit PIN 6A is a few tenths of an Ohm Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5A is a few tenths of an Ohm If one of t...

Page 116: ...and the throttle control unit PIN 6B is a few tenths of an Ohm Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5B is a few tenths of an Ohm If one of the two is different restore the cable harness If correct replace the complete throttle body Front throttle Limp Home autodetection P0160 test failed Error cause Throttle position kept by the sp...

Page 117: ...ete errors hindering throttle self learning Front throttle position error P0167 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body Rear throttle Limp Home autodetection P0180 test failed Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel doe...

Page 118: ...arning process has not been successful or has not been carried out The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Delete errors hindering throttle self learning Rear throttle position error P0187 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body R...

Page 119: ...or DSB 07 Error cause An oil sensor failure is signalled when with engine off it is detected that the sensor circuit is open The test is per formed only once when the key is set to ON This error is signalled by the bulb icon and the general warning light turns on as well Troubleshooting Check the sensor connector and the instrument panel connector PIN 17 If not OK restore If OK check the con tinui...

Page 120: ...t in neu tral or in gear Operation Operating principle for gear in neutral the circuit is closed to ground connection then via CAN the control unit sends the signal to the instrument panel which turns on the neutral speed warning light Level in wiring diagram start up enabling switches Location on the vehicle left side of the vehicle near flywheel cover connector upper part of the flywheel cover E...

Page 121: ...or and ENGINE connector PIN 16 if there is no continuity restore the cable harness If there is replace the instrument panel if the vehicle performance is correct the engine starts with gear in neutral but the neutral warning light is off or replace the control unit if the vehicle performance is not correct the engine does not start with gear in neutral Indication on the instrument panel always gea...

Page 122: ...he cable terminals on the connector and the correct connection of the cables on the terminals If they are not correct restore the cable harness if correct disconnect the two terminals from the sensor and with key set to ON check continuity to ground connection of PIN 2 if there is no con tinuity restore the cable harness if there is replace the sensor Indication on Axone always Pulled disconnect t...

Page 123: ...UBLESHOOTING CAREFULLY READ THE GENERAL CON CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE STATUSES Side stand Example value up down Indication on Axone always down check the connector if not OK restore if it is OK disconnect the two terminals from the sensor and check continuity to ground of PIN 1 if there is no...

Page 124: ...ING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE PARAMETERS Fall sensor Example value Normal Tip over Indication on Axone always Normal even when the sensor is inverted disconnect the connector and with sensor inverted check if there is continuity between the two PINS of the sensor if there is no continuity replace the sensor if there is check the connector If not OK r...

Page 125: ...trical characteristics relay normally open drive coil resistance 110 Ohm 10 AXONE STATUSES Fan relay Example value on off AXONE ACTIVATIONS Fan The fan relay No 44 in the wiring diagram placed under fuel tank left side first front relay CHECK however the identification of the relay with the colour of the cables is energised for 10 seconds The continuity of the wiring is necessary for correct activ...

Page 126: ...he relay if correct restore the cable harness pink blue cable If the circuit is open check the relay connector and the Marelli control unit VEHICLE connector If not OK re store if OK restore the cable harness red blue cable RUN STOP switch Run stop switch Function It tells the control unit if the driver wishes to enable engine start up or to keep the engine running Operation Operating principle If...

Page 127: ...d black cable if there is no voltage restore the cable harness if there is check the yellow grey cable earth insulation if there is continuity to ground restore the cable harness if it is correct take the key to OFF and check the VEHICLE connector is in good conditions and the continuity of the grey yellow cable between the sensor in question and the VEHICLE connector PIN 26 if not OK restore the ...

Page 128: ...ack A Vehicle connector 42 6 Throttle grip input Track B Vehicle connector 40 7 Throttle grip input Track C Engine connector 30 8 Throttle grip input Track D Engine connector 44 9 Front cylinder intake pressure sensor input Vehicle connector 34 10 Rear cylinder intake pressure sensor input Vehicle connector 5 11 Water temperature sensor input Engine connector 45 12 Side stand input Vehicle connect...

Page 129: ...onnector 43 32 Lambda sensor input Engine connector 60 33 Purge Canister valve control output optional Engine connector 51 34 Control unit direct power supply Vehicle connector 16 35 Power ground connection 1 Engine connector 21 36 Power ground connection 2 Engine connector 5 37 Power ground connection 3 Engine connector 22 38 Power ground connection 4 Engine connector 6 39 Reference voltage outpu...

Page 130: ...nput for front throttle potentiometer 2 signal Front throttle body PIN 4 6 6A Input for front throttle potentiometer 1 signal Front throttle body PIN 1 7 7A Front throttle reset signal input 8 8A Rear throttle motor control Rear throttle body PIN 3 9 1B Battery power supply input 10 2B CAN H 11 3B Voltage for rear throttle potentiometers 5 V Rear throttle body PIN 2 12 4B Firmware reprogramming po...

Page 131: ...N CABLE HARNESS AND INTO THE CONNEC TOR Dashboard NOTE THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR INSTRUMENT PANEL PIN Specification Desc Quantity 1 GREY BODY Live PIN 1 2 GREY BODY Right indicator control PIN 2 3 GREY BODY PIN 3 4 GREY BODY High beam lights input PIN 4 5 GREY BODY PIN 5 6 GR...

Page 132: ...relli injection control unit the throttle control unit and the in strument panel Level in wiring diagram CAN line Pin out see wiring diagram AXONE ELECTRICAL ERRORS U1602 CAN line without signals Bus Off Error cause No communication on CAN line PIN 20 and or PIN 51 VEHICLE problem on the whole network for example battery cut off or short circuited or shorted to ground Troubleshooting Check the Mar...

Page 133: ...anel CAN line to the throttle control unit U1705 no signal Error cause No signal is received by the throttle control unit Troubleshooting Check the filter housing large connector and the throttle control unit connector if not OK restore if OK check the continuity of the two lines from the filter housing large connector to the VEHICLE connector of the Marelli control unit if not OK restore the cabl...

Page 134: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 135: ...tem Place the optional under sump and rear wheel service stands Undo and remove the screw and move the coil Disconnect the engine temperature sensor connector Disconnect the engine oil pressure sensor connector Disconnect the starter motor power supply cable DORSODURO Engine from vehicle ENG VE 135 ...

Page 136: ... the washer Disconnect the ground leads Move the breather pipe Disconnect the speed sensor connec tor Undo and remove the three screws Remove the clutch control cylinder Lock the plunger using a clamp Engine from vehicle DORSODURO ENG VE 136 ...

Page 137: ...remove the three screws fix ing the chain guide Remove the clutch pin CAUTION UPON REFITTING PROPERLY GREASE THE O RING IN DICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT Disconnect the gear in neutral sensor connector DORSODURO Engine from vehicle ENG VE 137 ...

Page 138: ...ion connecting rod keeping it linked to the gear shift lever through the rod Slacken the gearing chain tension Undo and remove the screw collect the washer and the spacer Slide off the pinion from the chain and remove Disconnect the generator connections Engine from vehicle DORSODURO ENG VE 138 ...

Page 139: ...e by means of belt and hoist Working on the left side unscrew and remove the two upper nuts Working on the right side slightly slide off the two upper bolts Collect the spacers on the opposite side Check spacers length so as not to in terchange them upon refitting Remove the two upper bolts and col lect the washers DORSODURO Engine from vehicle ENG VE 139 ...

Page 140: ...he spacer on the opposite side Remove the lower pin and collect the washer Lower the engine See also Vehicle preparation Installing the engine to the vehicle Place the engine on a suitable lower stand Lift the engine Place the engine so that the rear attachments on the chassis are aligned Engine from vehicle DORSODURO ENG VE 140 ...

Page 141: ...Y WERE BEFORE BEING REMOVED Working from the left side tighten the three nuts Release the engine from the belt and the hoist Refit the pinion and restore the gearing chain clearance Reconnect the electric connections and clamp the cable harnesses Carry out the vehicle preparation oper ations but in reverse order restore the correct level of all fluids and carry out the adjustments that may be requ...

Page 142: ...See also Vehicle preparation Adjusting Engine from vehicle DORSODURO ENG VE 142 ...

Page 143: ...INDEX OF TOPICS ENGINE ENG ...

Page 144: ...ctor lock 3 Selector sprocket wheel 4 M5x16 Screw 5 Sprocket wheel pawl 6 Spring 7 Pin for spring 8 Tone wheel 9 Complete transmission gear shaft 10 Forks 11 Fork shaft 12 Spring 13 Pin for spring 14 Gear selector 15 Fork shaft 16 Fork Engine DORSODURO ENG 144 ...

Page 145: ...ed screw M6x15 22 Complete index lever 23 Spring Gearbox shafts Gearbox shafts diagram Key 1 Main gear shaft Z 14 2 2nd gear on primary Z 17 3 3rd 4th gear on secondary Z 20 22 4 5th gear on primary Z 23 5 6th gear on primary Z 24 6 Thrust washer 7 Circlip 8 Thrust washer 9 Thrust washer DORSODURO Engine ENG 145 ...

Page 146: ...6 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 Remove the gear selector as descri bed in the Crankcase Opening section Remove the two bolts of the forks Engine DORSODURO ENG 146 ...

Page 147: ...um con trol Remove the three gear selection forks CAUTION THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE Carefully rotate the engine support DORSODURO Engine ENG 147 ...

Page 148: ...remove the gear selector refer to the operations described under Crankcase opening Checking the gear selector Selector spring Make sure that the spring ends on the two shifting positions forward downshifting and backward up shifting are always in contact with the selector plate Make sure that the clearance between the end of the spring on the selector plate and the stop pin is almost null when in ...

Page 149: ...r plate spring With a thickness gauge check that the spring is not deformed by over stretching Starter motor Removing the starter motor Disconnect the starter motor power supply cable Undo and remove the four screws and remove the starter motor DORSODURO Engine ENG 149 ...

Page 150: ...4 Freewheel flange 5 Freewheel 6 Complete rotor 7 Complete stator 8 Flywheel cover gasket 9 Flywheel cover 10 TCEI low head screw M6x30 11 TBIC screw M5x12 12 TE flanged screw 13 Cap 14 Gasket 15 TCEI screw M6X18 16 Woodruff Key 17 TE flanged screw 18 Washer 19 Plate Engine DORSODURO ENG 150 ...

Page 151: ...ng the flywheel cover Remove the flywheel cover inspection cap Unscrew and remove the ten screws 1 2 NOTE THE FLYWHEEL COVER SCREW 2 IS SHORTER THAN SCREWS 1 Use the specific tool to remove the fly wheel cover Specific tooling 020712Y Handle for Flywheel cover removal DORSODURO Engine ENG 151 ...

Page 152: ...VED SIMUL TANEOUSLY AS THEY ARE PART OF THE SAME ELEC TRICAL BRANCH Magneto flywheel removal Remove the flywheel cover Undo and remove the screw and re move the retention plate Heat the magneto flywheel with the specific heater Lock the flywheel using the specific tool and loosen the screw Specific tooling 020713Y Flywheel extractor Engine DORSODURO ENG 152 ...

Page 153: ...r Unscrew and remove the anticlockwise bolt of the special tool from the external body Undo the screw from the crankshaft Specific tooling 020713Y Flywheel extractor Remove the flywheel together with the freewheel Remove the start up transmission gear In case of malfunction the start up transmission gear cannot be over hauled Therefore the complete trans mission gear should be replaced Collect the...

Page 154: ...e the freewheel from the mag neto flywheel Installing the flywheel Insert the woodruff key on the crank shaft Insert the start up transmission gear after applying a layer of grease Insert the flywheel on the crankshaft Screw the screw together with the washer but without tightening Engine DORSODURO ENG 154 ...

Page 155: ...ft Remove the special tool Specific tooling 020713Y Flywheel extractor Locking torques N m Screw fixing Rotor Crankshaft M12x1 25 1 120 Nm 88 51 lbf ft Place the retention plate Tighten the screw Clutch side Remove the water pump cover Undo and remove the eleven screws working in a diagonal sequence Collect the gasket DORSODURO Engine ENG 155 ...

Page 156: ...er possible to remove the complete clutch assembly by removing only the clutch cover In this case carry out the following operations measure the clutch bell protrusion from the crankcase before removal during refitting first check that the measurement has not changed then tighten the clutch nut If it has changed rotate the crankshaft so that the oil pump control drive gear engages cor rectly with ...

Page 157: ...l 2 Washer 3 Clutch hub 4 Clutch pressure plate 5 Clutch spring 6 Washer 7 TCEI screw M6 8 Spacer 9 Anti juddering 10 Belleville spring 11 Anti juddering 12 Nitrided driven disc 13 Lathed drive disc 14 Drive disc 15 Driven disc DORSODURO Engine ENG 157 ...

Page 158: ... loosening them 1 4 of a turn at a time operate in stages and diagonally and collect the washers and the clutch springs Remove the pressure plate Remove the mushroom rod for clutch control Remove the discs Remove the spacer and the belleville spring Engine DORSODURO ENG 158 ...

Page 159: ...l Specific tooling 9100896 Clutch bell locking tool Unscrew and remove the clutch hub nut and collect the washer Remove the clutch hub Collect the special washer between the clutch hub and the bell Collect the clutch bell DORSODURO Engine ENG 159 ...

Page 160: ...llowed 0 20 mm 0 0079 in Measure the driving plate thickness at four positions replace them all if not complying with specifications CAUTION THE STEEL DISCS MUST SHOW NO SCORES OR TEM PERING COLOUR Measure the thickness of the clutch discs at four positions replace them if not complying with specifications Thickness of nine drive discs 2 5 mm 0 10 in Driven disc thickness 2 95 3 05 mm 0 116 0 120 ...

Page 161: ...ng 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 Remove the rotation locking pin from the oil pump control gear Check the clutch bell for damage and wear that may result in clutch irregular operation Deburr the teeth or replace the bell MAIN DRIVEN GEAR CHECK DORSODURO Engine ENG 161 ...

Page 162: ...plate Check the pressure plate and the bearing for dam age 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 bell Checking the springs Check the springs for damage and if necessary replace the them all togeth er Measure the clutch spring length when unloaded if necessary r...

Page 163: ...clutch bell Make sure that the oil pump control drive gear of the clutch bell engages correctly with the oil pump driven gear Place the special washer correctly be tween the clutch bell and the hub CAUTION FIT THE SPECIAL WASHER WITH THE MACHINING FAC ING THE BELL DORSODURO Engine ENG 163 ...

Page 164: ...ol drive gear engages cor rectly with the oil pump driven gear on the clutch bell Fit the washer and a new clutch hub nut Tighten the clutch hub nut using the specific tool Specific tooling 9100896 Clutch bell locking tool Tighten the nut and proceed to caulk Insert the flat ring 1 Insert the cupped ring 2 CAUTION BE CAREFUL WITH THE CUPPED RING FITTING SIDE THE RING CONE SHALL BE DIRECTED TOWARDS...

Page 165: ...steel discs Position all friction material discs with their teeth aligned in one of the long slots of the clutch bell Place the control rod Place the pressure plate Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally Replace the gasket upon refitting Head and timing DORSODURO Engine ENG 165 ...

Page 166: ...nd collect the rubber rings Remove the head cover Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Remove the head cylinder unit Undo and remove the screw on the in let side Undo and remove the screws on the outlet side Engine DORSODURO ENG 166 ...

Page 167: ...Collect the washer See also Removing the cylinder Cylinder head Key 1 Complete cylinder head 2 Inlet valve 3 Outlet valve 4 External valve spring 5 Internal valve spring 6 Upper cap 7 Lower cap 8 Stud bolt M8X3X46 DORSODURO Engine ENG 167 ...

Page 168: ...mshaft Remove the clutch side crankcase half Rotate the crankshaft until the rear cyl inder reaches the TDC First remove the rear head cover in order to re move the rear head camshafts First remove the front head cover in order to re move the front head camshafts Mark the head camshafts the corresponding sprocket wheels and cam caps in order not to in terchange them upon refitting Undo and remove ...

Page 169: ...emove the camshafts with the gears Removing the valves When removing the valve mark the components according to the position and the cylinder they belong to in order to refit the components to their correct positions Remove the bowl tappets and the ad justment shims using a magnet DORSODURO Engine ENG 169 ...

Page 170: ...h the spring compressing tool Specific tooling AP8140179 Valve spring compressor 020721Y Adaptor for valve removal Remove the cotters using a magnet Release the valve springs Remove the valve spring fittings plus the springs Slide off the valves Engine DORSODURO ENG 170 ...

Page 171: ...5 mm 1 4232 in b 28 mm 1 1023 in Outlet a 35 13 35 17 mm 1 3831 1 3846 in Limit 35 00 mm 1 3779 in b 28 mm 1 1023 in Fasten the camshaft in horizontal po sition as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the component Camshaft eccentricity maximum limit 0 040 mm 0 0016 in Valve check CAUTION REPLACE THE VALVES ONE AT A TIME DO NOT MIX T...

Page 172: ...ity allowed 0 05 mm 0 00197 in Check that the fixing grooves 5 of the valve cot ters are in proper conditions VALVE SPRINGS 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 6 42 5 mm 1 673 in Valve springs minimum wear limit 7 38 mm 1 496 in Checking the cylin...

Page 173: ...03 mm 0 0012 in Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn replace the defective part s Installing the overhead camshaft The camshaft refitting procedure is described in the Timing section See also Timing Timing Key 1 Camshaft front inlet 2 Camshaft front outlet 3 Axial restraint 4 Complete timing system gear 5 Complete front timing system gear 6 Comp...

Page 174: ...chain 15 Chain guide slider 16 Chain tightener rod 17 Camshaft rear inlet 18 Camshaft rear outlet 19 Left nut M15x1 20 Spacer screw Removing the chain tensioner Undo and remove the screw and col lect the washer and the internal spring Undo and remove the two screws Remove the chain tightener and collect the gasket Engine DORSODURO ENG 174 ...

Page 175: ...im ing chain intermediate gear paying at tention not to damage the O ring Collect the washer Remove the timing chain intermediate gear Slide off the timing chain from the crankshaft NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED See also Removing the chain sliders Removing the chain tensioner DORSODURO Engine ENG 175 ...

Page 176: ...f from the head to remove it Undo and remove the fixed chain ten sioner slider screw First remove the head in order to re move it REAR HEAD First remove the flywheel in order to remove the chain sliders from the front head Undo and remove the movable chain tensioner slider screw Slide it off from the head to remove it Undo and remove the fixed chain ten sioner slider screw First remove the head in...

Page 177: ...e If necessary replace the parts Installing the chain tensioner Refit the removed timing system chain tensioner on the cylinder head Fit the timing chain on the crankshaft and on the intermediate gear Remove the screw and collect the washer and the spring Fit the chain tensioner body on the cyl inder and insert a new paper gasket Tighten the two screws to the prescri bed torque Insert the spring a...

Page 178: ...ice and protect the cams of the camshaft adequately Unscrew and remove the nut ANTICLOCKWISE NUT FOR BOTH REAR CYLINDER SHAFTS AN ANTICLOCKWISE ARROW HAS BEEN PUNCHED ON IT Collect the washer Remove the timing system gear from the camshaft Clean gears surfaces camshaft cone and gear cone with System MC 217 spray metal cleaner Pre fit the gear on the camshaft so that it can turn freely Place the tw...

Page 179: ...FLYWHEEL SIDE NOTE THE TEMPLATE IS NOT A TOOL DESIGNED FOR TIMING BUT FOR IDENTIFYING THE CORRECT DIRECTION FOR CAMSHAFT FITTING THE SHAFTS MAY BE FITTED RO TATED BY 180 WITH REFERENCE TO THE CORRECT POSITION Specific tooling 020723Y Template for timing overhead cam shafts Place the cam cap Pre tighten the eight screws in the se quence indicated to the prescribed tor que Tighten the eight screws i...

Page 180: ...en it to the prescribed torque DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE ULTIMATE TIGHTENING TORQUE WITH THE SHAFT MOUNTED ON THE CYLINDER THIS OPERATION WOULD IRRETRIEVABLY DAMAGE THE HEAD Locking torques N m Nut fixing camshaft gears M15x1 4 90 Nm 66 38 lbf ft Remove the gear alignment tool Specific tooling 020718Y Camshaft gear alignment pin Release the crankshaft from the specific special to...

Page 181: ...iston 2 Piston 3 Compression ring 4 Oil scraper ring 5 Oil scraper ring 6 Pin 7 Pin stop ring 8 Gasket 9 Plate 10 TE flanged screw 11 Complete chain tensioner 12 TE flanged screw 13 Head cylinder gasket 14 11 8X10 Pin DORSODURO Engine ENG 181 ...

Page 182: ...ove the external screw Unscrew and remove the four nuts working in a diagonal sequence and in stages Slide off the head cylinder unit from the stud bolts Remove the three fixing screws of the cylinder head to the discharge and in take sides Remove the gasket between the cylin der and the crankcase See also Chain removal Engine DORSODURO ENG 182 ...

Page 183: ...ide off the pin and remove the piston Specific tooling 020716Y Connecting rod locking Lock the connecting rod using circlips FOR SAFETY REASONS COVER THE CRANKCASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE Remove the top ring the intermediate ring and the three oil scraper rings DORSODURO Engine ENG 183 ...

Page 184: ...s must be clean and flat Make sure all threads are in proper conditions Check cylinder sliding surface for signs of friction and scratches Also check the seal sur faces for damages CAUTION IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT REPLACE THE CYLINDER AND THE PISTON Engine DORSODURO ENG 184 ...

Page 185: ...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 cylinder clearance C C P Piston cylinder clearance 0 050 0 064 mm 0 00197 0 00252 in Limit 0 100 mm 0 00039 in Replace the cylinder the piston and the piston ring all together if not com plying with specifications PISTON RINGS Clean off any carbon d...

Page 186: ...THE THREE PISTON RINGS Piston ring end gap Top ring 0 25 0 40 mm 0 0079 0 0157 in Intermediate ring 0 35 0 55 mm 0 0138 0 0216 in Oil scraper ring 0 20 0 70 mm 0 0079 0 0276 in PIN Clean off combustion residues from the piston crown and from the area above the top ring Check for cracks on the piston and for compression on the piston sliding surface seizing Replace the piston if required CAUTION SM...

Page 187: ...97 in Piston cylinder coupling Type B Cylinder 91 997 92 004 mm 3 6219 3 6222 in Piston 91 940 91 947 mm 3 6197 3 6199 in Piston cylinder coupling Type C Cylinder 92 004 92 011 mm 3 6222 3 6225 in Piston 91 947 91 954 mm 3 6199 3 6202 in Piston cylinder coupling Type D Cylinder 92 011 92 018 mm 3 6225 3 6227 in Piston 91 954 91 961 mm 3 6202 3 6205 in Fitting clearance 0 050 0 064 mm 0 00197 0 002...

Page 188: ... the cylinder Fit the stud bolts if previously removed CAUTION THE STUD BOLTS SHOULD BE FITTED SO THAT THEY PROTRUDE DISTRIBUTE Loctite 270 high strength ON THE THREAD AND SCREW THE STUD BOLT ON THE CRANKCASE UNTIL THEY PROTRUDE BY 137 mm 5 39 in THEN MAKE SURE THE Loctite HAS SET Insert a new cylinder base gasket it should be as thick as the gasket previ ously removed 0 40 0 50 0 60 mm 0 0157 0 0...

Page 189: ...UBRICATION DUCT AND LUBRICATE THE CYLINDER LINER Insert the cylinder head unit on the stud bolts Working in a diagonal sequence and in stages screw the four nuts once the stud bolt threads have been greased Screw the screw located outside the cylinder Tighten the three screws on the intake and discharge sides Screw the two head fixing screws lo cated inside the timing chain compart ment DORSODURO ...

Page 190: ...earance be tween the pin and the gear is between 0 30 and 0 60 mm 0 0118 0 0236 in Tighten the intermediate gear pin once Loctite residues are thoroughly re moved and a high strength threadlock is applied on the thread Make sure that both timing chain slid ers are correctly fitted Refit the overhead camshafts following the procedure described in the Tim ing section See also Selecting the base gask...

Page 191: ...gauge on the specific tool Set the dial gauge to zero on a refer ence surface with a medium preload e g 5 mm 0 2 in Keeping the zero setting fit the tool on the cylinder and lock it with two nuts 10 Nm 7 38 lb ft as shown in the figure Specific tooling 020714Y Comparator support Rotate the crankshaft up to the TDC the reversal point of the dial gauge ro tation Lock the crankshaft at TDC using the ...

Page 192: ...0157 in Measured protrusion 0 05 0 10 mm 0 0020 0 0039 in Gasket 0 5 mm 0 0197 in Measured protrusion 0 15 0 30 mm 0 0059 0 0118 in Gasket 0 6 mm 0 0236 in Installing the cylinder head Place the fixed chain tensioner slider on the cylinder timing chain compart ment opposite to the chain tensioner Fit a new gasket between the cylinder and the head Couple the cylinder and the head Screw without tigh...

Page 193: ...ankcase stud bolts Installing the head cover CAUTION BEFORE REFITTING HEAD COVERS CLEAN HEAD AND COVER SURFACES CAREFULLY Apply THREEBOND on the head cover perimeter along the gasket housing Apply THREEBOND on the head in the areas indicated in the figure For the remaining operations follow the removal operations but in reverse order DORSODURO Engine ENG 193 ...

Page 194: ...bearing 25x42x9 6 Ball bearing 20x47x14 7 Roller casing 30x37x12 8 Roller casing 9 Washer 10 TSPEI screw M6x12 11 Sealing ring 12 Sealing ring 8x16x7 13 Sealing ring 14x22x5 14 Sealing ring 20x30x5 15 Threaded cap 16 Oil spraying pipe 17 OR sealing ring 18 TCEI screw M5X16 19 Timing sensor Engine DORSODURO ENG 194 ...

Page 195: ...tting the crankcase halves Fit the special tool by fixing the four fix ing screws steadfastly on the crank case Using the special tool unscrew and re move the crankshaft locking nut and collect the washer Specific tooling 020711Y Engine pinion locking DORSODURO Engine ENG 195 ...

Page 196: ... remove the crankshaft gear Remove the gear control rod and col lect the washer Undo and remove the screw fixing the speed sensor Carefully remove the speed sensor Heat the screws of the gear selector supporting plate Engine DORSODURO ENG 196 ...

Page 197: ...d remove the three screws fix ing the gear selector plate Remove the plate together with the se lector Undo and remove the two screws fixing the neutral sensor Remove the neutral sensor DORSODURO Engine ENG 197 ...

Page 198: ...h bell locking tool The tone wheel is sealed with Loctite Heat it with a suitable blower paying special attention not to reach high temperatures Remove the speed sensor catch with the specific special tool Reposition the tone wheel and seal it with high strength Loctite upon refitting Specific tooling 020715Y Tone wheel removal Engine DORSODURO ENG 198 ...

Page 199: ... Undo and remove the gear selector drum fixing screw Remove the gear selector drum Remove the pinion Slide off the clutch control rod DORSODURO Engine ENG 199 ...

Page 200: ...e left side undo and re move the nine M6 screws fixing the crankcase Remove the fuel breather clamping plate CAUTION UPON REFITTING THE FUEL BREATHER CLAMPING PLATE REMEMBER TO INSTALL IT IN THE PINION AREA Rotate the engine and the engine sup port into horizontal position Engine DORSODURO ENG 200 ...

Page 201: ...sealing CAUTION PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUP PORT STABILITY AND MAKE SURE THE ENGINE TO PLATE FIXING IS RELIABLE Remove the two screws fixing the sup port Separate the crankcase halves by giv ing a few taps with a rubber hammer Open the crankcase halves DORSODURO Engine ENG 201 ...

Page 202: ... to the engine sup port again If necessary undo and remove the two screws fixing the strum box Remove the strum box See also Removing the cylinder Magneto flywheel removal Disassembling the clutch Engine DORSODURO ENG 202 ...

Page 203: ... crankshaft 2 Complete connecting rod 3 Connecting rod screw 4 Bushing half shell 5 Main transmission gear 6 Woodruff Key 7 Water pump gear 8 Plain washer 9 Nut 10 Roller 11 Bushing Slide off the crankshaft See also DORSODURO Engine ENG 203 ...

Page 204: ... 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 silently or if there is some noise while it turns it means that the bearing is faulty and must be replaced OIL FILTER AND OIL DELIVERY PIPE CHECK Check the oil filter fo...

Page 205: ...cked with a com parator mounted on the specific com parator support The clearance should be between 0 1 0 4 mm 0 0039 0 0157 in If the clearance is beyond tolerance check the reference surfaces Specific tooling 020714Y Comparator support 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 CHA...

Page 206: ...ngine support into horizontal position Place the left crankcase half on the engine support fitting it on the engine support pins CAUTION PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUPPORT STABILITY AND MAKE SURE THE ENGINE TO PLATE FIXING IS RELIABLE Fit the complete transmission gears unit Apply black sealing paste Threebond on the left crankcase half CAUTION BE CAREFUL NOT TO APPLY THREEBOND IN ...

Page 207: ...e half with the aid of a rubber hammer Tighten the two fixing pins Rotate the engine and the engine support into vertical position Working on the left side place the nine M6 screws fixing the crankcase DORSODURO Engine ENG 207 ...

Page 208: ...all the crankcase fixing screws both M6 and M8 type Slide in the clutch control rod Place the pinion Place the gear selector drum and check that it is correctly timed thrust the desmo drum axially from the fly wheel side so that the timing roller pro trudes Engine DORSODURO ENG 208 ...

Page 209: ... wheel Tighten the tone wheel with the special tool Use Loctite medium strength for sealing Specific tooling 020715Y Tone wheel removal Tighten the pinion fixing nut using the special tool Specific tooling 9100896 Clutch bell locking tool DORSODURO Engine ENG 209 ...

Page 210: ...e neutral sensor and lubricate its seat to facilitate refitting BE CAREFUL NOT TO DAMAGE THE O RING WHEN IN SERTING THE SENSOR IN ITS POSITION Tighten the two screws fixing the neu tral sensor Position the plate together with the se lector Engine DORSODURO ENG 210 ...

Page 211: ...e speed sensor with caution Tighten the speed sensor fixing screw Place the transmission control rod with the washer Remove the grease off the primary pin ion tapered pins crankshaft coupling surfaces Position the crankshaft gear Position the washer and the crankshaft lock nut DORSODURO Engine ENG 211 ...

Page 212: ...e four fixing screws on the crankcase Tighten the crankshaft gear lock nut Specific tooling 020711Y Engine pinion locking Lubrication Oil pump Removing Lock the pump gear with the commer cially available hook spanner and undo the screw collect the washer Engine DORSODURO ENG 212 ...

Page 213: ... Collect the shim washer Undo and remove the two screws fixing the oil pump Remove the entire pump DORSODURO Engine ENG 213 ...

Page 214: ...ness gauge check clear ance between rotor and stator and re place the rotor stator unit if required clearance between rotor and stator 0 04 0 10 mm 0 0016 in 0 0039 in Slide off the shaft with the cover Collect the lock pin from the shaft Engine DORSODURO ENG 214 ...

Page 215: ...CORES OR ANY OTH ER MARKS Installing Follow the oil pump removal opera tions carefully align the stator and ro tor references upon fitting and check clearance with a thickness gauge If required replace the stator rotor unit Locking torques N m Screw fixing oil Pump with Gear M5 1 8 Nm 5 90 lbf ft Loctite 270 DORSODURO Engine ENG 215 ...

Page 216: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 217: ...ICAL ERRORS Fuel pump relay control P0230 Example value shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 62 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 62 of the VEHICLE connector Injection DORSODURO Power supply P SUPP 217 ...

Page 218: ...to translate the rider s power request into an electrical signal to be sent to the electronic control unit The two throttle cables opening and closing actuate on a scroll mounted on a shaft and which is sent back to its home position by a return spring On the shaft covers there are 2 double track potentiometers 4 control tracks by means of which the torque demand is read and checked Marelli 5DM el...

Page 219: ...For medium high throttle openings alpha n For temporary speed speed change alpha n The main parameters that correct the injection map are Engine temperature Atmospheric pressure calculated Lambda probe signal Air temperature 3 System safety checks The checks are structured in several levels Level 1 sensor correct operation Level 2 comparison between requested torque and estimated torque generated ...

Page 220: ...ng in safety the warning light turns on the message Urgent Service is displayed the engine stops running Removing the throttle body Remove the filter casing Working on both bodies undo and re move the four screws and slide off the filter support Remove the upper plate Remove both bodies UPON REFITTING REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE Power supply DORSODURO P SUPP 22...

Page 221: ...s Remove the plate Working on both bodies undo and re move the screw and detach the body 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 DORSODURO Power supply P SUPP 221 ...

Page 222: ...rs etc is available at the home page of the website www serviceaprilia com in the search section Axone Parameters The same parameters device status errors etc are grouped per type of component they refer to in the Electrical system chapter Checks and Controls Power supply DORSODURO P SUPP 222 ...

Page 223: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 224: ...ealing ring 30x47x7 6 Seeger ring 7 Front wheel right external spacer 8 Front brake disc 9 Washer 25 2x36x1 10 Wheel pin nut 11 TE flanged screw M8x20 12 Front wheel pin 13 Front cover 120 70 ZR 17 Removing the front wheel Hold the scooter front part Suspensions DORSODURO SUSP 224 ...

Page 225: ... the sealing washer Loosen the screws on the wheel pin clamps Tap the wheel pin with a rubber hammer so that the holes on the opposite side are exposed Remove the wheel pin by inserting a screwdriver in the holes on the pin During extraction support the wheel and then remove it DORSODURO Suspensions SUSP 225 ...

Page 226: ...ntrol parameters Replace both wheel bearings RADIAL AND AXIAL CLEARANCE CHECK Check the radial and axial clearance Axial clearance a minimum axial clearance is allowed Radial clearance none If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE GASKETS Check that the gaskets...

Page 227: ...g a dial gauge check that the ra dial A and the axial B eccentricities of the rim do not exceed the limit value An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2 mm 0 0079 in Handlebar Key DORSODURO Suspensions SUSP 227 ...

Page 228: ... vibration weight 6 TCEI screw 7 Upper U bolt 8 Screw 9 Handgrips 10 Right rear view mirror 11 Left rear view mirror 12 Throttle opening cable 13 Throttle closing cable 14 Right hand guard 15 Left hand guard 16 Bushing 17 Spacer 18 Rubber ring 19 Clamp Front fork Suspensions DORSODURO SUSP 228 ...

Page 229: ...ding pipe 6 Right pumping member assembly 7 Left pumping member assembly 8 Sleeve cap 9 O ring 10 Rubber ring 11 O ring 12 Snap ring 13 Stem right wheel holder 14 Stem left wheel holder 15 Dust guard 16 Seeger ring 17 Oil seal 18 Ring 19 Guide bushing DORSODURO Suspensions SUSP 229 ...

Page 230: ...oving the fork legs Remove the front wheel Support the fork stem and loosen the screws on the upper and then the lower plate Remove the fork stem Draining oil NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS NOTE BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE CAPACITY TO COLLECT THE OIL Remove the fork Suspensions DORSODURO SUSP 230 ...

Page 231: ...table capacity to collect fluids DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL STORED IN A SEALED CON TAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM See also Removing the fork legs Disassembling the fork WARNING DO NOT INTERCHANGE THE STEMS THEY HAVE INTERNAL DIFFERENCES THE LEFT CAR TRIDGE 2 HAS A SLOT AT THE BOTTOM WHEREAS THE RIGHT ONE 1 HAS A...

Page 232: ...tem on a work table in upright position Fit the special tool Specific tooling AP8140147 Spacer tool With the help of a second operator Insert the special tool between the nut and the preloading pipe Specific tooling AP8140148 Spacer pumping element separat ing plate Suspensions DORSODURO SUSP 232 ...

Page 233: ...moving it Remove the spacer See also Draining oil Measure the distance between the nut and the thread to restore this setting if necessary Compress the spring so as to take out the tool Specific tooling AP8140148 Spacer pumping element separat ing plate DORSODURO Suspensions SUSP 233 ...

Page 234: ...s ited on the spring turns fully drip into the sleeve Be careful not to damage the fork stem when placing it in a vice in horizontal position using the appropriate protections Specific tooling AP8140149 Protection for fitting operations Unscrew and remove the bottom screw and collect the special washer Suspensions DORSODURO SUSP 234 ...

Page 235: ... cap Slide off the dust scraper from the sleeve using a screwdriver as a lever Do not damage the sleeve edge while doing this Remove the snap ring Take out the sleeve from the stem using the stem as a hammer puller DORSODURO Suspensions SUSP 235 ...

Page 236: ...ings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION 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 Suspe...

Page 237: ...llowing components are in good conditions upper bushing lower bushing pumping member If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE Replace the following components with new ones sealing ring DORSODURO Suspensions SUSP 237 ...

Page 238: ...in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges with fork oil or sealing grease Fit the dust guard the snap 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 SUSP 238 ...

Page 239: ...ecific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in holes AP8140146 Weight Insert the snap ring in its position Fit the dust guard with the specific tool Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in holes AP8140146 Weight DORSODURO Suspensions SUSP 239 ...

Page 240: ...t under the stem in order to leave it compressed Pour part of the fork oil into the sleeve Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT FOR A CORRECT OIL LEVEL MEASUREMENT THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Specific tooling AP8140149 Protection...

Page 241: ...her with the spring centring Fit the special tool Specific tooling AP8140147 Spacer tool With the aid of a second operator hold the pumping member rod firmly lower the spacer retention tool insert the stop ring and the plate separating the spacer pumping member between the ring and the nut Specific tooling AP8140148 Spacer pumping element separat ing plate DORSODURO Suspensions SUSP 241 ...

Page 242: ... Insert the sleeve cap and screw the nut Tighten the sleeve cap Steering bearing Key 1 Folk lower plate 2 Screw Suspensions DORSODURO SUSP 242 ...

Page 243: ...le so that the front wheel is off the ground Shake the fork in the riding direction Adjust if clearance is detected Undo and remove the four screws of the fixing U bolt Remove the U bolt Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out Unscrew and remove the top bolt on the headstock and collect the washer DORSODURO Suspensions SUSP...

Page 244: ...strument panel support to the fork upper plate Slide off the fork upper plate by moving it towards the instrument panel Adjust the steering bearings preload ing by tightening the ring nut with the specific tool When refitting the U bolt position the two referen ces facing the front part of the vehicle Suspensions DORSODURO SUSP 244 ...

Page 245: ... 6 Anti vibration rubber buffer 7 Tubeless valve 8 Rear wheel spacer 9 Pin 10 Lower self locking nut M10 11 Sprocket carrier assembly 12 Anti vibration buffer spacer 13 Bearing 30x55x13 14 Seeger ring for hole 15 Sealing ring 30x52x7 16 Internal spacer 17 Seeger ring 18 10x20 Pin 19 Bearing DORSODURO Suspensions SUSP 245 ...

Page 246: ...h using belts To facilitate operations it is advisable to remove the chain protection by un doing the two screws Fully slacken the gearing chain ten sion Make the wheel move forward and re lease the gearing chain from the crown gear Unscrew and remove the nut on the wheel pin Collect the thrust washer and the right chain tensioner slider Suspensions DORSODURO SUSP 246 ...

Page 247: ...heel by freeing the disc from the brake calliper Collect the spacer from the rear wheel right side Working from the left side unscrew and remove the five nuts and remove the crown and the bolts Undo and remove the five screws and remove the anti vibration buffer holder Check the anti vibration buffers ac cording to the routine maintenance ta ble See also Adjusting DORSODURO Suspensions SUSP 247 ...

Page 248: ...S OF THE SAME TYPE Check the radial and axial clearance Axial clearance a minimum axial clearance is allowed Radial clearance none If one or both bearings do not fall within the control parameters Replace both wheel bearings REAR WHEEL 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 GAS...

Page 249: ...the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2 mm 0 0079 in Shock absorbers Removing Place the optional 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 Undo and remove the lower screw and collect the nut Remove the sho...

Page 250: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 251: ...g for hole 7 O ring 8 Sealing ring 9 Swing arm pin 10 Adjustment bushing 11 Swingarm pin internal bushing 12 Swingarm pin ring nut 13 Rear wheel bolt nut 14 Rear wheel pin washer 15 Left chain guide slider 16 Right chain guide slider 17 Chain tensioner set screw 18 Serpress Nut DORSODURO Chassis CHAS 251 ...

Page 252: ... Removing Remove the exhaust system Support the vehicle by means of the engine service stand and a hoist with belts fastened to the rear section of the frame Remove the rear wheel Slide off the rear calliper holding plate keeping it linked to the brake pipe CAUTION DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER REMOVING THE WHEEL OTHERWISE THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT RESULTING I...

Page 253: ...pecific box spanner un screw and remove the locking ring nut Working from the left side unscrew and remove the nut and collect the washer REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOW ERING AND TO KEEP IT UPRIGHT DORSODURO Chassis CHAS 253 ...

Page 254: ...ICATIONS To check clearance Shut off the engine Place the vehicle on the service stand Engage neutral gear Check that the vertical oscillation at a point between the pinion and the crown on the lower branch of the chain is ap prox 25 30 mm 0 98 1 18 in Move the vehicle forward so as to check vertical oscillation in other posi tions too clearance should remain constant at all wheel rotation phases ...

Page 255: ...he pinion and the crown do not show damaged rollers loosened pins dry rusty flattened or jammed chain links excessive wear missing sealing rings excessively worn or damaged pinion or crown teeth IF THE CHAIN ROLLERS ARE DAMAGED THE PINS ARE LOOSE AND OR THE O RINGS ARE MISSING OR DAMAGED THE WHOLE CHAIN UNIT PINION CROWN AND CHAIN SHOULD BE REPLACED LUBRICATE THE CHAIN ON A REGULAR BASIS PARTICULA...

Page 256: ...ntenance table and whenever necessary After washing and drying the chain lubricate it with spray grease for sealed chains Exhaust Key 1 Central exhaust manifold 2 Rear exhaust pipe 3 Front exhaust pipe 4 Serpress Nut 5 Exhaust gasket 6 Gasket 7 Left clamp 8 Silencer 9 Gasket 10 Silencer clamp 11 Lambda Probe 12 TE flanged screw 13 Spacer bushing 14 Rubber ring Chassis DORSODURO CHAS 256 ...

Page 257: ...er 21 TE flanged screw 22 T shaped bushing 23 TBEI screw 24 Washer 25 TCEI screw 26 Safety washer 27 Right clamp 28 Flange Removing the tail pipe Loosen the clamp between the ex haust end and the manifold Remove the saddle Undo and remove the two upper screws and collect the washers DORSODURO Chassis CHAS 257 ...

Page 258: ...ifold and the exhaust end clamps from the rear cyl inder Remove the manifold terminal coupling See also Removing the exhaust manifold Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut off Before handling these components make sure that you are wearing insulating gloves or w...

Page 259: ...xhaust manifold REAR Loosen the exhaust pipe between the manifold and the exhaust end Unscrew and remove the two nuts on the head exhaust stud bolts See also Removing the manifold tail pipe Removing the lambda sensor Remove the clamp Disconnect the lambda probe connec tor DORSODURO Chassis CHAS 259 ...

Page 260: ... Unscrew and remove the lambda probe Chassis DORSODURO CHAS 260 ...

Page 261: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 262: ...IONS OF THE SYSTEM Rear brake calliper Key 1 Brake pump with reservoir 2 Rear brake calliper 3 Rear brake lever 4 Rear brake lever pin 5 O ring 6 Washer 7 Brake lever foot 8 Linking pin 9 Spring 10 Brake fluid reservoir support 11 O ring 12 Nut 13 Fork 14 Clips for gear fork Braking system DORSODURO BRAK SYS 262 ...

Page 263: ...r pads torque 22 REAR BRAKE DISC 23 TE flanged screw 24 Cable guide 25 Flanged TBEI screw 26 Clamp Front brake calliper Key 1 Front left brake calliper 2 Front brake calliper 3 Front brake pads pair 4 Pin calliper spring 5 Bleeding Kit 6 TE flanged screw M10x1 25x55 DORSODURO Braking system BRAK SYS 263 ...

Page 264: ...ollect the anti vibration springs Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Rear brake pads Removal Remove the safety circlip Braking system DORSODURO BRAK SYS 264 ...

Page 265: ...s signalled by the sponginess of the brake control and poor braking efficiency CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY TO BOTH CALLIPERS THE VEHICLE MUST BE ON LE...

Page 266: ... OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleed valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and block the front brake oil reservoir cap Refit the rubber protection cover Rear If there is air in the hydraulic system it acts as a bearing absorbing a large part of the pressure from the brake pump and minimising calliper ...

Page 267: ... release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before the lever reaches its end of stroke Repeat the operation until the fluid draining into the container is air bubble free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE R...

Page 268: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS ...

Page 269: ...10x14x1 6 8 Clutch control cylinder 9 Bleeding Kit 10 TSPEI screw 11 TSPEI screw 12 Stop switch 13 Rubber ring CAUTION IF CLUTCH LEVER TRAVEL OR CLUTCH DISENGAGEMENT ARE IRREGULAR CHECK THE CLUTCH SYSTEM FOR AIR BUBBLES AND BLEED THE SYSTEM THROUGH VALVE 9 DORSODURO Clutch system CLU SYS 269 ...

Page 270: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 271: ... tank cap 6 Water pipe 7 Thermostat radiator pipe 8 Radiator pump pipe 9 Radiator filling pipe 10 Pipe 11 Valve motor pump pipe 12 Bleed pipe 13 TE flanged screw 14 T shaped bushing 15 Rubber ring 16 Thermostat valve unit 17 Pin 18 Spacer DORSODURO Cooling system COOL SYS 271 ...

Page 272: ...d self locking nut 30 Radiator support 31 Clic clamp 32 Clic clamp 33 From front cylinder 34 From rear cylinder 35 To rear cylinder Electric fan Remove the radiator Undo and remove the three screws and collect the washers remove the electric fan See also Removing the radiator Coolant replacement Remove the right side fairing Cooling system DORSODURO COOL SYS 272 ...

Page 273: ... and move the clamp Slide off the sleeve and empty the sys tem completely Refit both sleeves place the corresponding clamps and tighten their screws Fill the expansion tank up to the marked level After bleeding the air from the tank place the expansion tank cap Refit the front protection and tighten the screw Fit the right side fairing DORSODURO Cooling system COOL SYS 273 ...

Page 274: ...al insert Remove the rotor control gear From the cover inside to the outside remove the rotor control shaft with a punch and a rubber hammer REFITTING Upon refitting carry out the removal operations but in reverse order Refill the expansion tank so that the level is between the MAX and MIN marks Fill the system through the radiator cap Place the radiator cap on its seat to avoid accidental leaks b...

Page 275: ...e cooling system Undo and remove the screw Remove the filler Remove both clamps and slide off the corresponding pipes Disconnect the electric fan connector Undo and remove the screw remove the horn DORSODURO Cooling system COOL SYS 275 ...

Page 276: ...f toward the vehicle right hand side To install the radiator follow the operations explained above but in reverse order and re place all the clamps removed Restore the correct coolant level See also Coolant replacement Removing the expansion tank Remove the right side fairing Loosen and move the clamp Slide off the pipe Cooling system DORSODURO COOL SYS 276 ...

Page 277: ...ol lect the washer Slide off the expansion tank 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 Cooling system COOL SYS 277 ...

Page 278: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 279: ...t frame fixing screw and collect the nut Remove the instrument panel Working from the vehicle left side un screw and remove the pin and collect the nut and the washer from the right side Disconnect the front turn indicator ca ble harness DORSODURO Bodywork BODYW 279 ...

Page 280: ...remove the front headlight assembly See also Instrument cluster support Taillight assy Remove the license plate support Undo and remove the four screws Undo and remove the screw Undo and remove the three internal screws Bodywork DORSODURO BODYW 280 ...

Page 281: ...nect the rear headlight connec tors Remove the rear headlight See also Tail guard Footrest RIGHT FOOTREST Undo and remove the two external screws Remove the right footrest Undo and remove both rear brake pump internal fixing screws DORSODURO Bodywork BODYW 281 ...

Page 282: ...e the two external screws Loosen the gear shift lever rod screw Slide off the gear shift lever rod Remove the left footrest Side body panels Undo and remove the screw Unscrew and remove the rear screw Bodywork DORSODURO BODYW 282 ...

Page 283: ...er Remove the saddle Remove the tail section Undo and remove the three screws Disconnect the rear headlight connec tor Release the rear headlight cable har ness from the clamps Disconnect the saddle unlocking ca ble DORSODURO Bodywork BODYW 283 ...

Page 284: ...back See also Seat Tail guard Air box Remove the air filter Slide off the electrical components fas tened to the air filter casing Undo and remove the eight screws Undo and remove the inner screw Undo and remove the screw Bodywork DORSODURO BODYW 284 ...

Page 285: ...er support partition Release the cable harness from the clamps Undo and remove the two screws after loosening the front and rear manifold clamps Loosen the clamp to slide off the bleed pipe DORSODURO Bodywork BODYW 285 ...

Page 286: ...r re covery pipe Working on the left side disconnect the two control unit connectors CAUTION THE CONNECTORS ARE MARKED BY THE LETTERS V VEHICLE AND E ENGINE DO NOT INTERCHANGE THEM WHEN REFITTING Undo and remove the screw and re move the ground lead Disconnect the two connectors Bodywork DORSODURO BODYW 286 ...

Page 287: ...een 60 and 60 b rear cylinder throttle valve correction between 60 and 60 c potentiometer 1 front throttle valve value is 0 5 or above d potentiometer 1 rear throttle valve value is 0 5 or above e the difference of throttle valve correction values between the front and rear cylinders should not exceed 0 6 See also Air filter Fuel tank CAUTION DURING FUEL TANK LIFTING AND REPOSITIONING BE CAREFUL S...

Page 288: ...EMOVAL Lift the fuel tank Unscrew and remove the rear screw Disconnect the fuel pipe Disconnect the tank breather pipe from the Y branch Release the cable harness from the clamps Bodywork DORSODURO BODYW 288 ...

Page 289: ...Instrument cluster support Working on both sides loosen the nuts and screws and remove them Disconnect the connectors of arrow in dicators headlamps ignition key lock and relay Remove the three screws that fix the instrument panel DORSODURO Bodywork BODYW 289 ...

Page 290: ...rument panel from its support Disconnect the instrument panel con nector Remove the instrument panel Radiator cover Working from both sides undo and re move the screw Remove the radiator cover Bodywork DORSODURO BODYW 290 ...

Page 291: ...the saddle Remove the rear passenger grab han dle if present Working from both sides undo and re move the external screw Undo and remove the three screws Slide off the tail section backwards DORSODURO Bodywork BODYW 291 ...

Page 292: ...INDEX OF TOPICS ...

Page 293: ...PRE DELIVERY PRE DE ...

Page 294: ... parts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning...

Page 295: ...ASE OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORK...

Page 296: ...pection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMME...

Page 297: ...eft side chain protection Fit a left bracket and a left chain pro tection fasten then with a TEFL M8x35 mm screw at the top and with a TCEI M8x35 mm screw at the bottom NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE THE SPECIFIC WRENCH RH Remove the rubber cap DORSODURO Pre delivery PRE DE 297 ...

Page 298: ...racket fasten then with a TEFL M8x35 mm screw at the top and with a TCEI M8x35 mm screw at the bottom NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE THE SPECIFIC WRENCH Refit the shock absorber protection on the exhaust HAND GUARDS Pre delivery DORSODURO PRE DE 298 ...

Page 299: ...bration weight Fit the rubber ring in the hand guards Place the lower spacer on the rear view mirror hole Place the hand guards fastening them on the sides using TCEI M6 X 50 screw being careful when inserting the bush ing DORSODURO Pre delivery PRE DE 299 ...

Page 300: ...lace the upper spacer on the rear view mirror hole Fit the rear view mirror screwing the corresponding support column NOTE PERFORM THE SAME PROCEDURE FOR BOTH HAND GUARDS Pre delivery DORSODURO PRE DE 300 ...

Page 301: ...60 163 177 202 269 Clutch lever 121 Coolant 272 276 E Engine oil 39 119 F Fork 228 230 231 238 Fuel 217 287 Fuses 80 H Headlight 279 I Identification 11 Instrument panel M Maintenance 8 35 O Oil filter 41 R Recommended products 24 Ride by wire 218 S Shock absorbers 249 Spark plug 36 Spark plugs Stand 123 ...

Page 302: ...T Tank 276 287 Transmission 12 Tyres 14 W Warning lights ...

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APRILIA DORSODURO 2007, Service Station Manual

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