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APRILIA DORSODURO FACTORY ABS 2011, Service Station Manual

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APRILIA DORSODURO FACTORY ABS 2011 Service Station Manual Download Page 227

•

Measure the pin outside diameter (a)

and if not complying with specifica-

tions, replace the pin.

Pin outside diameter: 22.00 - 21.97 mm (0.8661

- 0.8650 in) Limit: 21.96 mm (0.8646 in)

•

Measure the pin housing diameter (b)

and replace the piston if not complying

with specifications.

Pin housing diameter (b): 22.010 - 22.015 mm

(0.8665 - 0.8667 in)

•

Calculate the clearance between pin

and pin hole and, if not complying with

specifications, replace both pin and

piston.

Pin - piston clearance: C = b - a

0.010 - 0.045 mm (0.0004 - 0.0018 in)

Limit: 0.060 mm (0.0024 in)

C

YLINDER

 - 

PISTON

 

COUPLING

Specification

Desc./Quantity

Piston - cylinder coupling Type A

Cylinder: 91.990 - 91.977 mm (3.6216 - 3.6219 in)

Piston: 91.933 - 91.940 mm (3.6217 - 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 (0.00197 - 0.00252 in)

Fitting the piston

An arrow stamped on the piston crown indicates the exhaust side.

•

When refitting the piston rings on the piston, the arrow stamped inside the piston must be

turned towards the operator.

DORSODURO FACTORY ABS

Engine

ENG - 227

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

email: [email protected]

Summary of Contents for DORSODURO FACTORY ABS 2011

Page 1: ...SERVICE STATION MANUAL 898998 DORSODURO FACTORY ABS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 3: ...all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle NOTE Provid...

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

Page 5: ...M ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS COOLING SYSTEM COOL SYS BODYWORK BODYW PRE DELIVERY PRE DE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

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

Page 8: ...IRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant contains ethylene glycol which under certain conditions can become flammab...

Page 9: ... gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATT...

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

Page 11: ...OMPROMISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Engine run in is essential to ensure engine long life and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your riding speed during the run in This ensures that components operate under both loaded and unloaded conditions allowing th...

Page 12: ...sion variation 0 free digit Y year of manufacture S production plant S Scorzè XXXXXX serial number 6 digits ENGINE NUMBER The engine number is printed on the base of the engine crankcase left hand side Engine No CHASSIS NUMBER The chassis number is stamped on the right hand side of the headstock Chassis No Dimensions and mass DIMENSIONS Specification Desc Quantity Max length 2210 mm 87 01 in Max w...

Page 13: ... 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 drive gear ratio 16 46 Capacities CAPACITY Specification Desc Quantity Fuel capacity reserve included 12...

Page 14: ...4 Front daylight running light 12V 6W H6 Turn indicator light 12V 10W Rear daylight running 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 Side stand down LED Fuel reserve LED ABS LED F...

Page 15: ... with four Ø 32 mm 1 26 in pistons and two calliper pads Rear 240 mm 9 45 in disc brake with 34 mm 1 34 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 PIRELLI CORSA III DUNLOP SPORTMAX QUALIFIER Front tyre 120 70 ZR17 Front tyre pressure...

Page 16: ...g Torques Chassis Front side COOLING SYSTEM pos Description Type Quantity Torque Notes 1 Fan fastener screw 3 3 Nm 2 21 lbf ft 2 Flanged TE screw fixing LH side ra diator to trellis frame and radiator bracket to engine M6x25 2 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix ...

Page 17: ... Screw Pumping member pin fixing to the stem base 2 30 Nm 22 13 lbf ft 3 Upper cover 2 20 Nm 14 75 lbf ft 4 Upper cover locking nut 2 20 Nm 14 75 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 18: ...bf ft Loctite 243 3 Stainless steel TCC screw fastening stanchions to upper and lower yokes M8x30 6 25 Nm 18 44 lbf ft 4 TCEI screw fastening lower clamp onto fork yoke M10x60 2 50 Nm 36 88 lbf ft INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 TCEI screw fastening instrument panel mounting to fork yoke M6x20 2 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 18 Manuals b...

Page 19: ...5x9 6 6 Nm 4 42 lbf ft Loct 243 2 TBEI screw fastening mudguard to stanchions M5x9 4 4 Nm 2 95 lbf ft 3 Screw fastening number panel to headlamp 4 1 Nm 0 74 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 19 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 20: ...otes 1 Clutch cylinder fastener M6 2 10 Nm 7 37 lbf ft 2 Union with breather and fixing pipe M10x1 1 1 25 Nm 18 44 lbf ft 3 Fastener for clutch pump on handle bar 2 10 Nm 7 37 lbf ft 4 Screw fastening clutch control mounting on flywheel side crankcase half M6 1 10 Nm 7 37 lbf ft 5 TBEI tank fixing screw M5x10 1 6 Nm 4 42 lbf ft 6 TBEI plate fixing screw M6x12 1 10 Nm 7 37 lbf ft Characteristics DO...

Page 21: ...10 Nm 7 37 lbf ft 3 TBEI screw fastening the brake tank to the plate M6x20 1 10 Nm 7 37 lbf ft 4 Plate fixing screw M6x12 1 10 Nm 7 37 lbf ft 5 Screw fastening the brake pipe to steering base M6x25 1 10 Nm 7 37 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 21 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 22: ... base M6x16 2 10 Nm 7 37 lbf ft 2 Fastener for front turn indicators M5 2 3 Nm 2 21 lbf ft 3 TCEI screw fastening headlamp mounting to fork yoke M6 3 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 22 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 23: ...ning ignition block cover to spacer M5x9 3 4 Nm 2 95 lbf ft Front tank fastener spacer M6 2 10 Nm 7 37 lbf ft FRONT WHEEL pos Description Type Quantity Torque Notes 1 Wheel axle nut 1 80 Nm 59 lbf ft 2 Flanged TE screw fastening front disc M8x20 12 30 Nm 22 13 lbf ft Loctite 243 DORSODURO FACTORY ABS Characteristics CHAR 23 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycl...

Page 24: ...m 18 44 lbf ft 2 TEFL screw Fixing calliper to fork stems M10x1 25 4 50 Nm 36 88 lbf ft Fastener for brake pipe on steering base M6x25 1 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 24 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ...m 59 lbf ft 3 Screw fastening chain roller bracket to LH plate M8x35 1 25 Nm 18 44 lbf ft Loctite 243 4 Screw fastening chain roller to chain roller bracket M8x45 1 25 Nm 18 44 lbf ft Loctite 243 5 Screw fastening chain roller bracket to LH plate M8x20 1 25 Nm 18 44 lbf ft Loctite 243 DORSODURO FACTORY ABS Characteristics CHAR 25 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mot...

Page 26: ... fit on RH side panel M4x10 2 3 Nm 2 3 lbf ft 3 SWP self tapping screw fastening demand sensor mounting to demand sensor M5x14 4 2 6 Nm 1 92 lbf ft 4 Flanged TE screw fastening demand sensor to frame M6x20 3 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 26 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 27: ... TCEI screw fastening passen ger footrests to rider footrest mount ing M8x35 2 25 Nm 18 44 lbf ft 3 TCEI screw fastening rider footrest mounting to frame M8x35 4 28 Nm 20 65 lbf ft Loctite 243 DORSODURO FACTORY ABS Characteristics CHAR 27 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 28: ...bf ft 4 TCEI screw fastening stand switch M5x16 2 7 Nm 5 16 lbf ft FUEL TANK pos Description Type Quantity Torque Notes 1 TCEI screw fastening filler cap flange M5x16 5 3 Nm 2 21 lbf ft 2 Rear TE screw fastening tank M6x90 1 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 28 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 29: ...t AIR FILTER BOX pos Description Type Quantity Torque Notes 1 Cross head self tapping screw fas tening separator filter box M5x20 10 3 Nm 2 21 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 29 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 30: ...0 Nm 7 37 lbf ft 3 LH locknut for ball joint M6 1 10 Nm 7 37 lbf ft 4 RH locknut for ball joint M6 1 10 Nm 7 37 lbf ft 5 Screw fastening engine bracket clutch side crankcase half M6 2 12 Nm 8 85 lbf ft 6 Map sensor union brass 2 2 Nm 1 48 lbf ft Loctite 243 6 Map sensor union steel 2 3 50 Nm 2 58 lbf ft Loctite 243 7 LH ball joint on gearbox control lever 1 10 Nm 7 37 lbf ft Loctite 243 8 RH ball ...

Page 31: ...Coil fixing screw M6 2 13 Nm 9 59 lbf ft 2 TE screw fastening regulator to frame M6x30 2 10 Nm 7 37 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 31 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 32: ...s Description Type Quantity Torque Notes 1 TCEI screw M8x40 1 25 Nm 18 44 lbf ft 2 Switch fastener shear head screw 1 Manual 3 TE screw fastening saddle lock bat tery compartment to saddle mount ing M6x25 2 10 Nm 7 37 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 32 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 33: ... screw M5 2 3 50 Nm 2 58 lbf ft Loctite 242 3 Injector fastener screw M6 2 12 Nm 8 85 lbf ft Loctite 242 4 Injection Throttle Body fastener screw M6 8 12 Nm 8 85 lbf ft Loctite 242 Back side DORSODURO FACTORY ABS Characteristics CHAR 33 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 34: ...t 1 60 Nm 44 25 lbf ft 3 Swingarm pin nut 1 90 Nm 66 38 lbf ft 4 TPSI screw fastening rear stand bushing M6x40 2 10 Nm 7 37 lbf ft 5 TBEI screw fastening chain guard to swingarm M5x9 1 6 Nm 4 42 lbf ft 6 TBEI screw fastening rear mudguard to swingarm M5x9 2 6 Nm 4 42 lbf ft Loctite 243 7 TBEI screw fastening chain guard to rear mudguard M5x9 1 4 Nm 2 95 lbf ft 8 TBEI screw fastening chain guide to...

Page 35: ...r TCEI mounting screw M10x50 1 50 Nm 36 88 lbf ft 2 Lower TCEI mounting screw M10x90 1 50 Nm 36 88 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 35 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 36: ... to saddle mounting M8x20 2 25 Nm 18 44 lbf ft 5 Self tapping TE screw fastening front silencer fixture to silencer mounting bracket M8x35 2 35 Nm 25 81 lbf ft REAR WHEEL pos Description Type Quantity Torque Notes 1 Lower self locking nut fastening sprocket to sprocket carrier M10 5 50 Nm 36 88 lbf ft 2 TCEI screw fastening flexible cou pling mounting on wheel M10x30 5 50 Nm 36 88 lbf ft Loctite 2...

Page 37: ...12 4 6 Nm 4 42 lbf ft 4 Flanged self locking nut M6 1 10 Nm 7 37 lbf ft 5 Screw nut fastening pedal to brake lever M6 1 1 10 Nm 7 37 lbf ft 6 Brake pipe union M10x1 2 25 Nm 18 44 lbf ft 1 Flanged TE screw fastening rear disc M8x20 5 30 Nm 22 13 lbf ft Loctite 243 Flanged TE screw M6x16 1 10 Nm 7 37 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 37 Manuals by Motomatrix www motomatrix co uk The ...

Page 38: ...m 7 37 lbf ft 2 Fastener for rear turn indicators M6 2 3 Nm 2 21 lbf ft 3 Reflector fastener M5 2 2 Nm 1 47 lbf ft 4 Fastener for license plate light M5 1 5 Nm 3 69 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 38 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 39: ... 2 pos Description Type Quantity Torque Notes 1 TBEI screw fastening LH RH covers to silencer M6x20 4 10 Nm 7 37 lbf ft 2 TBEI screw fastening tail fairing to saddle mounting M5x9 2 6 Nm 4 42 lbf ft 3 Screw fastening tail fairing to battery compartment 3 4 Nm 2 95 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 39 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded ...

Page 40: ...er for license plate mounting frame assembly to gusset plate saddle lock M6 4 10 Nm 7 37 lbf ft 3 Screw fastening license plate mount ing cover to license plate mounting 3 0 8 Nm 0 59 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 40 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 41: ...U fastener nut M6 2 10 Nm 7 37 lbf ft Engine HEAD COVER pos Description Type Quantity Torque Notes 1 Special screw for fastening head cover M6 8 9 Nm 6 64 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 41 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 42: ...before tight ening 4 Fastener for Head Cylinder Outer side crankcase M6 2 13 Nm 9 59 lbf ft 5 Fastener for Head Cylinder Inner side crankcase M6 4 12 Nm 8 85 lbf ft 4 Nut fastening Stud Bolts Head M6 4 12 Nm 8 85 lbf ft 7 Nut fastening Stud Bolts Head M8 2 26 Nm 19 18 lbf ft 8 Bleed union fastener screw M5 4 6 5 Nm 4 79 lbf ft 9 Water bleed union steel 1 3 50 Nm 2 58 lbf ft Loctite 243 10 Water bl...

Page 43: ...3 Nm 9 59 lbf ft 2 Cylinder plate fastener screw M6 4 13 Nm 9 59 lbf ft 3 Chain tensioner adjustment screw M6 2 5 50 Nm 4 06 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 43 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 44: ...en ing M15x1 4 90 Nm 66 38 lbf ft 2 Timing drive gear fastener screw M24x1 5 2 40 Nm 29 50 lbf ft 3M SCOTCH GRIP 2353 3 Special screw for fastening mobile fixed shoes M8 4 19 Nm 14 01 lbf ft Loctite 242 Characteristics DORSODURO FACTORY ABS CHAR 44 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 45: ...bf ft Loctite 270 CRANKSHAFT pos Description Type Quantity Torque Notes 1 Crankshaft primary gear fastener nut M24x1 5 1 270 Nm 199 14 lbf ft Anticlockwise nut 2 Connecting rod screw M10 4 15 30 Nm 11 06 22 13 lbf ft 50 2 final control torque 65 78 Nm 47 94 57 53 lbf ft Lubricate the threads before tight ening DORSODURO FACTORY ABS Characteristics CHAR 45 Manuals by Motomatrix www motomatrix co uk...

Page 46: ...14 Nm 10 33 lbf ft 5 Oil pressure regulator valve 3 4 Unf 16 1 43 Nm 31 72 lbf ft 6 Oil pump fastener screw M6 2 5 50 Nm 4 06 lbf ft Loctite 242 7 Rose pipe fastener screw 2 12 Nm 8 85 lbf ft 8 Complete oil pump gear fastener 1 9 11 Nm 6 64 8 11 lbf ft 9 Oil pump cover fastener screw M3 2 0 80 Nm 0 59 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 46 Manuals by Motomatrix www motomatrix co uk T...

Page 47: ...sprocket M8 1 23 Nm 16 96 lbf ft 4 Gear sensor fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 243 5 Selector pin fastener onto clutch side crankcase half M10x1 5 1 16 Nm 11 80 lbf ft 6 Tightening tone wheel on secondary gearbox M16x1 1 43 Nm 31 72 lbf ft Loctite 270 DORSODURO FACTORY ABS Characteristics CHAR 47 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys...

Page 48: ...Nm 1 48 lbf ft 4 Screw fastening fixing Plate Clutch control Mounting M5 3 5 50 Nm 4 06 lbf ft 5 Screw fastening clutch control mounting on flywheel side crankcase half M6 2 13 Nm 9 59 lbf ft 6 Clutch Cover Clutch side Cover TCEI fixing screw inox protection M6x55 2 10 Nm 7 38 lbf ft Characteristics DORSODURO FACTORY ABS CHAR 48 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 49: ... Nm 8 85 lbf ft WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 13 13 Nm 9 59 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 49 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 50: ...fastening Rotor Crankshaft M12x1 25 1 120 Nm 88 51 lbf ft 4 Screw fastening Stator Flywheel Cover M6 3 9 Nm 6 64 lbf ft 5 Screw fastening pick up Flywheel cover M5 2 3 50 Nm 2 58 lbf ft 6 Flywheel cover fastener screw M6 10 13 Nm 9 59 lbf ft 7 Screw fastening starter motor brack et to crankcase M6 2 13 Nm 9 59 lbf ft 8 Crankshaft access cap 1 4 Nm 2 95 lbf ft 9 Retainer plate fastener screw M6 1 8...

Page 51: ...M5 2 5 50 Nm 4 06 lbf ft Loctite 242 3 Tapered plug for crankshaft main bearing lubrication M8x1 4 15 Nm 11 06 lbf ft 4 Calibrated Brass dowel fixed to com plete crankcase M8 2 5 50 Nm 4 06 lbf ft DORSODURO FACTORY ABS Characteristics CHAR 51 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 52: ... ring is available CYLINDER PISTON COUPLING Specification Desc Quantity Piston cylinder coupling Type A Cylinder 91 990 91 977 mm 3 6216 3 6219 in Piston 91 933 91 940 mm 3 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 ...

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

Page 54: ...ass 2 Class 4 main journal l v Semi bushing type A red Semi bushing type B blue Class 5 main journal l v Semi bushing type B blue Semi bushing type C yellow Class 6 main journal l v Semi bushing type E green Semi bushing type A red Class 7 main journal l f Semi bushing type A red Semi bushing type B blue Class 8 main journal l f Semi bushing type B blue Semi bushing type C yellow Class 9 main jour...

Page 55: ...mechanism area NOTE IN THE EVENT OF CRANKCASE REPLACEMENT THE PRI MARY REDUCTION GEAR IS SUPPLIED READY MESHED CRANKCASE CLASSES 02 Specification Desc Quantity Crankcase class A Centre to centre distance 110 50 110 54 mm 4 3504 4 3519 in Crankcase class B Centre to centre distance 110 46 110 50 mm 4 3488 4 3504 in Class one Two different pinion classes A or B are available selected in relation to ...

Page 56: ...of the crank pin BUSHINGS Crank pin diameter Connecting rod class 1 Crankshaft class 0 Semi bushing type E green Crankshaft class 1 Semi bushing type A red Crankshaft class 2 Semi bushing type B blue Crankshaft class 3 Semi bushing type C yellow Selecting connecting rods Not all weight classes are available as spare parts Only the two most significant weight classes are available refer to the foll...

Page 57: ...rod CAUTION THE CONNECTING RODS INSTALLED ON THE SAME ENGINE MUST BE OF THE SAME COLOUR AND MUST USE THE SAME TYPE OF ASSEMBLY WITH THE CRANKSHAFT WHEN REFITTING ALSO ENSURE THAT THE SEMI BUSHINGS ARE ALL OF THE SAME CLASS See also Removing the flywheel cover Recommended products chart RECOMMENDED PRODUCTS Product Description Specifications AGIP TEC 4T SAE 15W 50 Engine oil Use top brand oils that...

Page 58: ...odegradable coolant with long life technology and characteristics red Freezing protection up to 40 40 F Compliant with CUNA 956 16 stand ard Characteristics DORSODURO FACTORY ABS CHAR 58 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 60: ...40187 Engine support stand 020711Y Engine pinion locking 020712Y Handle for Flywheel cover removal 020713Y Flywheel extractor Special tools DORSODURO FACTORY ABS S TOOLS 60 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 61: ...tch housing locking tool 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool AP8140302 tool for sealing ring fitting DORSODURO FACTORY ABS Special tools S TOOLS 61 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 62: ...iming tool AP8140179 Valve spring compressor 020721Y Adaptor for valve removal 020722Y Guide for oil seal 020376Y Adapter handle Special tools DORSODURO FACTORY ABS S TOOLS 62 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 63: ...439Y 17 mm guide for oil seal 020263Y Sheath for fitting the driven pulley 020365Y 22 mm 0 87 in guide 020364Y 25 mm Guide DORSODURO FACTORY ABS Special tools S TOOLS 63 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 64: ...020358Y 37 x 40 mm adaptor 020357Y 32 x 35 mm adaptor 020359Y 42 x 47 mm adaptor 020360Y 52 x 55 mm adaptor Special tools DORSODURO FACTORY ABS S TOOLS 64 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 65: ... overall seal replacement kit 020725Y Punch for water pump overall sealing 020885Y Water pump oil seal punch 020726Y Extractor for bushings 020727Y Punch for bushings DORSODURO FACTORY ABS Special tools S TOOLS 65 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 66: ...P8140199 Tool panel 8202222 Generic adhesive film for panel 8140426 Hooks for panel 020880Y Panel graphics AP8140149 Protection for fitting operations Special tools DORSODURO FACTORY ABS S TOOLS 66 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 67: ...g member ring nut locking span ner 020888Y Pliers for pre fill pipe 020884Y 46 mm wrench for steering ring nut 020890Y Pumping member stanchion support rod DORSODURO FACTORY ABS Special tools S TOOLS 67 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 68: ...INDEX OF TOPICS MAINTENANCE MAIN Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 69: ...ICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE 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 Check each time the rear tyre is changed ROUTINE MAINTENANCE TABLE km x 1 000 1 5 10...

Page 70: ...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 reach the spark plugs CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE FRONT SPARK PLUG Working on the left s...

Page 71: ...diator forwards and lower it to act on the coil Undo and remove the screw Slide off the front coil DORSODURO FACTORY ABS Maintenance MAIN 71 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 72: ...the rear coil Unscrew and slide off the rear spark plug Check the gap between the electrodes with a feeler feeler gauge CAUTION DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP Maintenance DORSODURO FACTORY ABS MAIN 72 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 73: ...CE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM IF YOU CHECK LEVEL WHEN THE 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 D...

Page 74: ... 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 oil into the container allow several minutes for oil to drain out c...

Page 75: ...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 FACTORY ABS Maintenance MAIN 75 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info...

Page 76: ...THER OBJECT HAS BEEN LEFT INSIDE THE FILTER BOX MAKE SURE THE FILTERING ELEMENT IS CORRECTLY PLACED SO THAT UNFILTERED AIR DOES NOT FLOW IN DO NOT FORGET THAT EARLY WEAR OF THE PISTON RINGS AND THE CYLINDER CAN BE CAUSED BY A MALFUNCTIONING OR MISPLACED FIL TERING ELEMENT REFITTING Upon refitting pay attention when inserting intake ducts and check that the bayonet joint is released once every duct...

Page 77: ...sing the cor responding timing pins Specific tooling 020719Y Timing pin Characteristic Intake valve clearance 0 11 0 18 mm 0 0043 0 0071 in Exhaust 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 THE ENGINE SPINS MAKING TIMING NECESSARY Remove the bowl tappets...

Page 78: ...1 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 THREEBOND on the head cover perimeter along the gasket housing Ma...

Page 79: ...d in the areas indicated in the figure See also Removing the head cover DORSODURO FACTORY ABS Maintenance MAIN 79 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 80: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 81: ... INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 7 READ THE ACTIVATION PROCEDURE FOR A NEW CONTROL UNIT ON THE ELEC TR...

Page 82: ...REEN 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 WITH ENGINE AT IDLE OR A 0 5 CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT CYLINDER MUST NOT BE 0 4 YES go to 16 NO note D 16 CHECK ENGINE SPE...

Page 83: ...NS OF NAVIGATOR 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 MAIN INJECTOR RELAY POLARISED TO THE BATTERY POSITIVE 6 WITH THE KEY TURNE...

Page 84: ... 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 to 26 23 RESTORE THE CABLE HARNESS END 24 CHECK IF THE PUMP RESIS...

Page 85: ... 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 SPEED SENSOR FOLLOW THE TROUBLESHOOTING STEPS IN THE SEC TION REFERRING TO NAVIGATOR ELECTRICAL ERRORS CAUTION failure NOT identif...

Page 86: ...SING 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 THE REAR RED CABLE WITH PROTECTION COVER OF THE START UP RELAY 36 ...

Page 87: ... 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 NAVIGATOR 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 SENSOR INDICATION ON NAVIGATOR ALWAYS TIP OVER END 70 SET THE...

Page 88: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 89: ...l fixing screw M6 2 13 Nm 9 59 lbf ft 2 TE screw fastening regulator to frame M6x30 2 10 Nm 7 37 lbf ft DORSODURO FACTORY ABS Electrical system ELE SYS 89 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 90: ...U to filter box base 4 2 5 Nm 1 47 lbf ft Starter relay fastener 2 3 4 2 Nm 2 21 3 1 lbf ft Components arrangement Key Electrical system DORSODURO FACTORY ABS ELE SYS 90 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 91: ...HE FOLLOWING INDICATIONS THIS SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the wiring diagram 7 Location on the vehicle under the fuel tank right side first relay starting from the rear side START UP RELAY Location on the wiring diagram 34 Location on the vehicle under the fuel tank left side seco...

Page 92: ...ERY LOGIC RELAY URGENT SERVICE Location on the wiring diagram 65 Location on the vehicle behind the instrument panel Electrical system installation INTRODUCTION 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 corres...

Page 93: ...linder coil and rear cylinder coil connectors 7 Filter Housing 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 BE...

Page 94: ...a rubber retainer TABLE C FRONT ABS SENSOR FASTENER 1 Cable grommets 2 Front ABS sensor Leave the cable loosen so that it makes a slight curve and the cable grommet must be turned towards the outside of the fork Electrical system DORSODURO FACTORY ABS ELE SYS 94 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 95: ...NERS 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 DORSODURO FACTORY ABS Electrical system ELE SYS 95 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 96: ...ction cap reinsert it observing the correct poles 1 Side stand switch 2 Neutral switch 3 Horn 4 Control unit connectors TABLE D The generator output cable must be laid behind the thermostatic valve under the airbox Electrical system DORSODURO FACTORY ABS ELE SYS 96 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 97: ...x7 08 Clamps TABLE G Plastic cable guide holding the auxiliary fuses branch and the cylinder coil cable 1 horizontal DORSODURO FACTORY ABS Electrical system ELE SYS 97 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 98: ...s relay 6 Auxiliary injection relay 7 Control relay 8 Logic relay TABLE J 4 5x290 0 18x11 42 Clamp TABLE K Plastic cable guide that holds the lambda probe branch the rear stop switch branch and the rear wheel speed sensor Electrical system DORSODURO FACTORY ABS ELE SYS 98 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 99: ...key switch connectors 11 Demand 1 Master Connector TABLE M The clamp holds the cables going out from the light switches and the immobilizer aerial cable going out from the key switch 4 5x180 0 18x7 08 Clamp TABLE N 2 5x160 0 10x6 30 Clamp TABLE O 12 Cable grommet 13 2 5x98 0 10x3 86 Clamps 14 4 5x290 0 18x11 42 Clamps DORSODURO FACTORY ABS Electrical system ELE SYS 99 Manuals by Motomatrix www mot...

Page 100: ...ness and the engine battery ground connec tion cable harness TABLE Q Rubber clamp TABLE R Metallic cable guide Electrical system DORSODURO FACTORY ABS ELE SYS 100 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 101: ... 2 4 5x180 0 18x7 08 Clamps TABLE V LAMBDA PROBE Place the cable harness of the lambda probe in the cable grommet on the clutch crankcase 20 Fasten the cable harness to the chassis with the clamp 21 Place the cable harness of the lambda probe behind the cable grommet on the clutch crankcase DORSODURO FACTORY ABS Electrical system ELE SYS 101 Manuals by Motomatrix www motomatrix co uk The Solution ...

Page 102: ...dary lock closing TABLE ZA ZB Tables with tips on filter box cable harness fitting Electrical system DORSODURO FACTORY ABS ELE SYS 102 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 103: ...p 26 2 5x160 0 10x6 30 Clamp ZD engine battery ground connection cable path TABLE ZE Procedure for the correct insertion of the ABS control unit connector The initial position of the lever that couples the connector must be as shown in figures 1 and 2 DORSODURO FACTORY ABS Electrical system ELE SYS 103 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 104: ...l position of the connector and the driving lever is not as shown in figure ZE the connector will not get properly coupled and the distance measured will be longer 12 mm approx 0 47 in In this case repeat the operation as described in the ZF ZG picture It is advisable to create a jig in order to check the correct connector insertion Electrical system DORSODURO FACTORY ABS ELE SYS 104 Manuals by Mo...

Page 105: ... UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A Taillight cable harness fitting 1 2 5x98 0 10x3 86 Clamp 2 4 5x180 0 18x7 08 Clamp TABLE B Rear wheel speed sensor fitting 3 Clamps 4 Cable grommets DORSODURO FACTORY ABS Electrical system ELE SYS 105 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcyc...

Page 106: ...LTIPLE CONNECTORS 2 FRONT RIGHT TURN INDICATOR 3 COMPLETE HEADLAMP Electrical system DORSODURO FACTORY ABS ELE SYS 106 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 107: ...21 LICENSE PLATE LIGHT BULB 22 23 COMPLETE TAILLIGHT WITH LED 24 REAR STOP SWITCH 25 FRONT STOP SWITCH 26 SPEED SENSOR 27 Fall sensor 28 NEUTRAL SENSOR 29 TIMING SENSOR OPTIONAL 30 Secondary fuses 31 Flywheel 32 Voltage regulator 33 STARTER MOTOR 34 START UP RELAY 35 MAIN FUSE 36 BATTERY 37 START UP MAINTENANCE RELAY 38 CONTROL RELAY START UP LOGIC 39 MAIN INJECTION RELAY POLARISED 40 AUXILIARY IN...

Page 108: ...57 EFG 1X THROTTLE CONTROL UNIT 58 REAR CYLINDER THROTTLE 59 FRONT CYLINDER THROTTLE 60 DEMAND CONTROL UNIT 61 PICK UP 62 ECU 63 64 LOW HIGH BEAM PASSING LIGHT RELAY WITH N C MATTING 65 RECOVERY LOGIC RELAY URGENT SERVICE 66 PROTECTION RESISTANCES 67 ABS CONTROL UNIT 68 FRONT ABS SENSOR 69 REAR ABS SENSOR 70 ABS CONTROL UNIT FUSE Colour key Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M ...

Page 109: ...n the connector no rust marks or dirt should be present and it is important to check terminal correct positioning on the connector i e all terminals aligned at the same depth and 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 connecto...

Page 110: ... THE CIR CUIT VOLTAGE check Check goal this control is to check if a cable is energised i e if it receives power supply from the battery or the control unit Tester set the tester on the direct current symbol and place the tester red probe on the cable being inspected and the black probe on the vehicle ground connection or on the battery terminal CAUTION IN CASE OF TEMPORAL MALFUNCTIONING CARRY OUT...

Page 111: ...rrors stored in its memory INSTRUMENT PANEL ERRORS In this mode a chart is displayed showing potential errors in the 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 fault key code read but not recognised DSB 02 Immobilizer fault key code not read key...

Page 112: ...t panel errors a further confirmation is requested Use Navigator to reset ECU errors VEHICLE SERVICING RESET This function is used to reset vehicle servicing Using this function the odometer can be reset only once within the first 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 sho...

Page 113: ...tion the odometer can be reset only once within the first 200 km 124 mi of the vehicle provided this has not been done by the Quality Check In order to activate this function follow the instructions in the DIAGNOSIS 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 ...

Page 114: ...d to EFG 1x control unit and to instrument panel Instrument panel diagnosis 10 A D Instrument battery positive 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 positiv...

Page 115: ... up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal Example value yes no Indicates whether the control unit has received 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 u...

Page 116: ...et P0608 Error cause As the level 2 safety system comparison between requested torque and calculated torque has detected a fault the control unit has reset engine C gravity Troubleshooting Continue fault search for the other errors detected Safety Engine Stop P0609 Error cause As the level 3 safety system control EEPROM has detected a fault the control unit has shut off the engine D gravity Troubl...

Page 117: ...tus for Throttle self learning is carried out and the status for Handle self learning is not carried out this last status entails Urgent service being displayed on the instrument panel If Throttle Self learning shows Not carried out go to stage 1 If it shows Carried out go to stage 2 Stage 1 current errors have probably been detected by the control unit solve these malfunctions and check the Throt...

Page 118: ...unction Electrical fault in sensor or cable harness Troubleshooting Check the sensor connector and the ABS control unit connector If they are not OK restore the connectors If they are OK check continuity of the white brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor o...

Page 119: ...xed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5D94 no acceleration after pressure reduction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK ...

Page 120: ...nd PIN 11 of the ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor on the cable harness side with the sensor disconnected and key set to ON must have 12V voltage approximately if there is no voltage check PIN 2 for continuity with the vehicle ground connection if it is grounded restore the cable harness If OK replace the control unit If PIN 2 has app...

Page 121: ... tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5DA5 excessive measured speed Faulty sensor or tone wheel or tone wheel with wrong nu...

Page 122: ...refers to the engine revs signal in case the signal has not been correctly identified yet the under analysis or standby statuses may be displayed NAVIGATOR ACTIVATION NAVIGATOR ELECTRICAL ERRORS CAUTION IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT CIRCUITED OR NO ERROR IS DIS PLAYED CHECK THE ENGINE SPEED SENSOR CONNECTOR AND THE MARELLI CONTROL UNIT CONNECTOR IF NOT OK RESTORE IF OK CHECK THE ...

Page 123: ...nd checked The 4 potentiometers are tinned and magnetically controlled contactless they cannot be overhauled nor replaced Level in electrical circuit diagram Throttle grip position sensor Location on the vehicle under the fuel tank connector direct to the Marelli control unit Electrical characteristics Not detected by a multimeter as they are contactless read voltage on the 4 tracks through Naviga...

Page 124: ...mV Voltage corresponding to the potentiometer track A Throttle grip opening percentage 0 With a released throttle grip the value read should be 0 whereas 100 should be read with throttle grip fully twisted NAVIGATOR STATUSES Throttle grip Example value Slightly twisted_choked_fully twisted Handle self learning Example value carried out not carried out NAVIGATOR PARAMETER ADJUSTMENT Handle self lea...

Page 125: ...the wiring Left side Throttle Grip Position sensor track B P0151 short circuit to positive open circuit short circuit to negative Error cause Voltage that is excessive equal to zero has been detected at PIN 40 of the VEHICLE connector Troubleshooting short circuit to positive check the value shown by the parameter of the left Throttle Grip position Sensor track B disconnect the left connector and ...

Page 126: ...re is continuity replace the control unit if not restore the wiring Right side Throttle Grip Position sensor track D P0153 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 44 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 44 of the ENGINE...

Page 127: ... left Throttle Grip Position Sensor tracks C and D 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 of Ohm if this is not the case restore w...

Page 128: ...ensors one per cylinder are fundamental not only for the injection configuration at low and stabilised speeds but also for checking the Ride by wire system their signal is connected to a TORQUE CHAIN for checking the correct opening of the throttle valves Operation Operating principle Diaphragm sensor which translates the diaphragm position into electrical voltage when in contact with the intake a...

Page 129: ... the circuit is open shorted to negative voltage equal to zero has been detected at PIN 34 of the VEHICLE connector Troubleshooting If short circuit to positive see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx 1200 mbar disconnect the large connector from the filter box if the value does not vary it means that the cable is shorted between the fi...

Page 130: ... disconnect the large connector from the filter box if the value does not vary it means that the cable is short circuited between the filter box connector and the control unit connector restore the cable harness If the value varies reconnect the filter box connector and disconnect the sensor connector if the value does not vary it means that the cable is short circuited between the filter box conn...

Page 131: ...the Marelli control unit connector and the sensor con nector if not OK restore If everything is OK check that resistance between VEHICLE connector PIN 5 and sensor connector PIN 3 is a few tenths of an Ohm If it is above that value restore cable harness Replace the sensor if it is correct Error for unexpected intake air in the front cylinder manifold P0210 signal not valid Error cause A small diff...

Page 132: ... estimated pressure and the measured pressure has been detected for example the pipe between sensor and throttle body is fully detached clogged or squashed Troubleshooting Check the pneumatic system between the pressure sensor 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 there is an evident defect i...

Page 133: ...variable with temperature Level in electrical circuit diagram Temperature sensors Location on the vehicle on the front cylinder on the internal side facing the rear cylinder connector on the sensor Electrical characteristics Resistance at 25 2 05 kOhm 100 Ohm Resistance at 60 575 Ohm 15 Ohm Resistance at 90 230 Ohm 5 Ohm Pin out 1 Yellow brown 0 5 V signal PIN B1 2 Brown PIN B2 ground connection C...

Page 134: ...necessary to restore the cable harness between the EN GINE PIN 45 and the sensor PIN 1 if there is no continuity with the ground connection check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If OK check continuity between the ENGINE connector PIN 35 and the sen sor connector PIN 2 restore the cable harness if there is not continuity If there is it...

Page 135: ...ensor near the probes Electrical characteristics Resistance at 0 32 5 kΩ 5 Resistance at 25 10 0 kΩ 5 Pin out 1 0 5 V signal PIN 1 2 Ground connection PIN 2 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Air temperature...

Page 136: ... continuity between the ENGINE connector PIN 35 and the sensor connector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If shorted to negative check sensor correct resistance if resistance 0 replace the sensor if resistance is correct it means that the cable has ground conn...

Page 137: ...NESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Lambda probe example value 0 1000 mV If there is a short c...

Page 138: ...d the heating circuit is closed to ground 5 times pin 3 of the lambda probe connector The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation NAVIGATOR ELECTRICAL ERRORS Lambda probe P0130 Shorted to positive Error cause Excessive voltage battery voltage has been detected at PIN 43 of the ENGINE connector Caution the lambda ...

Page 139: ... ENGINE PIN 32 and restore the cable harness NAVIGATOR LOGIC ERRORS Lambda probe P0134 voltage without variation Error cause An abnormal behaviour of the voltage at PIN 43 of the ENGINE connector has been detec ted the voltage that should vary over time keeps a constant value instead Troubleshooting Check circuit continuity from probe connector PIN 1 and PIN 2 toward the probe replace the lambda p...

Page 140: ...from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the grey green cable of the injector is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are dis played...

Page 141: ...control unit if there is no voltage reconnect the connector and disconnect the injector connector and check if there is a ground connec tion on PIN if there is voltage restore the filter box cable harness If there is no voltage replace the injector the circuit is open check the component correct electrical characteristic if it is not correct replace the component if it is correct check the filter ...

Page 142: ...rect replace the component if it is correct check the filter box small connector the connector on the component and the Marelli control unit connector If not OK restore If OK check cable continuity between the ENGINE PIN 34 and component PIN and restore the cable harness Coil COIL Function Spark generation Operation Operating principle Inductive discharge system Level in electrical circuit diagram...

Page 143: ...ck of activation Rear coil The auxiliary injection relay No 40 in the wiring diagram placed under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the sky blue green 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 ...

Page 144: ...ith Navigator and check voltage at connector PIN 3 if there is voltage restore the cable har ness if voltage 0 replace the coil If the circuit is open shorted to negative check the coil connector and the Marelli control unit connector If not OK restore if everything is OK check cable continuity between the two cable terminals If there is no continuity restore the cable harness if there is cable co...

Page 145: ...value in the example refers to engine conditions with key set to ON Front throttle Potentiometer 2 voltage Example value 3878 mV The value in the example refers to engine conditions with key set to ON Rear throttle Potentiometer 1 voltage Example value 780 mV The value in the example refers to engine conditions with key set to ON Rear throttle Potentiometer 2 voltage Example value 3756 mV The valu...

Page 146: ...ort circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN A6 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN A6 of the throttle control unit Troubleshooting shorted to positive check the value shown by the parameter of the front throttle Potentiom eter 1 voltage disconnect the left co...

Page 147: ... to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN B6 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN B6 of the throttle control unit Troubleshooting shorted to positive check the value shown by the parameter of the Rear throttle Potenti ometer 1 vol...

Page 148: ... during self acquisition P0164 Example value low supply voltage Error cause The throttle power supply voltage is too low to carry out the self acquisition test correctly at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting The throttle test is not carried out when the key is set to ON because the test could show unreal errors becau...

Page 149: ...oes not indicate the presence of this error even in the ATT status Troubleshooting The throttle test is not carried out when the key is set to ON because the test could show unreal errors because the voltage is too low Voltage is detected by the Marelli control unit Rear throttle control circuit P0186 Example value short circuit to positive short circuit to negative open circuit overcurrent excess...

Page 150: ...or 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 If this is not the case restore the cable harness If the value is correct replace the complete throttle body Potentiometer 2 sensor front throttle position P0123 signal not valid Error cause Signal not within the expected value drawn according to the values of the...

Page 151: ...essure Troubleshooting Check the parameter of the Potentiometer 2 Rear throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 2 Front throttle voltage Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5B is a few tenth...

Page 152: ...n If they are replace the throttle body Detection of front throttle valve Recovery conditions air Tº water Tº P0163 possible presence of ice Error cause A correct throttle rotation cannot be detected given low ambient and engine temperatures some ice may have formed in the duct at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting C...

Page 153: ...ition of the throttle stop not within the expected range at each key ON Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Detection of the rear throttle Recovery conditions air Tº water Tº P0183 possible presence of ice Error cause A correct throttle rotation cannot be detected given low ambient and engine temperatures some ice may have ...

Page 154: ...delete any possible errors present in the vehicle Carry out Throttle self learning process on the adjustable parameters screen page screwdriver and hammer and check again that the throttle self learning status reads carried out Engine oil pressure sensor ENGINE OIL PRESSURE SENSOR Function it indicates to the instrument panel if there is enough oil pressure 0 5 0 2 bar 7 25 2 9 PSI in the engine O...

Page 155: ...ontinuity of the purple cable between the sensor connector and the instru ment panel connector PIN 17 if not OK restore the cable harness if OK replace the sensor Error DSB 08 Error cause An oil sensor fault is signalled when with engine running it is detected that the sensor circuit is closed There is an error when the general warning light turns on Troubleshooting Check if oil pressure is low wi...

Page 156: ...ENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR STATUSES Gear in neutral Example value yes no NAVIGATOR NOTES Indication on the instrument panel always gear engaged check the correct position of the cable terminals on the connector and the correct connection of the cables on the terminals If they a...

Page 157: ...ector PIN 16 is shorted to ground restore the cable harness Clutch lever sensor CLUTCH LEVER SENSOR Function It tells the clutch lever position to the control unit Operation Operating principle If there is gear engaged but the clutch is pulled i e circuit closed to ground vehicle start up is not enabled Level in electrical circuit diagram Start up enabling switches Location on the vehicle under cl...

Page 158: ...DE STAND SENSOR Function It tells the side stand position to the control unit Operation Operating principle If the gear is engaged and the side stand is unfol ded and therefore the circuit is open the control unit does not enable vehicle start up or shuts off the engine if it is rotating Level in electrical circuit diagram Start up ena bling switches Location on the vehicle on the side stand conne...

Page 159: ...unit Operation Operating principle When the sensor is inverted the circuit is closed to ground When the Marelli control unit detects this ground connection it does not enable start up or shuts off the engine Level in electrical circuit diagram Start up ena bling switches Location on the vehicle under the saddle connector near the sensor Electrical characteristics Sensor in vertical position open c...

Page 160: ...l be shorted to ground Electric fan circuit ELECTRIC FAN CIRCUIT Function Radiator fan and coolant Operation Operation Operating principle When the control unit detects a temperature of approx 102 C it closes the fan control relay pickup circuit to ground Level in electrical circuit diagram electric fan Location the relay is located under the fuel tank left side first front relay CHECK however the...

Page 161: ...ct by disconnecting it from the cable har ness If they are not correct replace the relay if correct restore the cable harness pink blue cable If shorted to negative check the relay electrical specifications are correct by disconnecting it from the cable har ness If they are not correct replace the relay if correct restore the cable harness pink blue cable If the circuit is open check the relay con...

Page 162: ...SHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS NAVIGATOR STATUSES Run stop switch Example value Run Stop Indication on Navigator always STOP disconnect the connector and with the switch set to RUN check if there is continuity toward the switch of the two yellow grey and red black cables if there is no...

Page 163: ...able is shorted to positive restore the cable harness Throttle control unit THROTTLE CONTROL UNIT Function It receives the throttles target position from the Marelli control unit and it moves them so that they reach that target by reading their position through the potentiometers 2 per throttle body Level in wiring diagram throttle control unit Location on the vehicle inside the filter casing conn...

Page 164: ...ngine connector 34 24 Air temperature sensor input Engine connector 63 25 Front throttle reset output Vehicle connector 56 26 Rear throttle reset output Vehicle connector 55 27 Engine stop input Vehicle connector 26 28 Electric fan relay control output Vehicle connector 54 29 STOP light relay control output Vehicle connector 59 30 Lambda heater control output Engine connector 32 31 Lambda sensor i...

Page 165: ...THE CONNEC TOR 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 CONNEC TOR DORSODURO FACTORY ABS Electrical system ELE SYS 165 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 166: ...13 5B Input for rear throttle potentiometer 2 signal Rear throttle body PIN 4 14 6B Input for rear throttle potentiometer 1 signal Rear throttle body PIN 1 15 7B Rear throttle reset signal input 16 8B Battery power supply input 17 1C Front throttle motor control Front throttle body PIN 3 18 2C Ground connection 19 3C Ground connection Front throttle body PIN 6 20 4C Ground connection Rear throttle...

Page 167: ... 19 GREY BODY PIN 19 20 GREY BODY K Line PIN 20 21 BLACK BODY Battery PIN 21 22 BLACK BODY Front left turn indicator activation PIN 22 23 BLACK BODY Front right turn indicator activation PIN 23 24 BLACK BODY Aerial 2 PIN 24 25 BLACK BODY PIN 25 26 BLACK BODY CAN H PIN 26 27 BLACK BODY CAN L PIN 27 28 BLACK BODY ABS warning light input PIN 28 29 BLACK BODY PIN 29 30 BLACK BODY Ground for sensors PI...

Page 168: ...li control unit connector filter box large connector and instrument panel connector with 1 connector disconnected at a time and by setting the key to ON If not OK restore if OK replace the Marelli control unit Mute Node CAN Line U1601 Mute Node Error cause The injection ECU cannot send CAN signals it receives signals from the instrument panel and the throttle control unit the control unit may need...

Page 169: ...y of the two lines from the filter box large connector to the throttle control unit con nector if not OK restore the cable harness if OK replace the throttle control unit NAVIGATOR LOGIC ERRORS CAN Line to throttle control unit U1706 no message update Error cause No updated signal is received from the throttle control unit DORSODURO FACTORY ABS Electrical system ELE SYS 169 Manuals by Motomatrix w...

Page 170: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 171: ...t 3 Screw fastening chain roller bracket to LH plate M8x35 1 25 Nm 18 44 lbf ft Loctite 243 4 Screw fastening chain roller to chain roller bracket M8x45 1 25 Nm 18 44 lbf ft Loctite 243 5 Screw fastening chain roller bracket to LH plate M8x20 1 25 Nm 18 44 lbf ft Loctite 243 DORSODURO FACTORY ABS Engine from vehicle ENG VE 171 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorc...

Page 172: ...t on RH side panel M4x10 2 3 Nm 2 3 lbf ft 3 SWP self tapping screw fastening demand sensor mounting to demand sensor M5x14 4 2 6 Nm 1 92 lbf ft 4 Flanged TE screw fastening demand sensor to frame M6x20 3 10 Nm 7 37 lbf ft Engine from vehicle DORSODURO FACTORY ABS ENG VE 172 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 173: ...union steel 2 3 50 Nm 2 58 lbf ft Loctite 243 7 LH ball joint on gearbox control lever 1 10 Nm 7 37 lbf ft Loctite 243 8 RH ball joint on gearbox control lever 1 10 Nm 7 37 lbf ft Loctite 243 Fastener for positive cable on engine 1 10 Nm 7 37 lbf ft TE screw fastening negative cable to engine M6x12 1 10 Nm 7 37 lbf ft Vehicle preparation Remove the air filter box Remove the coolant radiator Remove...

Page 174: ...ector Disconnect the starter motor power supply cable Undo and remove the screw and col lect the washer Disconnect the ground leads Engine from vehicle DORSODURO FACTORY ABS ENG VE 174 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 175: ...rews Remove the clutch control cylinder Lock the plunger using a clamp Unscrew and remove the two screws Remove the chain guard DORSODURO FACTORY ABS Engine from vehicle ENG VE 175 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 176: ... O RING IN DICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT Disconnect the gear in neutral sensor connector Disconnect the side stand sensor con nector Engine from vehicle DORSODURO FACTORY ABS ENG VE 176 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 177: ...nsion Undo and remove the screw collect the washer and the spacer Slide off the pinion from the chain and remove Disconnect the generator connections See also Air box Removing the radiator DORSODURO FACTORY ABS Engine from vehicle ENG VE 177 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 178: ...per 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 Engine from vehicle DORSODURO FACTORY ABS ENG VE 178 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co u...

Page 179: ...d Lift the engine Place the engine so that the rear attachments on the chassis are aligned Working on the right side insert the three bolts with their washers Working on the right side place the spacers on the three bolts between the engine block and the chassis CAUTION THE SPACERS HAVE DIFFERENT SIZES REFIT THEM IN THE SAME WAY THEY WERE BEFORE BEING REMOVED DORSODURO FACTORY ABS Engine from vehi...

Page 180: ...ctric connections and clamp the cable harnesses Carry out the vehicle preparation oper ations but in reverse order restore the correct level of all fluids and carry out the adjustments that may be required Engine from vehicle DORSODURO FACTORY ABS ENG VE 180 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 181: ...e also Vehicle preparation Adjusting DORSODURO FACTORY ABS Engine from vehicle ENG VE 181 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 182: ...INDEX OF TOPICS ENGINE ENG Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 183: ...eel 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 DORSODURO FACTORY ABS Engine ENG 183 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 184: ...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 Engine DORSODURO FACTORY ABS ENG 184 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 185: ...rust 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 DORSODURO FACTORY ABS Engine ENG 185 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info...

Page 186: ...IN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE Carefully rotate the engine support Engine DORSODURO FACTORY ABS ENG 186 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 187: ...in reverse order make sure that the shim washer is fitted to the secondary shaft See also Splitting the crankcase halves Gear selector DORSODURO FACTORY ABS Engine ENG 187 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 188: ...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 home po...

Page 189: ... with the specific tool CAUTION TO INSTALL THE ROLLER CAGE IN THE RIGHT HAND CRANKCASE HALF WORK WITH THE CYLINDER ON THE SIDE OF THE 1 mm STEP ON THE TOOL TURNED TO WARD THE ROLLER CAGE WHEREAS TO INSTALL THE CAGE IN THE LEFT HAND CRANKCASE HALF USE THE CYLINDER ON THE SIDE OF THE 2 mm STEP ON THE TOOL Specific tooling 020724Y Gear control rod roller cage punch Starter motor DORSODURO FACTORY ABS...

Page 190: ...motor power supply cable Undo and remove the four screws and remove the starter motor Generator side Engine DORSODURO FACTORY ABS ENG 190 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 191: ...2 13 Nm 9 59 lbf ft 8 Crankshaft access cap 1 4 Nm 2 95 lbf ft 9 Retainer plate fastener screw M6 1 8 Nm 5 90 lbf ft Screw fastening bracket to starter motor M6x14 2 13 Nm 9 59 lbf ft Pick up cable retainer screw M5 2 3 Nm 2 21 lbf ft Removing the flywheel cover Remove the flywheel cover inspection cap Unscrew and remove the ten screws 1 2 NOTE SCREW 2 ON THE FLYWHEEL COVER IS SHORTER THAN SCREWS ...

Page 192: ...ANCH 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 FACTORY ABS ENG 192 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys emai...

Page 193: ...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 crankshaft woodruff key DORSODURO FACTORY ABS Engine ENG 193 Ma...

Page 194: ...el 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 FACTORY ABS ENG 194 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 195: ...ve 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 DORSODURO FACTORY ABS Engine ENG 195 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 196: ...lbf ft Loctite 244 5 Water pump rotor 1 4 50 Nm 3 32 lbf ft Remove the water pump cover Undo and remove the eleven screws working in a diagonal sequence Collect the gasket Removing the clutch cover CLUTCH COVER pos Description Type Quantity Torque Notes 1 Fastener screw for Clutch Cover Clutch side cover M6 4 13 Nm 9 59 lbf ft 2 Clutch fastener nut M24x1 5 1 180 Nm 132 76 lbf ft 5 Chamfer Engine D...

Page 197: ...com mended when replacing the clutch plates When removing the entire clutch assembly removing the clutch side crankcase is recommended However removing the entire clutch assembly is possible by removing the clutch cover alone In this case proceed as follows measure the projection of the clutch housing from the crankcase before dis assembling when refitting check that the projection has not changed...

Page 198: ...h side housing Unscrew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate Engine DORSODURO FACTORY ABS ENG 198 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 199: ... the clutch housing using the specific tool Specific tooling 9100896 Clutch housing locking tool Undo and remove the clutch hub nut retrieving the washer DORSODURO FACTORY ABS Engine ENG 199 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 200: ... hub and the clutch housing Collect the clutch bell Collect the spacer and the needle bearings Collect the shim washer Engine DORSODURO FACTORY ABS ENG 200 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 201: ...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 in MUSHROOM VALVE CHECK Check if the valve slides freely without jamming Blow compressed air into the valve and check that the lubricating oil passage holes open DORSODURO FACTO...

Page 202: ...gular operation Deburr the teeth or replace the bell MAIN DRIVEN GEAR CHECK Check the main driven gear for damage and wear and if necessary replace the main transmission driving gear and the clutch bell all together Make sure there is not excessive noise during operation if necessary replace the main transmission driving gear and the clutch bell all together Engine DORSODURO FACTORY ABS ENG 202 Ma...

Page 203: ...ion If neces sary replace the bell Checking the springs Check the springs for damage and if necessary replace the them all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Clutch spring length when unloaded 46 6 mm 1 83 in DORSODURO FACTORY ABS Engine ENG 203 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys...

Page 204: ...the oil pump control drive gear of the clutch bell engages correctly with the oil pump driven gear Place the washer correctly between the clutch housing and the hub Engine DORSODURO FACTORY ABS ENG 204 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 205: ...n 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 housing 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 THE ENGINE DORSODURO FACTORY ABS Engine ENG 205 Manuals by M...

Page 206: ...utch bell Place the control rod Place the thrust plate CAUTION ENSURE THAT THE ARROW ON THE THRUST PLATE IS ALIGNED WITH THE MACHINING ON THE HUB 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 Engine DORSODURO FACTORY ABS ENG 206 Manuals by Motomatrix www motomatrix co uk The Solution For Lost...

Page 207: ...cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY 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 DORSODURO FACTORY ABS Engine ENG 207 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 208: ...10x1 25 8 10 Nm 7 38 lbf ft Lubricate the threads before tight ening 3 Head stud bolt fastener nut tighten ing M10x1 25 8 13 Nm 9 59 lbf ft 90 90 Lubricate the threads before tight ening 4 Fastener for Head Cylinder Outer side crankcase M6 2 13 Nm 9 59 lbf ft 5 Fastener for Head Cylinder Inner side crankcase M6 4 12 Nm 8 85 lbf ft 4 Nut fastening Stud Bolts Head M6 4 12 Nm 8 85 lbf ft Engine DORSO...

Page 209: ...ad 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 the eight cam cap screws working in a diagonal se quence and in stages Remove the cam cap carefully so as not to go through it and d...

Page 210: ...ets and the ad justment shims using a magnet Compress the valve springs with the specific wrench and with the spring compressing tool Specific tooling AP8140179 Valve spring compressor 020721Y Adaptor for valve removal Remove the cotters using a magnet Engine DORSODURO FACTORY ABS ENG 210 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 211: ... wheel CAMSHAFT LOBES Check that they do not show blue col ouring pitting or scratches otherwise replace the camshaft and the relevant toothed wheel Use a micrometer to check the sizes a and b of the camshaft lobes Camshaft lobes sizes Inlet a 36 28 36 32 mm 1 4283 1 4299 in Limit 36 15 mm 1 4232 in b 28 mm 1 1023 in Outlet DORSODURO FACTORY ABS Engine ENG 211 Manuals by Motomatrix www motomatrix ...

Page 212: ...ON THE VALVE HEAD CANNOT BE REGROUND IF REQUIRED REPLACE THE VALVE GRINDING WITH ABRASIVE PASTE IS ALLOWED VALVE STEM END REGRINDING IS NOT AL LOWED Clean off any combustion residues from the valves Check the seat 1 on the valve head with a ruler flush The surface of the seat must not be concave re place the valve if necessary Check the clearance between the stem and the valve guide inlet 0 013 0 ...

Page 213: ...T USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK PLUG THREADS OR THE VALVE SEATS Check the head for damage or scratches and replace it if necessary Check there are no mineral deposits or rust in the head water cooled jacket clean off if required Use a checking ruler and a thickness gauge positioned diagonally to the ruler to measure the cylinder head distortion Maximum cylinder...

Page 214: ... Nm 22 13 lbf ft 1 Camshaft gear fastener nut tighten ing M15x1 4 90 Nm 66 38 lbf ft 2 Timing drive gear fastener screw M24x1 5 2 40 Nm 29 50 lbf ft 3M SCOTCH GRIP 2353 Engine DORSODURO FACTORY ABS ENG 214 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 215: ...tensioner Undo and remove the screw and col lect the washer and the internal spring Unscrew and remove the two screws Remove the chain tensioner and col lect the gasket Chain removal Remove the chain tensioner Remove the main pinion Remove the movable chain slider and release the fixed chain slider from the clamp Unscrew and remove the pin of the tim ing chain intermediate gear paying at tention n...

Page 216: ... tensioner Removing the chain sliders Remove the chain tensioner and the camshafts from the corresponding head FRONT HEAD First remove the clutch cover 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 Engine DORSODURO FACTORY ABS ENG 216 Manuals by Motomatrix www motomatrix co uk The Solution F...

Page 217: ... sioner slider screw First remove the head in order to re move it See also Removing the chain tensioner Removing the head cover Magneto flywheel removal Checking the chain Check the timing chain for damage or stiffness while moving If required replace both the timing chain and the camshaft sprocket wheels Check the timing chain guide for damage If necessary replace the parts DORSODURO FACTORY ABS ...

Page 218: ...sert a new paper gasket Tighten the two screws to the prescri bed torque Insert the spring and tighten the screw together with the washer Cam timing Timing Rotate the crankshaft until the front cylinder piston reaches the top dead centre Lock the crankshaft with the specific special tool Specific tooling 020720Y Timing tool Engine DORSODURO FACTORY ABS ENG 218 Manuals by Motomatrix www motomatrix ...

Page 219: ...e 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 two camshafts in the head seats and align the two camshaft holes with the head holes Align the clearance recovery gear to the main timing system gear using the specific tool Specific tooling 020718Y Camshaft gear alignment pin DORS...

Page 220: ...ed to the prescribed tor que Tighten the eight screws in the se quence indicated to the prescribed tor que Carry out camshaft timing with the ap propriate dowels Specific tooling 020719Y Timing pin Locking torques N m Cam cap head fixing screws M6 16 Pre tight ening 4 90 6 86 Nm 3 61 5 06 lbf ft Tightening 9 81 12 75 Nm 7 24 9 40 lbf ft CAUTION INSTALL THE CAMSHAFT TIGHTENING NUTS WITH THE MARK FA...

Page 221: ...ignment tool Specific tooling 020718Y Camshaft gear alignment pin Release the crankshaft from the specific special tool Rotate the crankshaft in the riding direction until the rear cylinder piston reaches the top dead centre Lock the crankshaft with the specific special tool Carry out the timing operations performed for the front cylinder Specific tooling 020720Y Timing tool Cylinder piston assemb...

Page 222: ...and remove the two head fas tener screws located in the timing chain compartment Undo and remove the outer screw Undo and remove the four nuts pro ceeding in stages and in a diagonal pattern Ease the cylinder head assembly off the stud bolts Remove the three nuts fastening the cylinder head on the intake and ex haust sides Engine DORSODURO FACTORY ABS ENG 222 Manuals by Motomatrix www motomatrix c...

Page 223: ... cific tool Slide 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 DORSODURO FACTORY ABS Engine ENG 223 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix c...

Page 224: ...g and the three oil scraper rings See also Removing the cylinder head Removing the cylinder Engine DORSODURO FACTORY ABS ENG 224 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 225: ... bore C 92 000 mm 3 6220 in C D1 or D2 max Cylindricity tolerance 0 020 mm 0 00079 in Replace the cylinder the piston and the piston ring all together if not complying with specifications Checking the piston Measure the piston skirt diameter P with a micrometer a 10 mm 0 39 in from the piston lower border Calculate the clearance between pis ton and cylinder as follows Piston cylinder clearance C C...

Page 226: ...replace it if not complying with specifications CAUTION IT IS NOT POSSIBLE TO MEASURE THE GAP OF THE OIL SCRAPER RING END IF CLEARANCE IS EXCESSIVE RE PLACE 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 t...

Page 227: ...990 91 977 mm 3 6216 3 6219 in Piston 91 933 91 940 mm 3 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 ...

Page 228: ...piston Fit the piston on the connecting rod and install the gudgeon pin Specific tooling 020470Y Pin snap ring fitting tool Fit a new retainer ring on the piston to fasten the gudgeon pin Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder Fit the stud bolts if previously removed CAUTION THE STUD BOLTS SHOULD BE FITTED SO THAT THEY PROTRUDE Engine DORSODURO FACTORY ABS ENG ...

Page 229: ... THE BASE GASKET SELECTION SECTION Before fitting the cylinder place the chain sliders and the timing chain on the crankshaft fit the timing chain on the crankshaft from the base side NOTE BEFORE FITTING THE CYLINDER CAREFULLY BLOW AIR INTO THE LUBRICATION 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 fo...

Page 230: ...clean With a hook hold the timing chain Fit the timing chain on the intermediate gear Slide in the pin together with a new O Ring and a washer Check that the axial clearance be tween the pin and the gear is between 0 30 and 0 60 mm 0 0118 0 0236 in Engine DORSODURO FACTORY ABS ENG 230 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk...

Page 231: ...ial tool with the clamp Specific tooling AP8140302 tool for sealing ring fitting Temporarily fit the piston to the cylin der without base or head gasket Remove the clamp from the sealing ring locking tool Remove the special tool for locking the connecting rod Fit a dial 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 z...

Page 232: ...move the specific tool and the cyl inder Specific tooling 020720Y Timing tool BASE GASKET Specification Desc Quantity Measured protrusion 0 10 0 0 mm 0 0039 0 0000 in Gasket 0 4 mm 0 0157 in Measured protrusion 0 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 ...

Page 233: ...ad fixing screws to the prescribed torque Place the cylinder head unit on the crankcase 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 DORSODURO FACTORY ABS Engine ENG 233 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 234: ...ainer fastener screw M6 3 10 Nm 7 38 lbf ft Loctite 270 2 Piston oil jet fastener screw M5 2 5 50 Nm 4 06 lbf ft Loctite 242 3 Tapered plug for crankshaft main bearing lubrication M8x1 4 15 Nm 11 06 lbf ft 4 Calibrated Brass dowel fixed to com plete crankcase M8 2 5 50 Nm 4 06 lbf ft Engine DORSODURO FACTORY ABS ENG 234 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Co...

Page 235: ... Special calibrated screw for gearbox lubrication 1 18 Nm 13 28 lbf ft Splitting the crankcase halves Fit the special tool tightly fastening the four screws securing the tool onto the crankcase Undo and remove the crankshaft fas tener nut anticlockwise using the spe cial tool retrieving the washer Specific tooling 020711Y Engine pinion locking DORSODURO FACTORY ABS Engine ENG 235 Manuals by Motoma...

Page 236: ...or to remove the crankshaft gear Remove the gearbox control rod re trieving the washer Engine DORSODURO FACTORY ABS ENG 236 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 237: ...the gearbox selec tor mounting plate Undo and remove the three screws fastening the gearbox selector mount ing plate Remove the plate complete with selec tor DORSODURO FACTORY ABS Engine ENG 237 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 238: ...ct complete with spring If the pinion has been removed refit fastening with the special tool Specific tooling 9100896 Clutch housing locking tool Engine DORSODURO FACTORY ABS ENG 238 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 239: ... sensor tooth with the special tool When refitting fix the tone wheel with strong Loctite threadlock Specific tooling 020715Y Tone wheel removal Undo and remove the selector drum fastener screw Remove the selector drum DORSODURO FACTORY ABS Engine ENG 239 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 240: ... and remove the nine M8 crankcase fastener screws Working on the left hand side undo and remove the nine M6 crankcase fastener screws Engine DORSODURO FACTORY ABS ENG 240 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 241: ...pin then retight en by one turn to give the crankcase halves free play and verify tightness CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE EN GINE AND ENGINE MOUNTING ARE STABLE AND EN SURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE Remove the two screws fastening the mounting DORSODURO FACTORY ABS Engine ENG 241 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mot...

Page 242: ...aps with a rubber mallet Open the crankcase halves Retighten the two screws to the engine mounting Engine DORSODURO FACTORY ABS ENG 242 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 243: ...ity Torque Notes 1 Crankshaft primary gear fastener nut M24x1 5 1 270 Nm 199 14 lbf ft Anticlockwise nut 2 Connecting rod screw M10 4 15 30 Nm 11 06 22 13 lbf ft 50 2 final control torque 65 78 Nm 47 94 57 53 lbf ft Lubricate the threads before tight ening DORSODURO FACTORY ABS Engine ENG 243 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatr...

Page 244: ...that all oil seals remaining in their position are not worn or damaged Check all ball bearings for clearance smoothness and potential distortions CAUTION LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING If the internal ring does not rotate smoothly and 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 DELIVE...

Page 245: ...nkshaft axial clearance check The shaft axial clearance on the crank case should be checked 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 Dial gauge mounting Removal Mark the position of the original semi bushings on the crankcase D...

Page 246: ...si ble NOTE WHEN REPLACING THE SEMI BUSHINGS ALONE THE NEW COMPONENTS MUST BE THE SAME COLOUR AS THE REMOVED COMPONENTS IF THE COLOUR OF THE OLD COMPONENTS IS NO LONGER VISIBLE USE THE TABLE TO IDENTIFY THE CORRECT COMPONENTS RE FERRING TO THE CRANKCASE AND CRANKSHAFT CLASSES Key Semi bushing joint line Fit the new bushings with the crank case cold using a press and the spe cific tool and pushing ...

Page 247: ...rankcase halves Fit the strum box if previously re moved Tighten the two strum box fixing screws Turn the engine support into horizontal position Place the left crankcase half on the engine support fitting it on the engine support pins CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE ENGINE AND ENGINE MOUNTING ARE STA BLE AND ENSURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE Fit the...

Page 248: ...CTS THROUGH THE CRANKCASE HALVES Place the right crankcase half with the aid of a rubber hammer Tighten the two fixing pins Rotate the engine and the engine support into vertical position Engine DORSODURO FACTORY ABS ENG 248 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 249: ...e the nine M8 screws fixing the crankcase Tighten all the crankcase fixing screws both M6 and M8 type Slide in the clutch control rod Place the pinion DORSODURO FACTORY ABS Engine ENG 249 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 250: ...rudes Tighten the gear selector drum fixing screw Position the tone wheel Tighten the tone wheel with the special tool Use Loctite medium strength for sealing Specific tooling 020715Y Tone wheel removal Engine DORSODURO FACTORY ABS ENG 250 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 251: ...ring Place the 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 DORSODURO FACTORY ABS Engine ENG 251 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 253: ...case by tightening the four fixing screws on the crankcase Tighten the crankshaft gear lock nut Specific tooling 020711Y Engine pinion locking Lubrication DORSODURO FACTORY ABS Engine ENG 253 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 254: ...43 Nm 31 72 lbf ft 6 Oil pump fastener screw M6 2 5 50 Nm 4 06 lbf ft Loctite 242 7 Rose pipe fastener screw 2 12 Nm 8 85 lbf ft 8 Complete oil pump gear fastener 1 9 11 Nm 6 64 8 11 lbf ft 9 Oil pump cover fastener screw M3 2 0 80 Nm 0 59 lbf ft Removing OLD GENERATION PUMP REMOVAL Lock the pump gear with the commer cially available hook spanner and undo the screw then collect the washer Engine D...

Page 255: ...ve the two screws fixing the oil pump Remove the entire pump NEW GENERATION PUMP REMOVAL DORSODURO FACTORY ABS Engine ENG 255 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 256: ... with a commercial hook spanner and unscrew the nut collecting the safety washer Remove the water pump gear Collect the shim washer Engine DORSODURO FACTORY ABS ENG 256 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 257: ...g a thickness gauge check clear ance between rotor and stator and re place the rotor stator unit if necessary clearance between rotor and stator 0 04 0 10 mm 0 0016 in 0 0039 in DORSODURO FACTORY ABS Engine ENG 257 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 258: ...p rotor Remove the oil pump stator CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAM AGED NO EVIDENT ABRASIONS SCORES OR ANY OTH ER MARKS Engine DORSODURO FACTORY ABS ENG 258 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 259: ...CE WITH A FEELER GAUGE IF REQUIRED REPLACE THE STATOR ROTOR UNIT OLD GENERATION PUMP INSTALLATION Fit the oil pump in its seat Tighten both oil pump fixing screws DORSODURO FACTORY ABS Engine ENG 259 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 260: ...y means of a commercial hook span ner lock the pump and tighten the screw to the prescribed torque NEW GENERATION PUMP INSTALLATION Fit the oil pump in its seat Engine DORSODURO FACTORY ABS ENG 260 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 261: ...gear Fit the safety washer By means of a commercial hook span ner lock the pump and tighten the nut to the prescribed torque DORSODURO FACTORY ABS Engine ENG 261 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 262: ...t and bend the safety washer opposite the fitting tabs until it rests on the nut Engine DORSODURO FACTORY ABS ENG 262 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 263: ...INDEX OF TOPICS POWER SUPPLY P SUPP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 264: ...orted 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 Power supply DORSODURO FACTORY ABS P SUPP 264 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mot...

Page 265: ...e bodies are mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit Therefore there is a Throttle map to which the control unit refers in order to decide the position at which the throttle valves should be and at what speed they should reach the pre set position The main parameters which influence the throttle map a...

Page 266: ...It checks through the throttle position sensor signal that the throttle bodies have reached the target position It communicates the position reached to the Marelli control unit It does not actuate on Safety strategies Throttle Body The two throttle bodies are made up of Throttle valve with 2 return springs for the controlled minimum opening position DC electrical motor Tinned double throttle posit...

Page 267: ...gine works regularly B the malfunction may affect riding in safety the warning light turns on the message Urgent Service is displayed the torque demands are not fully activated reduced torque C the malfunction may affect riding in safety the warning light turns on the message Urgent Service is displayed the engine operates in Limp Home function accelerated idle the throttles which are at the posit...

Page 268: ...ME TYPE Working on both bodies undo and re move the two plate screws Remove the plate Working on both bodies undo and re move the screw and detach the body Power supply DORSODURO FACTORY ABS P SUPP 268 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 269: ...us errors etc is available at the home page of the website www serviceaprilia com in the search section Parameters Navigator The same parameters device status errors etc are grouped per type of component they refer to in the Electrical system chapter Checks and Controls DORSODURO FACTORY ABS Power supply P SUPP 269 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded K...

Page 270: ...INDEX OF TOPICS SUSPENSIONS SUSP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 271: ...nt disc M8x20 12 30 Nm 22 13 lbf ft Loctite 243 Removing the front wheel Hold the vehicle front part Unscrew the screws fixing the front pli ers and slide them off the disc DORSODURO FACTORY ABS Suspensions SUSP 271 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 272: ...e on the opposite side is exposed Remove the wheel axle by inserting a screwdriver in the holes on the pin During extraction support the wheel and then remove it Collect the spacer from the front wheel right side Suspensions DORSODURO FACTORY ABS SUSP 272 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 273: ...e If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear ALWAYS REPLACE BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE wheel spindle Use a ...

Page 274: ...al and axial eccentricity 2 mm 0 0079 in Handlebar HANDLEBAR pos Description Type Quantity Torque Notes 1 TCEI screw fastening counterweight to handlebar end M6x50 2 10 Nm 7 37 lbf ft 2 Stainless steel TCC screw fastening upper clamp to lower clamp M8x25 4 25 Nm 18 44 lbf ft 3 Screws fastening light switch assem bly 2 2 1 5 Nm 1 11 lbf ft Front fork Suspensions DORSODURO FACTORY ABS SUSP 274 Manua...

Page 275: ...f ft 2 Screw Pumping member pin fixing to the stem base 2 30 Nm 22 13 lbf ft 3 Upper cover 2 20 Nm 14 75 lbf ft 4 Upper cover locking nut 2 20 Nm 14 75 lbf ft DORSODURO FACTORY ABS Suspensions SUSP 275 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 276: ... pre tightening M25x1 1 30 Nm 22 13 lbf ft Steering package settlement 1 Headstock ring nut tightening M25x1 1 12 Nm 8 85 lbf ft 2 Headstock nut pre tightening M22x1 1 10 Nm 7 37 lbf ft Loctite 243 2 Headstock nut M22x1 1 25 Nm 18 44 lbf ft Loctite 243 3 Stainless steel TCC screw fastening stanchions to upper and lower yokes M8x30 6 25 Nm 18 44 lbf ft 4 TCEI screw fastening lower clamp onto fork y...

Page 277: ...ng Loosen the cover without undoing it completely Place the fork vertically locking it in a vice by the specific tool Undo completely the cover Specific tooling AP8140149 Protection for fitting operations DORSODURO FACTORY ABS Suspensions SUSP 277 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 278: ...the cover Specific tooling 020888Y Pliers for pre fill pipe Unscrew the cap and remove it Remove the spring preload pipe Remove the lock nut and the washer Suspensions DORSODURO FACTORY ABS SUSP 278 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 279: ...ENTRE Discharge the fork remove the internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim DORSODURO FACTORY ABS Suspensions SUSP 279 Manuals by Motomatrix www...

Page 280: ...he stem Remove the lock seeger ring of the spring guide Remove the spring guide Using a hook spanner lock the pump ing member pin Remove the stem bottom screw Specific tooling 020889Y Pumping member ring nut locking spanner Suspensions DORSODURO FACTORY ABS SUSP 280 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 281: ...e stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in good conditions Check that the following components are in good conditions upper bushing DORSODURO FACTORY ABS...

Page 282: ...CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE Replace the following components with new ones sealing ring dust guard Suspensions DORSODURO FACTORY ABS SUSP 282 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 283: ...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 DORSODURO FACTORY ABS Suspensions SUSP 283 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 284: ... Weight Insert the retainer ring in its position Fit the dust gaiter with the specific tool Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight Insert the pumping member pin in the stem Suspensions DORSODURO FACTORY ABS SUSP 284 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 285: ...the appropriate seeger Place the fork vertically Insert the washer Refill the fork with oil according to the prescribed quantity Fit the spring CAUTION BE CAREFUL WHEN INSERTING THE SPRING SINCE THE COMPRESSED SPIRAL PART MUST BE PLACED DOWN WARDS See also Filling oil DORSODURO FACTORY ABS Suspensions SUSP 285 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 286: ...e nut as much as possible Insert the cover and tighten until it stops Remove the specific tools Screw the cover in the sleeve to the prescribed torque Filling oil Place the sleeve upright in a vice fitted with protection shoes Compress the sleeve in the stem Place a support under the stem in order to leave it com pressed Pour part of the fork oil into the sleeve Wait some minutes until the oil fil...

Page 287: ...n for fitting operations Oil level 135 mm 5 31 in from edge of sleeve without spring and with preload tube Characteristic Fork oil check also the correct air level in the stem 494 cm RIGHT stem 30 14 cu in 494 cm LEFT stem 30 38 cu in Steering bearing OPTION 01 Steering upper plate without a headstock cut DORSODURO FACTORY ABS Suspensions SUSP 287 Manuals by Motomatrix www motomatrix co uk The Sol...

Page 288: ... Nm 7 37 lbf ft Loctite 243 2 Headstock nut M22x1 1 25 Nm 18 44 lbf ft Loctite 243 3 Stainless steel TCC screw fastening stanchions to upper and lower yokes M8x30 6 25 Nm 18 44 lbf ft 4 TCEI screw fastening lower clamp onto fork yoke M10x60 2 50 Nm 36 88 lbf ft Adjusting play Place the vehicle so that the front wheel is off the ground Carry out a handlebar rotation test using a dynamometer at the ...

Page 289: ...of the ring nut Carry out the following operations carry out a first tightening of the ring nut to the indicated tightening torque for the settlement of the steering package turn the steering completely from both sides for several times Loosen the ring nut completely carry out the final tightening of the ring nut to the indicated tightening torque Specific tooling 020884Y 46 mm wrench for steering...

Page 290: ...e upper plate to the prescribed tightening tor que STEERING UPPER PLATES pos Description Type Quantity Torque Notes 2 Headstock nut M22x1 1 100 Nm 73 76 lbf ft 3 Stainless steel TCC screw fastening stanchions to upper and lower yokes M8x30 6 25 Nm 18 44 lbf ft When refitting the U bolt position the two referen ces facing the front part of the vehicle OPTION 02 Steering upper plate with a headstock...

Page 291: ...ve the top bolt on the headstock Screw the fixing screws of the upper plate Undo and remove the two screws fixing the instrument panel support to the fork upper plate Slide off the fork upper plate by moving it towards the instrument panel DORSODURO FACTORY ABS Suspensions SUSP 291 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 292: ...ue Notes 1 Headstock ring nut pre tightening M25x1 1 30 Nm 22 13 lbf ft Steering package settlement 1 Headstock ring nut tightening M25x1 1 12 Nm 8 85 lbf ft Fit the entire fork upper plate adjusting with short taps with a rubber hammer Scatter the nut thread with the specific product and pre fit it to the indicated tightening torque Recommended products LOCTITE 243 Loctite adhesive to assemble cy...

Page 293: ...ing Grease the lower and upper bearing rollers Prefit the shim dust gaiter and lower bearing on the steering yoke as shown in the figure Recommended products AGIP MP GREASE Grease for bearings joints couplings and linkages As an alternative to the recommended product use top brand grease for roller bearings with an operating temperature range of 22 F to 284 F 30 C to 140 C drop point between 302ºF...

Page 294: ... mating in its seat using a teflon buffer from a suitable di ameter Fit the specific upper seal ring with the lip placed upwards and the surface with the words downwards Enter it on the column and place it on the upper rim of the headstock Finish inserting until the stop with the teflon buffer and rubber hammer Suspensions DORSODURO FACTORY ABS SUSP 294 Manuals by Motomatrix www motomatrix co uk T...

Page 295: ...ightening ring nut with the rim placed downwards Carry out the steering bearings clear ance adjustment See also Assembling Rear DORSODURO FACTORY ABS Suspensions SUSP 295 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 296: ...ce the vehicle on its rear service stand Fasten the vehicle handlebar to the bench using belts To facilitate operations it is advisable to remove the chain protection by un 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 Suspensions DORSODURO FACTORY ABS SUSP 296 Manuals by Motomatrix www motomatrix co uk ...

Page 297: ... wheel 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 sprocket and the bolts Undo and remove the five screws and remove the anti vibration buffer holder Check the flexible couplings according to the routine maintenance table DORSODURO FACTORY ABS Suspensions SUSP 297 Manuals by...

Page 298: ...GS ALWAYS REPLACE THE BEARINGS WITH OTHERS 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 RE...

Page 299: ... and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2 mm 0 0079 in DORSODURO FACTORY ABS Suspensions SUSP 299 Manuals by Motomatrix www motomatrix co uk The So...

Page 300: ...ional under sump and rear wheel service stands Unscrew and remove the upper screw and collect the washer Loosen the under sump optional serv ice stand to lower the engine Unscrew and remove the lower screw and retrieve the nut Remove the shock absorber Suspensions DORSODURO FACTORY ABS SUSP 300 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

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

Page 302: ...Loctite 243 7 TBEI screw fastening chain guard to rear mudguard M5x9 1 4 Nm 2 95 lbf ft 8 TBEI screw fastening chain guide to swingarm M5x9 2 6 Nm 4 42 lbf ft 9 Wheel pin nut M25x1 5 1 120 Nm 88 5 lbf ft 10 Flanged TBEI screw fastening chain casing M5x9 2 4 Nm 2 95 lbf ft Loctite 243 Removing Remove the exhaust system Support the vehicle by means of the engine service stand and a hoist with belts ...

Page 303: ...BRAKE FLUID LEAKAGE Undo and remove the two lower swing arm screws Remove the cable guides Undo and remove the shock absorber lower screw and collect the nut Fasten the shock absorber to the chas sis With the specific box spanner un screw and remove the locking ring nut DORSODURO FACTORY ABS Chassis CHAS 303 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 304: ...ng The vehicle is fitted with an endless chain without master link NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE To check clearance Shut off the engine Place the vehicle on the service stand Engage neutral gear Check that the vertical oscillation at a point between the pinion and the c...

Page 305: ...O ENSURE THAT THE WHEEL IS CORRECTLY CEN TRED THERE ARE FIXED REFERENCE MARKINGS 2 3 INSIDE THE CHAIN TENSIONER SLIDER SEATS ON THE SWINGARMS IN FRONT OF THE WHEEL AXLE CHECKING THE CHAIN THE PINION AND THE SPROCKET FOR WEAR Furthermore check the following parts and make sure the chain the pinion and the sprocket do not show damaged rollers loosened pins dry rusty flattened or jammed chain links e...

Page 306: ...ne Maintenance operations should be more frequent if there are signs of quick rust Lubricate the chain at the intervals specified on the routine maintenance table and whenever necessary Wash the chain allow to dry and lubricate with spray grease for sealed chains Stand STAND ASSEMBLY pos Description Type Quantity Torque Notes 1 Stand screw M10x1 25 1 10 Nm 7 37 lbf ft Loctite 243 2 Thin nut M10x1 ...

Page 307: ...encer M6 1 7 Nm 5 16 lbf ft 4 Self tapping TE screw fastening si lencer mounting bracket to saddle mounting M8x20 2 25 Nm 18 44 lbf ft 5 Self tapping TE screw fastening front silencer fixture to silencer mounting bracket M8x35 2 35 Nm 25 81 lbf ft Removing the tail pipe Loosen the clamp between the ex haust end and the manifold DORSODURO FACTORY ABS Chassis CHAS 307 Manuals by Motomatrix www motom...

Page 308: ...ssis retainer in the lower part Removing the manifold tail pipe Remove the front exhaust manifold Disconnect the lambda probe Loosen the exhaust manifold and the exhaust end clamps from the rear cyl inder Remove the manifold terminal coupling See also Removing the Chassis DORSODURO FACTORY ABS CHAS 308 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 309: ...il the engine and the exhaust system have cooled down FRONT Unscrew and remove the two nuts on the head exhaust stud bolts Loosen the clamp Remove the exhaust 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 DORSODURO FACTORY ABS Chassis CHAS 309 Manuals by Motomatr...

Page 310: ...the breather pipe and the bracket with the lambda probe connector fixed to it Disconnect the lambda sensor con nector Unscrew and remove the lambda sen sor Chassis DORSODURO FACTORY ABS CHAS 310 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 311: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 312: ...M ABS ABS SYSTEM pos Description Type Quantity Torque Notes ABS ECU fastener screw M6x25 1 10 Nm 7 37 lbf ft Loctite 243 ABS ECU fastener nut M6 2 10 Nm 7 37 lbf ft Braking system DORSODURO FACTORY ABS BRAK SYS 312 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 313: ...onnection PIN 4 IGN Injection PIN 8 WL Alarm warning light PIN 11 R_SIGN Rear ABS sensor signal PIN 12 R_GND Rear ABS sensor ground connection PIN 13 F_GND Front ABS sensor ground connection PIN 14 F_SIG Front ABS sensor signal PIN 15 PCC2 Vehicle identification ground connection DORSODURO FACTORY ABS Braking system BRAK SYS 313 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 314: ...per 2 Modulator 3 Front bleed valve 4 Front brake reservoir 5 Front brake callipers 6 Rear brake pump 7 Rear brake reservoir Braking system DORSODURO FACTORY ABS BRAK SYS 314 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 315: ...nt system circuit 2 Front brake pump 3 Front brake lever control 4 Rear system circuit DORSODURO FACTORY ABS Braking system BRAK SYS 315 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 316: ...hen in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coincides with danger recognition wheel slippage above threshold the ...

Page 317: ...uit accordingly NOTE WHEN THE ABS SYSTEM STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED HANDLE BAR TURNED ON UN EVEN OR SLIPPERY ROADS OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE THEREFORE RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADU ALLY BRAKING ...

Page 318: ...0 ABS If on the vehicle NA 850 Mana ABS temporary errors of other control units are detected the word ABS shown on the display is displayed instead of the word relative to the other control units where errors have been detected e g GEAR or SERVICE The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The diagnosis requires exceeding the 5 km h Eac...

Page 319: ...the timer is reset and the system is no longer able to diagnose the error The ABS system is still inactive Example error code 5D93 requires some minutes before it is diagnosed during the given time A The EFI warning light keeps flashing with the word ABS on the display NA 850 Mana ABS B The ABS warning light keeps flashing SL 750 Shiver ABS Dorsoduro 750 ABS ABS FAULTS GUIDE TO THE DIAGNOSIS 1a NA...

Page 320: ...ample software type map ping control unit programming date INFO ECU SCREEN PAGE Characteristic Value example Unit of measure ment Notes Vehicle manufacturing date Chassis number Software version Vehicle code Mana Shiver Dorso duro Scarabeo The vehicle code stored in the control unit is read Vehicle identification according to the status of Pin 2 and 15 of the ABS control unit connector Mana Shiver...

Page 321: ...l unit injection time ignition advance etc PARAMETERS Characteristic Value example Unit of measure ment Notes Front wheel speed 0 km h With stopped wheel 0 Km h is displayed Rear wheel speed 0 km h With stopped wheel 0 Km h is displayed Battery voltage 11 9 V DORSODURO FACTORY ABS Braking system BRAK SYS 321 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 322: ...ent parameter error reading 3 for example if it indicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Ambient parameter error reading 4 Operation cycles from the last reading a cycle is counted if the following occurs key ON and speed over 20 km h Ambient parameter error reading 5 If for example 5 is...

Page 323: ...n very rare cases abnormal tone wheel vibrations Rear speed sensor 5DA3 no signal or speed measured too low in rela tion to the front wheel Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Rear speed sensor 5DA4 no accel eration after pressure reduction Faulty sensor or missing sensor tone wheel or ex c...

Page 324: ...is done according to the con nection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory Coding 3 The identification can be read in the INFO ECU screen page in the line Vehicle code NOTE the X in the table identifies the con nector pin is grounded Braking system DORSODURO FACTORY ABS BRAK SYS 324 Manuals by Motomatrix www motomatrix co uk The Solution For Lo...

Page 325: ...ake oil pipes following this sequence 3 4 6 5 Slide off the rear system pipes from the hooks 7 Undo and remove the three screws collect the washers and remove the ABS modulator DORSODURO FACTORY ABS Braking system BRAK SYS 325 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 326: ...ting M5x12 4 6 Nm 4 42 lbf ft 4 Flanged self locking nut M6 1 10 Nm 7 37 lbf ft 5 Screw nut fastening pedal to brake lever M6 1 1 10 Nm 7 37 lbf ft 6 Brake pipe union M10x1 2 25 Nm 18 44 lbf ft 1 Flanged TE screw fastening rear disc M8x20 5 30 Nm 22 13 lbf ft Loctite 243 Flanged TE screw M6x16 1 10 Nm 7 37 lbf ft Braking system DORSODURO FACTORY ABS BRAK SYS 326 Manuals by Motomatrix www motomatri...

Page 327: ...k stems M10x1 25 4 50 Nm 36 88 lbf ft Fastener for brake pipe on steering base M6x25 1 10 Nm 7 37 lbf ft Front brake pads Removal Turn the pins and remove both split pins Remove both pins Collect the anti vibration springs DORSODURO FACTORY ABS Braking system BRAK SYS 327 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 328: ... THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Bleeding the braking system Front 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 efficiency during braking Braking system DORSODURO FACTORY ABS BRAK SYS 328 Manuals by Mo...

Page 329: ...ect the fluid Remove the front brake oil reservoir cap Quickly press and release the front brake lever several times and then keep it fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will 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...

Page 330: ...ther end of this pipe into a container to collect the fluid Remove the rear brake oil reservoir cap Quickly press and release the rear brake lever several times and then keep it fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before th...

Page 331: ...bar 2 10 Nm 7 37 lbf ft 3 TBEI screw fastening the brake tank to the plate M6x20 1 10 Nm 7 37 lbf ft 4 Plate fixing screw M6x12 1 10 Nm 7 37 lbf ft 5 Screw fastening the brake pipe to steering base M6x25 1 10 Nm 7 37 lbf ft DORSODURO FACTORY ABS Braking system BRAK SYS 331 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 332: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 333: ...mp on handle bar 2 10 Nm 7 37 lbf ft 4 Screw fastening clutch control mounting on flywheel side crankcase half M6 1 10 Nm 7 37 lbf ft 5 TBEI tank fixing screw M5x10 1 6 Nm 4 42 lbf ft 6 TBEI plate fixing screw M6x12 1 10 Nm 7 37 lbf ft DORSODURO FACTORY ABS Clutch system CLU SYS 333 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 334: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 335: ...rame and radiator bracket to engine M6x25 2 10 Nm 7 37 lbf ft Electric fan Remove the radiator Undo and remove the three screws and collect the washers remove the electric fan See also Removing the radiator DORSODURO FACTORY ABS Cooling system COOL SYS 335 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 336: ...ve 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 fit the expansion tank cap Refit the front protection and tighten the screw Fit the right side fairing Cooling system DORSODURO FACTORY ABS COOL SYS 336 Manuals by Motomatrix www motomatrix co uk The Solut...

Page 337: ...ve input gear on shaft M6 1 12 Nm 8 85 lbf ft Loctite 244 5 Water pump rotor 1 4 50 Nm 3 32 lbf ft Removal COVER REMOVAL Drain off the cooling circuit completely Undo and remove the five screws Remove the water pump cover PUMP ROTOR REMOVAL Remove the clutch side cover Lock the pump shaft with a universal wrench on the hexagonal insert on the shaft DORSODURO FACTORY ABS Cooling system COOL SYS 337...

Page 338: ...ndicated CAUTION BEFORE TIGHTENING THE 3 SCREWS ENSURE THAT THE TOOL IS PERFECTLY CENTRED WITH THE SEAL AND THAT THE SCREWS ARE PERPENDICULAR TO THE SURFACE OF THE SEAL ITSELF TIGHTENING THE SCREWS INCORRECTLY MAY DAMAGE THE OIL SEAL UNDERNEATH THE WATER SEAL AND THE COVER IT SELF Fit the tool and use the specific punch to make 3 holes in the integrated seal Specific tooling 020661Y Water pump ove...

Page 339: ...using the appro priate tool to a depth of 2 mm 0 079 in determined by the tool relative to the upper part of the crankcase at the end of the flanged part of the seat orifice CAUTION AFTER INSTALLING THE OIL SEAL CHECK THAT THE WATER DRAINAGE HOLE UNDER THE OIL SEAL ITSELF IS NOT OBSTRUCTED Specific tooling 020885Y Water pump oil seal punch DORSODURO FACTORY ABS Cooling system COOL SYS 339 Manuals ...

Page 340: ... rotor drive gear fastener nut ap plying leverage on the hexagonal in sert on the gear itself Fit the rotor and tighten with the relative nut while preventing the pump shaft from turning with a spanner Cooling system DORSODURO FACTORY ABS COOL SYS 340 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 341: ... Undo and remove the screw Remove the filler Remove both clamps and slide off the corresponding pipes Disconnect the electric fan connector DORSODURO FACTORY ABS Cooling system COOL SYS 341 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 342: ... 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 Cooling system DORSODURO FACTORY ABS COOL SYS 342 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email ...

Page 343: ...n 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 FACTORY ABS Cooling system COOL SYS 343 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 344: ...INDEX OF TOPICS BODYWORK BODYW Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 345: ...2 10 Nm 7 37 lbf ft FRONT MUDGUARD pos Description Type Quantity Torque Notes 1 TBEI screw fastening fork guard to calliper mounting bracket M5x9 6 6 Nm 4 42 lbf ft Loct 243 DORSODURO FACTORY ABS Bodywork BODYW 345 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 346: ...I screw fastening front side pan els to tank M5x9 6 4 Nm 2 95 lbf ft 2 TBEI screw fastening front side pan els and duct to radiator M6x16 4 6 Nm 4 42 lbf ft 3 TBEI screw fastening ignition block cover to spacer M5x9 3 4 Nm 2 95 lbf ft Front tank fastener spacer M6 2 10 Nm 7 37 lbf ft Bodywork DORSODURO FACTORY ABS BODYW 346 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycl...

Page 347: ...cover to compartment M5 2 1 4 Nm 2 95 lbf ft 2 TBEI screw fastening battery com partment to saddle mounting M5x9 2 6 Nm 4 42 lbf ft DORSODURO FACTORY ABS Bodywork BODYW 347 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 348: ... BODYWORK 3 pos Description Type Quantity Torque Notes 1 TBEI screw fastening license plate mounting to mounting M5x9 3 6 Nm 4 42 lbf ft 2 Fastener for license plate mounting frame assembly to gusset plate saddle lock M6 4 10 Nm 7 37 lbf ft 3 Screw fastening license plate mount ing cover to license plate mounting 3 0 8 Nm 0 59 lbf ft Bodywork DORSODURO FACTORY ABS BODYW 348 Manuals by Motomatrix w...

Page 349: ...ing sad dle mounting to frame M8x60 1 25 Nm 18 44 lbf ft 3 Lower TCEI screw fastening Saddle mounting to frame M8x40 2 25 Nm 18 44 lbf ft TCEI screw fastening passenger grab handles to frame M8x80 4 30 Nm 22 13 lbf ft DORSODURO FACTORY ABS Bodywork BODYW 349 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 350: ...astener for front turn indicators M5 2 3 Nm 2 21 lbf ft 3 TCEI screw fastening headlamp mounting to fork yoke M6 3 10 Nm 7 37 lbf ft Operating from both sides undo and remove the front frame fixing screw and collect the nut Bodywork DORSODURO FACTORY ABS BODYW 350 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 351: ...from the right side Disconnect the front turn indicator ca ble harness Disconnect the headlamp connector and remove the headlamp assembly See also Instrument cluster support DORSODURO FACTORY ABS Bodywork BODYW 351 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 352: ...r for rear turn indicators M6 2 3 Nm 2 21 lbf ft 3 Reflector fastener M5 2 2 Nm 1 47 lbf ft 4 Fastener for license plate light M5 1 5 Nm 3 69 lbf ft Remove the license plate support Undo and remove the four screws Bodywork DORSODURO FACTORY ABS BODYW 352 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 353: ...ng from both sides undo and re move the screw Disconnect the taillight connectors Remove the taillight See also Tail guard DORSODURO FACTORY ABS Bodywork BODYW 353 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 354: ... passen ger footrests to rider footrest mount ing M8x35 2 25 Nm 18 44 lbf ft 3 TCEI screw fastening rider footrest mounting to frame M8x35 4 28 Nm 20 65 lbf ft Loctite 243 RIGHT FOOTREST Undo and remove the two external screws Bodywork DORSODURO FACTORY ABS BODYW 354 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 355: ...e two external screws Loosen the gear shift lever rod screw Slide off the gear shift lever rod Remove the left footrest Side body panels Unscrew and remove the screw DORSODURO FACTORY ABS Bodywork BODYW 355 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 356: ...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 Bodywork DORSODURO FACTORY ABS BODYW 356 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 357: ...Slide off the license plate holder to wards the back See also Seat Tail guard Air box DORSODURO FACTORY ABS Bodywork BODYW 357 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 358: ...ft 4 Cross head self tapping screw fas tening lateral cap filter box M5x20 3 3 Nm 2 21 lbf ft Cross head self tapping screw M5x10 2 3 Nm 2 21 lbf ft Remove the air filter Slide off the electrical components fas tened to the air filter box Undo and remove the eight screws Undo and remove the inner screw Unscrew and remove the screw Bodywork DORSODURO FACTORY ABS BODYW 358 Manuals by Motomatrix www ...

Page 359: ...ndo and remove the two screws after loosening the front and rear manifold clamps Loosen the clamp to slide off the bleed pipe DORSODURO FACTORY ABS Bodywork BODYW 359 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 360: ...rol 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 FACTORY ABS BODYW 360 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 361: ...erature to 90 C 194 F or above b front cylinder throttle valve correction between 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 fi...

Page 362: ... CRUSH BEND OR SLIDE OFF TANK BREATHERS FROM THE CORRESPONDING TUBE GUIDES LIFTING THE FUEL TANK Remove the saddle Remove both side fairings Undo and remove the two tank front screws See also Side body panels TANK REMOVAL Undo and remove the rear screw Remove the rubber ring on the ignition lock Bodywork DORSODURO FACTORY ABS BODYW 362 Manuals by Motomatrix www motomatrix co uk The Solution For Lo...

Page 363: ...NTION WHEN LIFTING THE TANK SINCE IF BREATHER PIPES ARE NOT ACCOMPANIED THEY MAY TEAR Insert a pin in the rear fixing screw hole so that you can lift the tank and be able to disconnect the breather pipes Disconnect the fuel pipe DORSODURO FACTORY ABS Bodywork BODYW 363 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 364: ...g to the new standard following the refitting procedure OPTION 02 Disconnect the breather pipes from the tank Release the cable harness from the clamps Bodywork DORSODURO FACTORY ABS BODYW 364 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 365: ...USLY FITTED AND TO DRAW THE TANK BACKWARD AS MUCH AS POSSIBLE IN ORDER TO FIT IT PROPERLY 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 DORSODURO FACTORY ABS Bodywork BODYW 365 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 366: ...pport Disconnect the instrument panel con nector Remove the instrument panel Radiator cover Working from both sides undo and re move the screw Bodywork DORSODURO FACTORY ABS BODYW 366 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 367: ...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 FACTORY ABS Bodywork BODYW 367 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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

Page 369: ...PRE DELIVERY PRE DE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 370: ...m lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Electric start up Engine stop via emergency stop switch ...

Page 371: ... AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK MEDICAL ATTENTION IMMEDIATELY BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHI...

Page 372: ...f brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BUR...

Page 373: ...with a TCEI M8x35 mm screw at the bottom NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE THE SPECIFIC WRENCH WARNING OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL RH Remove the rubber cap DORSODURO FACTORY ABS Pre delivery PRE DE 373 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 374: ...h 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 FACTORY ABS PRE DE 374 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 375: ... 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 FACTORY ABS Pre delivery PRE DE 375 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 376: ...view mirror screwing the corresponding support column NOTE PERFORM THE SAME PROCEDURE FOR BOTH HAND GUARDS Pre delivery DORSODURO FACTORY ABS PRE DE 376 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 377: ...Coolant 336 342 Crankcase 53 187 234 235 244 247 Crankshaft 53 234 243 245 247 Cylinder 52 207 208 213 222 224 225 228 232 243 D Drive chain 14 304 E ECU 163 320 Electric fan 160 335 Electrical system 14 89 92 370 Engine oil 73 Engine temperature sensor 133 Exhaust 307 309 Exhaust manifold 309 F Filter box Fork 274 276 283 Front wheel 271 273 Fuel 264 361 Fuel pump 264 Fuses 114 G Gearbox selector...

Page 378: ... 341 366 Rear wheel 296 298 304 Recommended products 57 Ride by wire 265 Run Stop switch 162 S Saddle Saddle mounting Shock absorbers 300 Side stand 158 Side stand sensor 158 Spark plug 70 Spark plugs Speed sensor 118 Stand 158 306 Starter motor 189 190 T Tank 342 361 Throttle body 144 267 Transmission 13 Tyres 15 W Warning lights Water pump 337 Wiring diagram 106 Manuals by Motomatrix www motomat...

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