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APRILIA SHIVER 900, Service Station Manual

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INDEX OF TOPICS

C

HARACTERISTICS

CHAR

S

PECIAL

 

TOOLS

S-TOOLS

M

AINTENANCE

MAIN

E

LECTRICAL

 

SYSTEM

ELE SYS

E

NGINE

 

FROM

 

VEHICLE

ENG VE

E

NGINE

ENG

P

OWER

 

SUPPLY

P SUPP

S

USPENSIONS

SUSP

C

HASSIS

CHAS

B

RAKING

 

SYSTEM

BRAK SYS

C

LUTCH

 

SYSTEM

CLU SYS

C

OOLING

 

SYSTEM

COOL SYS

B

ODYWORK

BODYW

P

RE

-

DELIVERY

PRE DE

Summary of Contents for SHIVER 900

Page 1: ...SERVICE STATION MANUAL 2Q000335 SHIVER 900...

Page 2: ...tself All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes on...

Page 3: ...d changes in repair procedures are communicated to all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of nee...

Page 4: ......

Page 5: ...OLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS CLUTCH SYSTEM CLU SYS COOLING SYS...

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

Page 7: ...NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot parts The engine and the exhaust system components get very hot and remain in this condition for a certain time in...

Page 8: ...WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE B...

Page 9: ...ith lubricant and consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start either from the components with the largest diameter or fr...

Page 10: ...AT WOULD COMPROMISE MA NOEUVRABILITY LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and function...

Page 11: ...OID IF THE VEHICLE IDENTIFICATION NUMBER VIN HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED This number consists of numbers and letters as in the example shown below ZD4RKH000YSXXXXXX KEY ZD4 WMI World...

Page 12: ...ine idle speed 1450 100 rpm Rpm of the engine at full power 8750 100 rpm Clutch Multi plate wet clutch with mechanical control lever on left side of the handlebar Lubrication Wet crankcase Pressure fe...

Page 13: ...6000 rpm Ignition Electronic inductive high efficiency ignition integrated with the injection system with variable advance and separate H V coil Ignition advance Three dimensional map managed by cont...

Page 14: ...and adjustable hydraulic monoshock Travel 43 1 mm 1 69 0 039 in SIZES A AND B Specification Desc Quantity Size A mm in Size B mm in Brakes BRAKES Specification Desc Quantity Front Double floating dis...

Page 15: ...Unleaded petrol max E10 95 RON Tightening Torques If the following tables do not expressly indicate the tightening torque values refer to the table with the generic torque values indicated below GENER...

Page 16: ...lb ft 2 Button head hex socket screws used to fasten the direction indica tors M5x16 2 3 Nm 2 21 lb ft 3 Self locking flanged direction indica tor fastening nuts M5 2 2 Nm 1 48 lb ft 4 Flanged self l...

Page 17: ...luster and cover to the support plate 5x14 3 3 Nm 2 21 lb ft 3 Button head hex socket screws for fastening the steering plate to the in strument panel plate M6x16 2 10 Nm 7 38 lb ft 4 Special screws f...

Page 18: ...tening the upper U bolt to the lower U bolt M8x25 4 25 Nm 18 44 lb ft 2 Electronic accelerator control fasten ing screws 1 4 Nm 2 95 lb ft 3 Light switch fastening screws 2 1 5 Nm 1 11 lb ft 4 Cyl hea...

Page 19: ...hex socket screws used for fastening the clutch actuator cylinder M6x75 1 8 Nm 5 90 lb ft Perform two tight ening cycles 5 Countersunk hex socket screws used for fastening the clutch actuator cylinde...

Page 20: ...steering plate fasten ing nut tightening M22 1 25 Nm 18 44 lb ft 3 Cyl head hex socket screws used for fastening the fork stanchions to the upper plate M8x30 2 25 Nm 18 44 lb ft 4 Low profile cyl head...

Page 21: ...orque Notes 1 Flanged hex head screws used for closing the fork feet M6x40 4 10 Nm 7 38 lb ft 2 Button head hex socket screws used for fastening the sensor to the right hand fork foot M5x16 1 6 Nm 4 4...

Page 22: ...4 4 Nm 2 95 lb ft Loct 243 2 Button head hex socket screws for fastening the engine fairing to the support M6x20 4 10 Nm 7 38 lb ft FRONT WHEEL Pos Description Type Quantity Torque Notes 1 Wheel axle...

Page 23: ...y Torque Notes 1 Flanged hex head screws for fas tening the brake callipers to the fork stanchions M10x1 25 4 50 Nm 36 88 lb ft 2 Special screws for fastening the brake pipe to the callipers M10 2 25...

Page 24: ...Description Type Quantity Torque Notes 1 Cyl head hex socket screws used for fastening the side fairings to the engine M12x282 3 80 Nm 59 00 lb ft 2 TORX cyl head screws used for fas tening the trelli...

Page 25: ...or fastening the rider s footrest sup port to the frame plates M8x25 4 18 Nm 13 28 lb ft Loct 243 3 Button head hex socket screws used for fastening the luggage rack to the rider s footrest support M6...

Page 26: ...astening the stand to the plate M10x1 25 1 10 Nm 7 38 lb ft 3 Low profile nut used for fastening the stand to the plate M10x1 25 1 30 Nm 22 13 lb ft 4 Cyl head hex socket screws used for fastening the...

Page 27: ...crews used to fasten the saddle lock to the saddle M6x25 2 10 Nm 7 38 lb ft 4 Cyl head hex socket screws used to fasten the filler cap to the fuel tank M5x16 4 5 Nm 3 69 lb ft 5 Cyl head hex socket sc...

Page 28: ...2 Button head hex socket block lid fuel tank cover fastening screws M5x9 2 10 Nm 7 38 lb ft 3 Button head hex socket fuel tank cover fastening screws M5x9 8 4 Nm 2 95 lb ft 4 Cyl head hex socket rear...

Page 29: ...K pos Description Type Quantity Torque Notes 1 Flanged hex head front fuel tank fastening screws M6x30 2 6 Nm 4 43 lb ft 2 Fuel pump fastening nuts M5 6 6 Nm 4 43 lb ft SHIVER 900 Characteristics CHAR...

Page 30: ...0 3 2 Nm 1 48 lb ft 6 SWP wiring harness support bracket fastening screws 5x20 3 2 Nm 1 48 lb ft 7 SWP control unit cover fastening screws 3 9x14 2 2 Nm 1 48 lb ft 8 SWP control unit support fastening...

Page 31: ...crews used to fasten the duct covers to the radiator M6x16 2 7 Nm 5 16 lb ft 4 Button head hex socket screws for fastening the conveyors to the tank M5x10 2 4 Nm 2 95 lb ft 5 Button head hex socket sc...

Page 32: ...0 Nm 7 38 lb ft 2 Flanged hex head screw used for fastening the trellis radiator M6x25 1 10 Nm 7 38 lb ft 3 Button cyl head screw used for fas tening the electric fan to the radiator 4 2x20 3 3 Nm 2 2...

Page 33: ...ft 6 Flanged hex head screws for fas tening the spacer plate on the frame plate M8x25 1 25 Nm 18 44 lb ft Loct 243 7 Cyl head hex socket screws used for fastening the pipes under the steering headstoc...

Page 34: ...VAPOUR RECOVERY SYSTEM Pos Description Type Quantity Torque Notes 1 Cyl head hex socket screws used for fastening the pinion cover guard M6x25 2 4 Nm 2 95 lb ft Back side Characteristics SHIVER 900 C...

Page 35: ...x socket screws used for fastening the chain guard on the chain guide shoe M6x35 2 10 Nm 7 38 lb ft 6 Wheel axle nut M25x1 5 1 120 Nm 88 51 lb ft 7 Chain tensioner adjustment screws 2 Manual 8 Flanged...

Page 36: ...pport M5x16 1 6 Nm 4 43 lb ft 3 DAX nut for fastening the crown gear on the hub M10x1 25 5 50 Nm 36 88 lb ft 4 Cyl head hex socket screws used for fastening the cush to the wheel M10x30 5 50 Nm 36 88...

Page 37: ...shaft fork M6 1 10 Nm 7 38 lb ft 4 Cyl head hex socket screws used for fastening the pump to the footrest support M6x16 2 10 Nm 7 38 lb ft 5 Special brake pipe coupling fasten ing screw M10x1 1 10 Nm...

Page 38: ...Type Quantity Torque Notes 1 Special brake pipe coupling fasten ing screw M10x1 1 10 Nm 7 38 lb ft 2 Button head hex socket screws used for fastening the brake pipe pro tection M5x9 1 4 Nm 2 95 lb ft...

Page 39: ...4 Button head hex socket screws used for fastening the number plate holder to the number plate holder support M5x9 3 4 Nm 2 95 lb ft 5 Flanged hex head screws used for fastening the grab bar support...

Page 40: ...2 5 Nm 9 22 lb ft 3 Cyl head hex socket screws used for fastening the shock absorber pro tection M4x6 2 3 Nm 2 21 lb ft 4 Manifold fastening clamps M6 2 7 Nm 5 16 lb ft 5 Terminal fastening clamp M6 1...

Page 41: ...R ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes 1 Button head hex socket screw used for fastening the anti rollover sensor M5x35 1 3 Nm 2 21 lb ft Engine SHIVER 900 Characteristics CHAR...

Page 42: ...Special head cover fastening screw M6 8 9 Nm 6 64 lb ft TIMING SYSTEM Pos Description Type Quantity Torque Notes 1 Cam shaft gear fastening nut M15x1 4 88 Nm 64 91 lb ft Thoroughly de grease both of t...

Page 43: ...53 or Loct DRI LOC 2045 BLUE HEAD Pos Description Type Quantity Torque Notes 1 Water Temperature Sensor M12x1 5 1 20 Nm 14 75 lb ft 2 Threaded plug M12x1 5 1 10 Nm 7 38 lb ft Loct drise AL 506 3 Nut f...

Page 44: ...21 lb ft Loct 262 CYLINDER Pos Description Type Quantity Torque Notes 1 Chain tensioner fastener screw M6x30 4 13 Nm 9 59 lb ft 2 Cylinder plate fastening screw M6x16 4 9 Nm 6 64 lb ft 3 Chain tensio...

Page 45: ...iller cap on clutch cover M25x1 25 1 2 Nm 1 48 lb ft 4 Clutch Control Plate Support coun tersunk hex head fastening screw M5x12 3 5 Nm 3 69 lb ft 3M SCOTCH GRIP 2353 5 Flywheel side clutch control sup...

Page 46: ...Clutch cover clutch side half crankcase fastening screw M6x60 2 13 Nm 9 59 lb ft 4 Water pump control crown fastening nut M6 1 12 Nm 8 85 lb ft Loct 244 5 Water pump impeller brass insert M6 1 4 Nm 2...

Page 47: ...fastening screw Flywheel cover M6x30 3 9 Nm 6 64 lb ft 5 Pick up fastening screw Flywheel cover M5x14 2 3 Nm 2 21 lb ft Loct 270 6 Flywheel cover fastening screw M6x30 10 13 Nm 9 59 lb ft 7 Crankshaf...

Page 48: ...e Quantity Torque Notes 1 Half crankcase coupling screw M8x80 9 28 Nm 20 65 lb ft 2 Half crankcase coupling screw M6x65 8 13 Nm 9 59 lb ft 3 Special oil calibration screw M10x1 1 14 Nm 10 33 lb ft Cha...

Page 49: ...UBRICATION Pos Description Type Quantity Torque Notes 1 Oil drainage plug M16x1 5 1 17 Nm 12 54 lb ft 15 2 Oil pressure sensor M10x1 1 13 Nm 9 59 lb ft 3 Fitting fixing of the oil filter 1 20 Nm 14 75...

Page 50: ...te fastening screw M5x12 3 5 Nm 3 69 lb ft 3M SCOTCH GRIP 2353 3 Desmodromic drum sprocket fasten ing screw M8x1 25x17 1 15 Nm 11 06 lb ft 3M SCOTCH GRIP 2353 4 Selector pin fastening screw M10x1 5 1...

Page 51: ...assy The pistons are available in four size types A B C D to be coupled to the four cylinder types A B C D Only one type of piston ring is available PISTON CYLINDER COUPLING Specification Desc Quanti...

Page 52: ...960 mm 2 1241 2 1244 in Crankcase class 2 Bearing housing diameter 53 960 53 966 mm 2 1244 2 1246 in CRANKSHAFT There are three crankshaft selection classes for each capacity 4 5 6 for the flywheel si...

Page 53: ...n the centre distance between the primary reduction gears The categories are indicated on the clutch side half crankcase in the area of the gearshift control devices NOTE IF THE CRANKCASE IS REPLACED...

Page 54: ...lf bearings E green Shaft class 1 Half bearings A red Shaft class 2 Half bearings B blue Shaft class 3 Half bearings C yellow CONNECTING RODS Spare parts are not available for all the weight classes b...

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

Page 56: ...Description 020709Y Engine support 020710Y Engine plate AP8140187 U bolt for motor support 020850Y Primary gear lock 020712Y Handle for removing the flywheel cover 020713Y Flywheel extractor Special t...

Page 57: ...4Y Dial gauge mount 9100896 Clutch bell stopper 020716Y Connecting stem lock 020470Y Pin snap ring fitting tool AP8140302 tool for installing seal rings 020718Y Camshaft gearwheel alignment pin SHIVER...

Page 58: ...on 020719Y Timing pin 020720Y Timing tool AP8140179 Valve springs compressor 020721Y Valve removal adaptor 020376Y Adaptor handle 020629Y 8 mm guide 0 31 in 020412Y 15mm oil seal guide Special tools S...

Page 59: ...de Description 020439Y 17mm oil seal guide 020263Y Driven pulley assembly sheath 020365Y 22 mm guide 0 87 in 020364Y 25 mm guide 020483Y 30 mm guide 020441Y Oil seals punch SHIVER 900 Special tools S...

Page 60: ...x 40 mm Adaptor 020357Y 32 x 35 mm Adaptor 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55 mm Adaptor 020724Y Punch cage with rollers gearbox control stem 020726Y Bushing extractor 020727Y Bushing punch S...

Page 61: ...ench for steering ferrule AP8140180 Bearing extractor AP8140199 Tool storage panel 8140426 Hooks for panel FORK Stores code Description AP8140149 Guard for assembly operations 020888Y Pre load pipe cl...

Page 62: ...diameter hole AP8140146 Weight AP8140150 Bored shaft for bleeding plunger air CAUTION BEFORE USING THE PRIMARY GEARWHEEL LOCK TOOL 020850Y IT IS NECESSARY TO MAKE THREE HOLES SO THAT IT MAY BE POSITIO...

Page 63: ...SHIVER 900 Special tools S TOOLS 63...

Page 64: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 65: ...0 24 9 EVERY 12 MONTH S EVERY 24 MONTH S Rear shock absorber bearings I I I I Spark plug R R Drive chain 1 I I I I I Steering bearings and steering clearance I I I I I Wheel bearings Wheels I I I I Di...

Page 66: ...I I Wheel bearings Wheels I I Diagnosis by tool I I I I I Brake discs Brake pads wear 8 I I I Air filter I R I R Engine oil filter R R R Fork I I General operation of the vehicle I I I Valve clearance...

Page 67: ...E J 1703 FMVSS 116 ISO 4925 CU NA NC 956 DOT4 Anti freeze liquid ready to use colour red Ethylene glycol antifreeze liquid with or ganic inhibition additives Red ready to use ASTM D 3306 ASTM D 4656 A...

Page 68: ...th a suitable key tighten by performing a 1 2 turn to each spark plug to compress the washer Loosen and tighten again the spark plug to the specified torque CAUTION TIGHTEN THE SPARK PLUG CORRECTLY OT...

Page 69: ...AD OR FOR TRACK USE THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE...

Page 70: ...m 244 cu in 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 completely...

Page 71: ...r Remove the fuel tank Disconnect the vapour recovery tube Disconnect the air temperature sensor Remove the eight screws fixing the air filter cover Remove the filter case cover SHIVER 900 Maintenance...

Page 72: ...D BY A FAULTY OR MISPLACED FILTER ELEMENT REFITTING When replacing pay attention to the introduction of the intake ducts making sure that the bayonet plug is snapped after each duct is inserted and ro...

Page 73: ...ving the 8 fastening screws in the order indicated on the cam tower itself Secure the cam shafts in position using the dedicated timing pins Specific tooling 020719Y Timing pin Remove one cam shaft at...

Page 74: ...2 70 6 Calibrated pad 2 75 7 Calibrated pad 2 80 8 Calibrated pad 2 85 9 Calibrated pad 2 90 10 Calibrated pad 2 95 11 Calibrated pad 3 00 12 Calibrated pad 3 05 13 Calibrated pad 3 10 14 Calibrated p...

Page 75: ...AND THE GASKET EACH TIME THE BIG END COVER IS REMOVED Apply THREEBOND around the perim eter of the big end cover along the gasket housings Apply THREEBOND to the head at the points indicated in figure...

Page 76: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 77: ...lb ft 2 Flanged SWP screws for fastening the control unit to the base of the filter box M5x20 4 2 5 Nm 1 84 lb ft 3 Screws used for fastening the coils to the heads M6 2 5 Nm 3 69 lb ft 4 Nut used for...

Page 78: ...AR ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes 1 Button head hex socket screw used for fastening the anti rollover sensor M5x35 1 3 Nm 2 21 lb ft Electrical system SHIVER 900 ELE SYS...

Page 79: ...Components arrangement Key 1 Engine speed sensor 2 intake air pressure sensor 3 Intake air temperature sensor 4 Instrument panel SHIVER 900 Electrical system ELE SYS 79...

Page 80: ...ION OF THE COLOUR OF THE RELAY CABLES RELAY LAYOUT Location of the component in the electrical circuit diagram Component name Position on the vehicle 7 High beam lights relay Right front side of the f...

Page 81: ...ABLE O2 5 Voltage regulator connector CENTRAL SECTION TABLE M2 M3 6 Front cylinder coil and rear cylinder coil connectors ENGINE TABLE A12 7 Main wiring harness connector CENTRAL SECTION TABLE A1 8 Co...

Page 82: ...LIGHT SWITCH RIDE BY WIRE The wiring harnesses must be routed to the left of the steering headstocks in particular column switch wiring har nesses must subsequently be routed underneath the headstock...

Page 83: ...mp 9 secure the various wiring harnesses as indicated and then position the connectors assembly under the steering headstock inside the frame TABLE A4 COLUMN LIGHT SWITCH RIDE BY WIRE The Ride By Wire...

Page 84: ...witch wiring harness 2 must be routed over the column switch wiring harness and the brake clutch pipes TABLE B1 INSTRUMENT PANEL The front indicator cables 3 must be routed as shown in the photo in or...

Page 85: ...TRUMENT PANEL Position a clamp 8 on the instrument panel in order to fasten the various wir ing harnesses TABLE B4 INSTRUMENT PANEL After connecting the ambient air tem perature sensor the USB option...

Page 86: ...ten the ABS sensor 3 wiring harness 2 and route it through the hole on the right hand fork foot TABLE C1 FRONT ABS SENSOR Fasten the ABS sensor wiring harness at the rear mudguard fastening point usin...

Page 87: ...ABS SENSOR Check that the front ABS sensor con nector is inserted correctly and cou pled to the respective support posi tioned under the filter box Central part CAUTION THE FOLLOWING IMAGES ILLUSTRATE...

Page 88: ...d side of the motorcycle engine as indicated TABLE A1 MAIN WIRING HARNESS ENGINE WIRING HARNESS The connector that units main wiring harness 1 with the engine wiring har ness 2 must be inserted correc...

Page 89: ...e engine wiring harness 2 using a clamp 3 at the point indicated by the grey tape TABLE A3 MAIN WIRING HARNESS ENGINE WIRING HARNESS Secure the main wiring harness 1 us ing two clamps 4 on the cannist...

Page 90: ...and side of the filter box in accordance with the coloured reference indicators The highbeam headlight relay 1 identified by the white tape must be secured to the respective fastening point using the...

Page 91: ...lectric washers 2 and secured using serrated washer applying the pre defined torque TABLE D1 STARTER MOTOR CABLE Cover the starter motor nut and the square terminal using water repellent dielectric gr...

Page 92: ...as indicated in the figures TABLE G1 PROCEDURE FITTING THE ABS CONTROL UNIT CONNECTOR CORRECTLY Place the connector on the opposite side of the control unit and lower the driving lever until the click...

Page 93: ...ment will be greater approx 12 mm In this case repeat the operation de scribed in TABLES G1 G2 We recommend creating a template in order to ensure that the connector is inserted correctly TABLE H ABS...

Page 94: ...ipes as indicated TABLE I OIL TEMPERATURE SENSOR Connect the oil temperature sensor connector 1 to the corresponding connector on the intermediate wiring harness 2 and attach it to the dedica ted supp...

Page 95: ...d support mounted on the base of the filter box TABLE L FAN Connect the fan connector to the water radiator using a large clamp TABLE M VOLTAGE REGULATOR TIMING SENSOR After fastening the voltage regu...

Page 96: ...sses must be routed internally through the frame as indicated TABLE M2 VOLTAGE REGULATOR TIMING SENSOR The timing sensor regulator connector must be connected correctly and fas tened to the support 5...

Page 97: ...sor regulator connector TABLE N HORN The horn must be fastened to its sup port bracket and once its connectors have been inserted must not be in con tact with any other component TABLE O SIDE STAND A...

Page 98: ...4 wiring harness using a clamp 3 TABLE O2 SIDE STAND Check that the side stand connector 5 is connected correctly and fasten the wiring harness to the flywheel wiring harness cable clamp using a clamp...

Page 99: ...re installed on the ABS control unit support TABLE P1 FRONT LAMBDA PROBE Using a clip 2 fasten the lambda probe wiring harness to the ABS con trol unit support TABLE P2 FRONT LAMBDA PROBE Using a clip...

Page 100: ...addle support frame Back side TABLE A REAR BRAKE SWITCH REAR ABS SENSOR Secure the rear ABS sensor wiring har ness 1 using the cable clamp 2 mounted on the brake calliper support TABLE A1 REAR BRAKE S...

Page 101: ...ing the clamps 6 TABLE A3 REAR BRAKE SWITCH REAR ABS SENSOR Check that the rear ABS sensor con nector is connected securely and posi tioned underneath the main wiring harness TABLE B MAIN SADDLE SUPPO...

Page 102: ...Check that the two screws used for fastening the cables are secured cor rectly Failure to secure them correctly may result in fires and vehicle malfunc tions TABLE D SADDLE SUPPORT ZONE Position a la...

Page 103: ...rab bar using a clamp 4 TABLE D2 SADDLE SUPPORT ZONE Position the fall sensor 5 and after connecting the connector close all the connectors that were positioned earli er TABLE D3 SADDLE SUPPORT ZONE I...

Page 104: ...ctor 12 in the respective housings TABLE D5 SADDLE SUPPORT ZONE After positioning the relay on its base and connecting it bend the cables that leave the connector by 90 in order to create an S as illu...

Page 105: ...e using two clamps TABLE E1 NUMBER PLATE HOLDER Make sure that the anti vibration foam is fitted on the number plate light Engine TABLE A ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX Fasten t...

Page 106: ...inder pressure sensors 5 and the throttle body connectors 6 CAUTION THE FRONT THROTTLE BODY AND FRONT CYLINDER PRESSURE SENSOR WIRING HARNESSES ARE MARKED WITH THE INDICATION FRONT WHILE THE REAR THR...

Page 107: ...ct the coil wiring harnesses to the filter box using the clamps 10 positioned at the points indicated by the grey tape CAUTION THE CLAMPS POSITIONED ON THE LOWER PART OF THE FILTER BOX MUST BE MOUNTED...

Page 108: ...OTTLE BODY AND FILTER BOX After reassembling the filter box com plete with air filter and intake ducts and before inserting it connect the water temperature sensor connector 13 TABLE A12 ENGINE WIRING...

Page 109: ...ss 15 under the tab on the control unit sup port box TABLE A14 ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX Connect control unit connectors 16 and apply a clamp 17 on the small connector so t...

Page 110: ...ILTER BOX After connecting the gear sensor con nector 18 attach it to the support on the base of the filter box 19 Using a clamp 20 fasten the fly wheel gear sensor and side stand switch wiring harnes...

Page 111: ...General wiring diagram Key 1 MULTIPLE CONNECTORS 2 FRONT RIGHT TURN INDICATOR 3 COMPLETE HEADLAMP 4 FRONT LEFT TURN INDICATOR SHIVER 900 Electrical system ELE SYS 111...

Page 112: ...DICATOR 20 REAR RIGHT TURN INDICATOR 21 LICENCE PLATE LIGHT 22 TAILLIGHT 23 INSTRUMENT PANEL FUSE 24 SECONDARY FUSES 25 ABS CONTROL UNIT 26 FRONT ABS SENSOR 27 REAR ABS SENSOR 28 VOLTAGE REGULATOR 29...

Page 113: ...ATURE SENSOR 54 7SM ENGINE CONTROL UNIT 55 HANDLE POSITION SENSOR 56 ENGINE SPEED SENSOR 57 FRONT CYLINDER COIL 58 REAR CYLINDER COIL 59 SPARK PLUG 60 FRONT CYLINDER INJECTOR 61 REAR CYLINDER INJECTOR...

Page 114: ...t 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...

Page 115: ...the resistance in the circuit is zero or of a few tenths of an Ohm IMPORTANT WHERE GROUND IS PROVIDED BY THE ECU CHECK THAT THE ECU IS EFFEC TIVELY PROVIDING THE GROUND CONNECTION FOR THE CIRCUIT DURI...

Page 116: ...ror cause Key transponder does not communicate its own code Troubleshooting Replace the key B0005 Immobilizer fault Immobilizer fault aerial not working open or short circuited Error cause An electric...

Page 117: ...ur you must connect the motorcycle to the diagnostic tool Turn key to ON and insert the USER CODE where required Carry out the self diagnosis of the dashboard and enter the SETTINGS section by clickin...

Page 118: ...TOOL WILL SHOW AN ERROR SAYING 1 KEY STORED The second key is stored and you will be asked to enter the third key if you have one The same operation will be repeated to store the fourth key To comple...

Page 119: ...CTIVATIONS Enable the command SERVICE RE SET Battery recharge circuit RECHARGING SYSTEM Remove the tank and the filter casing Disconnect the three way connector 1 white NOTE THE ENGINE SIDE IS IDENTIF...

Page 120: ...y touching the two lugs Example Resistance of stage 1 read on the display 0 65 Ohm Resistance of the wires read on the display 0 47 Ohm Effective resistance stage 1 0 65 0 47 0 18 Ohm If there is a si...

Page 121: ...LESS THAN THOSE DETECTED WITH THE ENGINE COLD EMPTY VOLTAGE rpm 2000 6000 8000 Vm linked voltage Reference values V rms 20 30 75 85 95 105 Short circuit current For a correct detection of the short ci...

Page 122: ...RE NO ELEMENTS IN THE SHORT CIR CUIT Start up system check Function Communicates to the control unit the will to start up the engine Operation Operating principle Press the start up button to close th...

Page 123: ...o positive excessive voltage identified at PIN 69 at the command time If open circuit short circuit to negative a voltage close to zero was identified when there is no command to the start up relay DI...

Page 124: ...OR SHORT CIRCUITS AND THE RISK OF FIRE NOTE A FUSE THAT BLOWS FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD SECONDARY FUSES Before replacing the fuse find if possible the cause of the problem T...

Page 125: ...are placed in the central part of the motorcycle under the rider saddle MAIN FUSES To check the main fuse H Remove the protective cover 3 un screwing the two screws 4 Remove the protective cover take...

Page 126: ...e Control unit To remove the control unit refer to chapter Bodywork Air filter housing section CONTROL UNIT Diagnosis Function It manages the Ride by wire system the injection ignition the system safe...

Page 127: ...rcent Lambda probe voltage indicates the value of the lambda probe voltage Atmospheric pressure indicates the atmospheric pressure Objective minimum speed minimum rpm required by the control unit Step...

Page 128: ...dlights relay activates the headlight relay DIAGNOSTIC TOOL ADJUSTMENTS Self adaptive param reset self adaptive parameter reset Saved data download save data files download TPS reset DIAGNOSTIC TOOL E...

Page 129: ...OWN DIAGNOSTIC TOOL LOGIC ERRORS P160C Level 2 safety reset Error cause Due to the fact that the level 2 safety system comparison between requested torque and calculated torque detected a fault the co...

Page 130: ...detected errors P1650 Engine events configuration Checksum calculation error Error cause Corrupt Flash eeprom hardware problem Upload e g in service of an incompatible software version therefore miss...

Page 131: ...Positive pole red approx 12 6 V 2 negative pole black ground lead DIAGNOSTIC TOOL PARAMETERS Battery voltage Example value with key ON 12 0 V Example value with engine on 14 2 V This is one of the va...

Page 132: ...at the voltage regulator is working correctly P1560 Low battery voltage error GCC error Functional diagnosis low voltage Error cause The error is enabled if after 5 seconds from the key to ON the batt...

Page 133: ...ensor or wiring 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...

Page 134: ...e sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the spe...

Page 135: ...l unit diagnosis REAR ABS VEHICLE SENSOR Function Generates a signal used by the ABS control unit to determine the speed value of the wheel Operation Operating principle Magneto resistive sensor gener...

Page 136: ...ORS Engine speed sensor 5DA1 the signal changes in intermittent manner faulty sensor or signal interference Troubleshooting Check speed sensor retainer If it is not OK restore it If it is OK check if...

Page 137: ...shooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone whe...

Page 138: ...CONTROL UNIT AND RPM SENSOR CONNECTORS CHECK PROCEDURE IF THE CONNECTORS ARE NOT OK REPAIR OR REPLACE THEM AS NECESSARY IF THEY ARE OK CHECK THE SENSOR CONFORMS TO THE ELECTRICAL SPEC IFICATIONS IF NE...

Page 139: ...d magnetically controlled contactless it cannot be overhauled or replaced Level in electrical circuit diagram Check of the throttle valves and handle sensor Position on the vehicle integrated in the h...

Page 140: ...continuity is present replace the control unit if not present replace the wiring harness P2130 Track B handle position sensor Electrical diagnosis short circuit to positive open circuit short circuit...

Page 141: ...track B must be comprised between 0 5 V gas throttle completely closed and 2 V gas throttle completely open If one of these values differs significantly from the indicated value it means that the pot...

Page 142: ...AL ERRORS P0105 Front cylinder air pressure sensor Electrical diagnosis short circuit to positive open circuit short circuit to negative signal not plausible Error cause Short circuit to positive exce...

Page 143: ...ECU This error is indicated by lighting up in a fixed manner the MI warning light Troubleshooting Short circuit to positive verify that the parameter of the rear cylinder air Pressure Sensor on the di...

Page 144: ...between the estimated pressure and the measured pressure the measured pressure is higher than the estimated one for example the pipe between sensor and throttle body is squashed or there is a hole in...

Page 145: ...e 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 a very evident defect in the...

Page 146: ...re to the control unit in order to optimise performance Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in electrical circuit diagram Temperat...

Page 147: ...OK check for continuity between the ENGINE con nector PIN 6 or 17 and the sensor connector PIN 1 restore the cable harness if there is not continuity If there is it means that the control unit does no...

Page 148: ...5 C 77 F 10 0 k 5 Pin out 1 0 5 V signal 2 Ground DIAGNOSTIC TOOL PARAMETERS Air temperature Example value with key ON 26 C 78 8 F This is one of the values set by the ECU in the event of recovery mod...

Page 149: ...i control unit connector If not OK restore the cable harness If OK check for continuity between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2 restore the cable harness if there is no...

Page 150: ...deactivation of it This diagnosis is activated when the correction constantly arrives 25 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECT...

Page 151: ...rcuit short circuit to negative a voltage equal to zero was detected at PIN 32 of the ENGINE connector The instrument panel indicates this error by lighting up in a fixed manner the MI warning light T...

Page 152: ...etect the following malfunctions of the lambda probe circuit relative to the signal interrupted circuit short circuit to ground or malfunction of the sensor for ex ample voltage not variable If the in...

Page 153: ...OL IN CLOSED LOOP REAR CYLINDER Function In charge of telling the control unit whether the mixture is lean or rich Operation Operating principle The Marelli injection control unit reads and interprets...

Page 154: ...OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Lambda probe Start up_Lean_Rich_Fault due to rich titre_Fault due to lean air fuel mixture If the probe conn...

Page 155: ...d cable If open circuit short circuit to negative check the continuity from the probe connector PIN 3 and 4 to the probe if NOT OK replace the probe if ok perform the check procedure for the sensor co...

Page 156: ...a certain adjusted number of dead points PMS or TDC If no switching from low is shown when the ratio control is in closed loop and when the secondary air valve is not operating The error is validated...

Page 157: ...ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL ACTIVATIONS Front cylinder injector The secondary injection relay no 35 in the el...

Page 158: ...if there is voltage on the grey red cable on the injector connector if there is restore the wiring harness of the filter housing if not replace the sensor If short circuit to negative disconnect the i...

Page 159: ...store the wiring harness Fuel pump Function Fuel pump keeps pressure of the injectors supply duct Low fuel tells to the instrument panel about low fuel Operation Operating principle Low fuel it is a r...

Page 160: ...are generated in case of no activation DIAGNOSTIC TOOL ELECTRICAL ERRORS Fuel pump relay command P0230 short circuit to positive open circuit short circuit to negative Error cause Short circuit to po...

Page 161: ...take place CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRI...

Page 162: ...it to positive disconnect the coil connector turn the key to ON activate the coil with the diagnostic tool and check the voltage at PIN 28 of the connector if there is voltage restore the wiring harne...

Page 163: ...ion and activates the throttle according to the control unit Operation Operating principle All the unit internal components potentiometer and electric motor are contactless therefore no elec trical di...

Page 164: ...s around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal to 0 5 When the gear is not engaged at approximately rpm the throttle valves opening...

Page 165: ...he throttle mechanical minimum position Rear throttle valve lower position Example value with key ON 492 mV Voltage stored in the control unit corresponding to the throttle mechanical minimum position...

Page 166: ...or and control unit connector if not ok restore if everything is ok check the con tinuity of the circuit between the two ends if not ok restore the wiring harness if ok check the ground insulation of...

Page 167: ...e circuit between the two ends if not ok restore the wiring harness if ok check the ground insulation of the circuit from the throttle body connector or control unit connec tor if ground insulated che...

Page 168: ...body If open circuit excessive internal temperature over current check the throttle body connec tor and the control unit connector if not ok restore if everything is ok disconnect the connector of the...

Page 169: ...Front throttle valve Limp Home self learning Functional diagnosis Test failed Error cause Position of the throttle valve maintained by the springs outside the specified range at each key ON The instr...

Page 170: ...ttle body and that there is no ice or condensate in the intake duct If ok replace the throttle body P1404 Front throttle valve power supply voltage during self learning Functional diagnosis Low power...

Page 171: ...mechanical position self learning Functional diagnosis Test failed Error cause Position of the throttle valve stopper outside of the specified range at each key ON Troubleshooting Check the cleanlines...

Page 172: ...spring performance or excessive throttle valve friction at each key ON This error is indicated by lighting up in a fixed manner the MI warning light Troubleshooting Using the diagnostic tool erase the...

Page 173: ...the throttle automatic learning is performed by the control unit according to the throttle body concerned check that the Front throttle automatic self learning or the Rear throttle automatic self lear...

Page 174: ...e purple cable between the sensor connector and the instrument panel connector PIN 13 if not OK restore the wiring harness if OK replace the sensor Oil pressure FAULT error B0002 Error cause An oil se...

Page 175: ...ity gear engaged open circuit infinite re sistance Gear circuit resistance 1st gear 0 8 kohm 2nd gear 0 5 kohm 3rd gear 15 0 kohm 4th gear 6 9 kohm 5th gear 2 8 kohm 6th gear 1 5 kohm Pin out From the...

Page 176: ...nergised disconnect the sensor connector and check if the cable is energised in this case restore the wiring harness if not energised replace the sensor there is an interruption or a short circuit to...

Page 177: ...witching time does not exceed a certain threshold If the operating time is too long the error is shown To check the origin of the problem it is enough to connect the diagnostic tool to see if despite...

Page 178: ...etto aperto quindi circuito aperto la centralina impedisce l av viamento o effettua lo spegnimento del motore se in rotazione Livello appartenenza schema elettrico Consensi all avviamento Posizione su...

Page 179: ...brown green cable that goes from PIN 2 of the sensor to PIN 70 of the VEHICLE connector restore the wiring harness Bank angle sensor Function indicates the vehicle position to the control unit Operat...

Page 180: ...cifications Resistance at 0 C 32 F 32 5 kOhm 5 Resistance at 25 C 77 F 10 0 kOhm 5 Pin out 1 5 V voltage 2 Ground DIAGNOSTIC TOOL PARAMETERS Troubleshooting Check the sensor connector and the instrume...

Page 181: ...ground check if the sensor resistance is correct if not ok replace the sensor if ok replace the instrument panel Electric fan circuit Function Activates coolant radiator fan Operation Operating princi...

Page 182: ...en detected If open circuit 5V voltage has been detected Error recognition carries out only when the fan relay is activated Troubleshooting Short circuit to positive check the relay electrical specifi...

Page 183: ...ty Pin out 1 Ground Green Pink colour 2 5V signal Engine start up Pink Brown colour 3 Ground Green Pink colour 4 5V signal Engine stop Pink Yellow colour CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTI...

Page 184: ...between the two cables of the switch if there is replace the switch if there is no continuity it means that with the key ON the Yellow Pink cable between the switch and PIN C7 of the engine vehicle w...

Page 185: ...nalogic ground 1 PIN 7 PIN 8 PIN 9 Rear cylinder lambda probe PIN 10 Front cylinder lambda probe PIN 11 PIN 12 Water temperature sensor input PIN 13 B handle input PIN 14 Serial line PIN 15 Motorised...

Page 186: ...35 Engine rpm sensor PIN 36 Throttle valve potentiometer 1 signal rear cylinder PIN 37 Air temperature sensor input PIN 38 Rear cylinder lambda probe PIN 39 A handle input PIN 40 Ignition switched liv...

Page 187: ...59 PIN 60 PIN 61 Fan command relay PIN 62 PIN 63 2 reference voltage output PIN 64 Neutral input PIN 65 Fall sensor input PIN 66 L CAN line PIN 67 Rear cylinder injector PIN 68 PIN 69 Start up enable...

Page 188: ...IN A7 Analogic ground PIN A8 Battery PIN B1 Injection power supply PIN B2 CAN line high PIN B3 CAN line low PIN B4 Key PIN B5 Electric fan relay control PIN B6 PIN B7 PIN B8 Power ground 1 PIN C1 Inje...

Page 189: ...Dashboard Instrument panel pinout key PIN 1 PIN 2 Antenna 1 PIN 3 Antenna 2 SHIVER 900 Electrical system ELE SYS 189...

Page 190: ...UP PIN 16 Key positive PIN 17 Battery positive PIN 18 PIN 19 Mode DOWN PIN 20 Mode SET PIN 21 LH arrow control PIN 22 RH arrow control PIN 23 PIN 24 Ground PIN 25 Ground PIN 26 PIN 27 RH front arrow...

Page 191: ...positive PIN 15 Power ground 3 PIN 16 Serial line PIN 17 PIN 18 Battery positive Can line Function Allows the communication between the Marelli injection control unit the instrument panel the ABS mod...

Page 192: ...re attempting to send a message with BUS Carrier Sense If during this period there is no activity on BUS every nod has the same chance to send a message Multiple Access If two nodes start transmitting...

Page 193: ...1121 Diagnosis of ABS control unit CAN line or CLF frame counter Functional diagnosis Signal absent Error cause If there is no signal no signal is received from the ABS control unit This error is indi...

Page 194: ...ot plausible there was a transcription error of the value of the rear wheel radius from the non volatile memory EEPROM to the volatile memory RAM at key ON In this case the default value is used This...

Page 195: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 196: ...ft 3 Cyl head hex socket screw used for fastening the shock absorber coun ter plate to the right hand frame side fairing M10x30 1 50 Nm 36 88 lb ft Pre impregnated screw 4 Cyl head hex socket screws...

Page 197: ...ear box output shaft M6x20 1 10 Nm 7 38 lb ft 3 TORX screw used for fastening the gear lever pedal M6x22 1 8 Nm 5 90 lb ft Loct 270 4 Flanged hex head screws used for fastening the pinion cover guard...

Page 198: ...the three clutch pump fasten ing screws 4 Remove the clutch pump 5 and use the clamps to secure the pump so that the piston cannot fall out See also Fuel tank Removing the radiator Removing the tail...

Page 199: ...ver 7 taking care to retrieve the respective bushings Remove the cover 7 Remove the two clutch pump support fastening screws 8 Remove the clutch pump support 9 Loosen the screws 10 used to fasten the...

Page 200: ...emove the gear lever 11 Disconnect the vehicle stand switch connector 12 Remove the three screws 13 used to fasten the stand support Remove the stand support 14 Engine from vehicle SHIVER 900 ENG VE 2...

Page 201: ...e the pinion 18 and detach the drive chain 19 Working on both sides of the vehicle remove the screws 20 used to fasten the ABS sup port taking care to retrieve the spacer 21 Access the left hand side...

Page 202: ...wingarm and remove it Remove the two screws 25 used to fasten the right hand rider s footrest Disconnect the engine oil pressure sensor connector 26 Remove the clamp 27 disconnect the connector 28 fro...

Page 203: ...s easier to remove the engine Removing the engine from the vehicle Carry out the operations described in the vehicle preparation procedure Access the left hand side of the motor cycle unscrew the uppe...

Page 204: ...washer 6 See also Vehicle preparation Access the right hand side of the mo torcycle partially extract the lower pin 7 and remove the spacer 8 posi tioned inside the frame on the left hand side Remove...

Page 205: ...wer the engine completely and raise the rear of the motorcycle so that it is possible to remove the engine completely Installing the engine to the vehicle NOTE IN ORDER TO INSTALL THE ENGINE ON THE VE...

Page 206: ...INDEX OF TOPICS ENGINE ENG...

Page 207: ...ft 5 complete index lever 6 Gear stopper lever spring 7 Threaded rod 8 Selector stopper plate 9 Screw 10 Selector shaft 11 Flat washer 14x30x1 12 Selector spring 13 Threaded rod M8x1 25 14 Selector sp...

Page 208: ...Ring 24 Selector stopper 25 Self locking nut Gearbox shafts Gearbox shafts diagram Key 1 Primary transmission shaft Z 14 2 2nd gear on primary Z 17 3 3rd 4th gear on primary Z 20 22 4 5th gear on pri...

Page 209: ...condary Z 28 17 5th gear on secondary Z 26 18 6th gear on secondary Z 25 19 Floating bushing 20 Shoulder washer 21 Shoulder washer 22 Shoulder washer 23 Shoulder washer 24 Snap ring 25 Shoulder washer...

Page 210: ...resent on the secondary shaft VERIFICATION OF PINION FASTENING ON SECONDARY SHAFT Perform the following procedure in order to check the hole for fastening the pinion onto the gearbox s secondary shaft...

Page 211: ...Wash with degreasing spray Blow with compressed air Replace the pinion s fastening ele ments with upgraded fastening ele ments as indicated in the Spare Parts Catalogue If the external diameter of th...

Page 212: ...oc 2040 Removing the gear selector After having removed the clutch side cover and the complete clutch the gear shift selector shaft can be extrac ted taking care to retrieve the flat washer Checking t...

Page 213: ...age with rollers gearbox con trol stem INSTALLATION Place the left hand crankcase in a press and install the roller cage with the specific tool CAUTION TO INSTALL THE ROLLER CAGE IN THE RIGHT HAND CRA...

Page 214: ...ces 4 Stator fastening screw Flywheel cover M6x30 3 9 Nm 6 64 lb ft 5 Pick up fastening screw Flywheel cover M5x14 2 3 Nm 2 21 lb ft Loct 270 6 Flywheel cover fastening screw M6x30 10 13 Nm 9 59 lb ft...

Page 215: ...Nm 9 59 lb ft 2 Free wheel ring fastening screw M6x18 6 14 Nm 10 33 lb ft 3M SCOTCH GRIP 2353 3 Rotor fastening screw Crankshaft M14x1 5 1 191 Nm 140 87 lb ft Thoroughly de grease both of the coupling...

Page 216: ...el cover inspection cap Unscrew and remove the ten screws 1 2 NOTE THE SCREW 2 FOR THE FLYWHEEL COVER IS SHORT ER THAN THE OTHER SCREWS 1 Position the appropriate tool in screw it in a clockwise direc...

Page 217: ...VED SIMUL TANEOUSLY AS THEY ARE PART OF THE SAME ELEC TRICAL BRANCH Magneto flywheel removal Remove the flywheel cover Unscrew and remove the screw and remove the retention plate Use a heater to heat...

Page 218: ...e pin in such a way as to extract the flywheel from the crankshaft Specific tooling 020713Y Flywheel extractor Unscrew and remove the special tool s left handed pin from the outer body Unscrew the scr...

Page 219: ...ust be completely replaced Freewheel removal Heat the magneto flywheel with the specific heater Undo and remove the six screws Remove the freewheel from the mag neto flywheel Installing the flywheel I...

Page 220: ...osition the appropriate tool to lock the flywheel in place Holding the flywheel still using the ap propriate tool tighten the screw on the crankshaft Remove the special tool Specific tooling 020713Y F...

Page 221: ...ch fastening nut M24x1 5 1 177 Nm 130 55 lb ft Chamfer 3 Oil filler cap on clutch cover M25x1 25 1 2 Nm 1 48 lb ft 4 Clutch Control Plate Support coun tersunk hex head fastening screw M5x12 3 5 Nm 3 6...

Page 222: ...spring fastening screw M6 6 12 Nm 8 85 lb ft WATER PUMP Pos Description Type Quantity Torque Notes 1 Clutch side cover fixing screw M6x40 13 13 Nm 9 59 lb ft 2 Pump cover Clutch side cover fas tening...

Page 223: ...upport fastening screw M6x30 3 12 Nm 8 85 lb 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 P...

Page 224: ...ARE NOT INTERCHANGEABLE THE CRANKCASE WITH THE PUNCH MARKS MUST BE COUPLED TO THE WATER PUMP WITH PUNCH MARKS INCORRECT COUPLING MAY CAUSE SERIOUS DAMAGE TO THE ENGINE Unscrew and remove the retaining...

Page 225: ...n the crank shaft in such a way as to properly align the engine s oil pump control gear on the clutch bell with the oil pump s driven gear See also Removal Disassembling the clutch CLUTCH Pos Descript...

Page 226: ...ews loosening them by a quarter of a turn at a time by stages and working in a diagonal fashion while recovering the washers and the clutch springs Remove the thrust plate Remove the mushroom head clu...

Page 227: ...appro priate tool and unscrew the nut on the hub Specific tooling 9100896 Clutch bell stopper Remove the disc spring Remove the clutch hub Remove the special washer between the clutch hub and the clut...

Page 228: ...cs and steel discs on a level surface and check them for cracks and potential distortions Maximum distortion allowed 0 20 mm 0 0079 in Measure the driving plate thickness at four positions replace the...

Page 229: ...mm 0 108 0 112 in MUSHROOM VALVE CHECK Check if the valve slides freely without jamming Blow compressed air into the valve and check that the lubricating oil passage holes open Checking the clutch hou...

Page 230: ...ary driven gear and replace the primary transmission s driven gear and the clutch bell if necessary Verify that the noise level is not too high during operation replace the primary transmission s driv...

Page 231: ...ngs and replace them if necessa ry Free length of the clutch spring 66 5 mm 2 62 in Assembling the clutch Fit the shim washer Fit the needle bearing and the spacer Fit the clutch housing Make sure tha...

Page 232: ...h nut check to make sure that the measurement has not changed with respect to that which was measured during the disas sembly phase If it is different turn the crank shaft in such a way as to properly...

Page 233: ...rt the flat ring 1 Insert the disc ring 2 CAUTION MAKE SURE THE DISC RING IS INSERTED FACING THE RIGHT DIRECTION THE RING S CONE MUST BE FACING THE ENGINE Insert the turned drive disc 3 Insert the nit...

Page 234: ...sition the thrust plate Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally Replace the gasket upon refitting Head and timing Engine SHIVER 900 ENG 2...

Page 235: ...ricate the threads before tight ening 3 Nut for fastening the stud bolts to the head Tightening M10x1 25 8 135 135 4 Head Cylinder Crankcase fasten ing outside M6x75 2 13 Nm 9 59 lb ft 5 Head Cylinder...

Page 236: ...emove the head cover Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO THE REMOVAL OF ONE HEAD ONLY BUT ARE VALID FOR BOTH Pre emptively remove the camshafts the chain tensioners...

Page 237: ...astening the stud bolts to the head Tightening M10x1 25 8 135 135 4 Head Cylinder Crankcase fasten ing outside M6x75 2 13 Nm 9 59 lb ft 5 Head Cylinder Crankcase fasten ing inside M6x125 4 13 Nm 9 59...

Page 238: ...to avoid mixing them up during the reassembly phase Unscrew and remove the cam tower s eight screws proceeding in a diagonal fashion and by stages Carefully remove the cam tower in or der to avoid da...

Page 239: ...ms using a magnet Compress the valve springs with the specific wrench and with the spring compressing tool Specific tooling AP8140179 Valve springs compressor 020721Y Valve removal adaptor Remove the...

Page 240: ...moothly replace both the timing chain and the camshaft toothed wheel CAMSHAFT LOBES Check that they do not show blue col ouring pitting or scratches otherwise replace the camshaft and the relevant too...

Page 241: ...ITS SEAT WHICH IS MARKED PRIOR TO REMOVAL CAUTION THE SEAT 1 ON THE VALVE HEAD CANNOT BE REGROUND IF REQUIRED REPLACE THE VALVE GRINDING WITH ABRASIVE PASTE IS ALLOWED VALVE STEM END REGRINDING IS NO...

Page 242: ...ff any carbon deposits in the combustion chamber CAUTION DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK PLUG THREADS OR THE VALVE SEATS Check the head for damage or scratche...

Page 243: ...orque Notes 1 Cam shaft gear fastening nut M15x1 4 88 Nm 64 91 lb ft Thoroughly de grease both of the coupling surfaces axle cone and gear cone 2 Timing lay shaft fastening screw M24x1 5 2 88 Nm 64 91...

Page 244: ...8 3 Nm 2 21 lb ft 3M SCOTCH GRIP 2353 6 Decompressor fastening screws M8 2 28 Nm 20 65 lb ft 3M SCOTCH GRIP 2353 or Loct DRI LOC 2045 BLUE 7 Decompressor fastening screw M5x12 9 2 5 Nm 3 69 lb ft 3M...

Page 245: ...e the two screws Remove the chain tensioner and re trieve the gasket Chain removal Remove the chain tensioner Remove the mobile chain slider and free the fixed chain slider from the fas tener Heat the...

Page 246: ...gear See also Removing the chain sliders Removing the chain tensioner Removing the chain sliders Remove the chain tensioner and the camshafts for the head in question FRONT HEAD In order to remove th...

Page 247: ...e it by extracting it from the head Unscrew and remove the fixed chain tensioner slider s screw The head must be removed in order to remove it See also Removing the chain tensioner Removing the head c...

Page 248: ...pring and tighten the screw together with the washer Cam timing Timing Position the plate 1 of the specific timing tool and lock it in place using the two screws 2 on the cover Insert the tool 3 on th...

Page 249: ...ft is adequately pro tected Unscrew the nut and remove it BOTH REAR CYLINDER SHAFTS ARE FITTED WITH LEFT HANDED THREAD NUTS WHICH HAVE BEEN STAMPED WITH A ANTICLOCKWISE ARROW Retrieve the washer Remov...

Page 250: ...ng 020719Y Timing pin Pre tighten the nuts on the camshaft gearwheels FIT THE NUTS SO THAT THE MACHINED SURFACE IS FACING THE GEARWHEEL MATERIAL CODE VISIBLE Remove the cam tower and the cam shafts pl...

Page 251: ...the camshaft anticlockwise until the rear cylinder piston is at TDC B Repeat the timing procedure for the front cylinder Specific tooling 020720Y Timing tool CAUTION AT TDC THE REAR BIG END CAMS MUST...

Page 252: ...ing the cylinder head Disassembling the piston Remove the big end and the cylinder Extract the pin locking ring Lock the connecting rod using the spe cific tool Slide the pin and remove the piston Spe...

Page 253: ...AFETY REASONS COVER THE CRANKCASE WITH A CLEAN MATERIAL TO AVOID THE FALL OF THE SAFE TY RINGS IN THE CRANKCASE Remove the upper ring the second ring and the oil ring See also Removing the cylinder he...

Page 254: ...est value should be con sidered to estimate wear limits Cylinder bore C 92 000 mm 3 6220 in Key C max D1 or D2 Cylindricity limit 0 028 mm 0 0011 in Replace the cylinder the piston and the piston ring...

Page 255: ...with the piston crown Measure piston ring port and replace it if not complying with specifications CAUTION IT IS NOT POSSIBLE TO MEASURE THE CLEARANCE OF THE END OF THE OIL SCRAPER RING IF THERE IS E...

Page 256: ...Quantity Cylinder piston class A coupling Cylinder 91 990 91 997 mm 3 6216 3 6219 in Piston 91 933 91 940 mm 3 6217 3 6197 in Cylinder piston class B coupling Cylinder 91 997 92 004 mm 3 6219 3 6222...

Page 257: ...al rings to the piston so that they are offset in relation to one another by 90 Apply the lock ring to the appropriate tool To facilitate its insertion onto the pis ton move the ring near to the edge...

Page 258: ...BOLTS MUST BE MOUNTED SO THAT THEY PROTRUDE THE PRE IMPREGNATED PART MUST BE SCREWED ONTO THE CRANKCASES SCREW THE STUD BOLT ONTO THE CRANK CASE UNTIL A PROTRUSION OF 138 MM 5 43 IN IS OBTAINED THEN W...

Page 259: ...on itself Use a clamp to lock the special tool in place Specific tooling AP8140302 tool for installing seal rings Provisionally mount the piston on the cylinder without the base and head gasket Remove...

Page 260: ...gasket thickness to keep the cor rect compression ratio Remove the special tool and the cylin der Specific tooling 020720Y Timing tool BASE GASKET Specification Desc Quantity Protrusion detected from...

Page 261: ...d bolts Apply the nuts 1 to the stud bolts and tighten them to the required torque val ue proceeding in a crossover fashion Insert and tighten the internal screws 2 Insert and tighten the external scr...

Page 262: ...IS REMOVED CAUTION BEFORE REMOVING THE BIG END COVERS CAREFULLY CLEAN THE SURFACES OF THE BIG END AND THE COVER Apply THREEBOND around the perim eter of the big end cover along the gasket housings App...

Page 263: ...ance based tighten ing SCOTCH GRIP 2510 GREEN 2 Bearing retainer fastening screws M6x12 3 10 Nm 7 38 lb ft 3M SCOTCH GRIP 2353 or Loct DRI LOC 2045 BLUE 3 Threaded plug M8x1 5 15 Nm 11 06 lb ft 3M SCO...

Page 264: ...n Type Quantity Torque Notes 1 Half crankcase coupling screw M8x80 9 28 Nm 20 65 lb ft 2 Half crankcase coupling screw M6x65 8 13 Nm 9 59 lb ft 3 Special oil calibration screw M10x1 1 14 Nm 10 33 lb f...

Page 265: ...ase halves Remove the water pump the oil pump the clutch the flywheel the intermediate gearwheel and the head engine block piston assembly complete with distribution CAUTION BEFORE USING THE PRIMARY G...

Page 266: ...uitable heater Remove the nut and the flat washer Remove the motor pinion locking tool Using a generic extractor tool remove the water pump gearwheel 4 and the primary drive gearwheel 5 simultane ousl...

Page 267: ...ox control rod tak ing care to retrieve the washer Heat up the gearbox selector support plate screws Unscrew the three gearbox selector plate fastening screws and remove them Remove the plate SHIVER 9...

Page 268: ...der to re move it Unscrew the threaded pin used to fas ten the selector drum and remove it Move the index lever to one side so that it is possible to remove the selector drum Remove the idle sensor fa...

Page 269: ...rankcase fastener screws Working on the left hand side unscrew and remove the nine M6 crankcase fastener screws Remove the fuel vapour breather pipe mounting plate CAUTION DURING REASSEMBLY REMEMBER T...

Page 270: ...mallet strike the guards gently in order to separate them Open the guards If necessary unscrew the two pick up tube fastening screws and remove them Remove the pick up tube Removing the crankshaft Rem...

Page 271: ...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...

Page 272: ...haft axial clearance on the crank case should be checked with a dial gauge mounted on the specific dial gauge support The clearance should be between 0 10 and 0 26 mm 0 0039 0 0102 in If the clearance...

Page 273: ...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 cr...

Page 274: ...e guards repeat the procedure described in the section OPENING THE GUARDS in reverse order CAUTION TAKE CARE NOT TO MAKE EXCESSIVE USE OF THREEBOND AS THIS COULD PREVENT THE OIL FROM PASSING BETWEEN T...

Page 275: ...Conceptual diagrams Key 1 Filter head support 2 Oil pump 3 Oil pressure regulator valve 4 Oil pressure sensor SHIVER 900 Engine ENG 275...

Page 276: ...on 8 Primary transmission shaft lubrication 9 Clutch discs lubrication 10 Oil pressure sensor 11 Main bushing lubrication 12 Piston oil jets 13 Water pump shaft lubrication 14 Distribution command gea...

Page 277: ...Pos Description Type Quantity Torque Notes 1 Oil drainage plug M16x1 5 1 17 Nm 12 54 lb ft 15 2 Oil pressure sensor M10x1 1 13 Nm 9 59 lb ft 3 Fitting fixing of the oil filter 1 20 Nm 14 75 lb ft SHIV...

Page 278: ...s 2 12 Nm 8 85 lb ft 8 Oil pump gear fastener nut M6 1 11 Nm 8 11 lb ft 9 Gear sensor fastening screws M5x16 2 5 Nm 3 69 lb ft 3M SCOTCH GRIP 2353 10 Oil temperature sensor M10x1 1 13 Nm 9 59 lb ft Re...

Page 279: ...Retrieve the shim Undo and remove the two screws fixing the oil pump Remove the entire pump Inspection Undo and remove the two fixing screws SHIVER 900 Engine ENG 279...

Page 280: ...or 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 Slide off the shaft with the cover Collect the lock pin from the shaft...

Page 281: ...ED NO EVIDENT ABRASIONS SCORES OR ANY OTH ER MARKS Installing NOTE PAY ATTENTION TO ALIGN THE REFERENCES ON STA TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE IF REQUIRED RE...

Page 282: ...ert the oil pump gearwheel making sure that the machined groove coin cides with the pin on the pump Insert the safety washer Using a commercial hook spanner lock the pump in position and tighten the n...

Page 283: ...Using a screwdriver raise and bend the safety washer on the side opposite the slot until it is touching the nut SHIVER 900 Engine ENG 283...

Page 284: ...INDEX OF TOPICS POWER SUPPLY P SUPP...

Page 285: ...Torque Notes 1 Flanged hex head front fuel tank fastening screws M6x30 2 6 Nm 4 43 lb ft 2 Fuel pump fastening nuts M5 6 6 Nm 4 43 lb ft Removing Remove the fuel tank Remove the six nuts fixing the f...

Page 286: ...ex head screws used for fastening the inlet coupling M6x60 8 12 Nm 8 85 lb ft Loct 242 2 Button head hex socket screws used for fastening the throttle body to the bracket M6 8 12 Nm 8 85 lb ft Loct 24...

Page 287: ...the four screws and slide off the filter support Remove the upper plate Remove both bodies UPON REFITTING REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE Working on both bodies undo a...

Page 288: ...FIGURE Use of diagnostics instrument for injection system L elenco completo di tutti i parametri stati errori ecc disponibile nella home page del sito www serviceaprilia com nella sezione ricerca Par...

Page 289: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 290: ...ectronic accelerator control fasten ing screws 1 4 Nm 2 95 lb ft 3 Light switch fastening screws 2 1 5 Nm 1 11 lb ft 4 Cyl head hex socket anti vibration counterweight fastener screws M6x45 2 10 Nm 7...

Page 291: ...ews used for fas tening the front brake pump U bolt Move the front brake pump to one side Remove the two screws used for fas tening the clutch pump U bolt Move the clutch pump to one side SHIVER 900 S...

Page 292: ...e as sistance of compressed air Remove the two screws used for fas tening the left hand column switch and disconnect it from the handlebars Remove the screw used for fastening the Ride By Wire gas con...

Page 293: ...Remove the two screws used for fas tening the left hand column switch Remove the four screws and the U bolt Remove the handlebars SHIVER 900 Suspensions SUSP 293...

Page 294: ...hydraulic fork connected to the headstock by means of two plates The right stem of the fork has an upper nut 2 for adjusting the spring pre load and an upper adjust ment screw 1 for adjusting the hyd...

Page 295: ...ETTING FRONT FORK ADJUSTING Description Pilot Pilot Passenger Baggage Rebound damping adjustment screw 1 from completely closed un screw 6 7 clicks from completely closed un screw 6 7 clicks Spring pr...

Page 296: ...NE ROD ONLY BUT APPLY EQUALLY TO BOTH RODS Unscrew the screw that fastens the rod to the upper steering plate Unscrew the screws that fasten the rod to the lower steering plate Slide the rod of the st...

Page 297: ...Guard for assembly operations Using the special tool 2 fastened to the pre loading pipe 3 compress the spring and with the assistance of a second operator insert the separator plate 4 under the cap r...

Page 298: ...8 allowing the oil inside the stem to drip out Drain the oil into a container having sufficient capacity extending the stem several times in order to ensure the oil is drained completely DO NOT DISPO...

Page 299: ...9 Specific tooling AP8140149 Guard for assembly operations Remove the seeger ring 10 from in side the sleeve Pull the stem repeatedly towards your self in order to remove it from the sleeve Secure the...

Page 300: ...and the dust guard 9 THE FOLLOWING OPERATIONS APPLY WHEN REMOVING THE RIGHT HAND STEM Taking care not to damage it secure the fork vertically in a vice using the appropriate protection devices Unscrew...

Page 301: ...container having sufficient capacity extending the stem several times in order to ensure the oil is drained completely DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONT...

Page 302: ...e sleeve Pull the stem repeatedly towards your self in order to remove it from the sleeve Observing the indicated sequence ex tract and remove the slider bushing 6 the guide bushing 7 the ring 8 the o...

Page 303: ...on of the spring making sure that the length is within the acceptable limits If not replace the spring MINIMUM LENGTH OF FREE SPRING mm in Check the condition of the following components slider bushin...

Page 304: ...seeger ring 2 the oil seal 3 the ring 4 the guide bushing 5 and the slider bushing 6 Insert the complete plunger 7 Secure the stem in a vice and after in serting the screw 8 used to fasten the plunge...

Page 305: ...fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight Position the seeger ring 2 inside the sleeve Insert the dust guard 1 into its hous ing correctly Place the fork stem vertically on a...

Page 306: ...e After positioning the device 13 on the pre load pipe 11 and the plunger sup port shaft 14 with the assistance of a second operator raise the plunger so that it is possible to insert the plate 15 und...

Page 307: ...cap adjust the hydraulic regulator screw so that the internal distance is as close as possi ble to 13 mm 0 51 in Screw the cap 17 onto the plunger as far as it will go Ensure that the cap cannot rota...

Page 308: ...and remove the dust guard 1 the seeger ring 2 the oil seal 3 the ring 4 the guide bushing 5 and the slider bushing 6 Insert the stem in the sleeve Using a suitable tool complete with striking hammer...

Page 309: ...sleeve Insert the dust guard 1 into its hous ing correctly Place the fork stem vertically on a work surface Fill the stem with the quantity of oil in dicated in the Refilling oil section Insert the bu...

Page 310: ...ten it as far as it will go Insert the cap 9 and tighten it as far as it will go Ensure that the cap cannot rotate and then tighten the nut Tighten the cap on the sleeve applying the pre defined torqu...

Page 311: ...1 85 cu in Check the oil level from the rim of the sleeve Characteristic Oil level from sleeve rim without the spring and with the pump all the way lowered 90 mm 3 54 in THE FOLLOWING OPERATIONS APPLY...

Page 312: ...ged upper steering plate fasten ing nut tightening M22 1 25 Nm 18 44 lb ft 3 Cyl head hex socket screws used for fastening the fork stanchions to the upper plate M8x30 2 25 Nm 18 44 lb ft 4 Low profil...

Page 313: ...n a raised po sition After removing the instrument panel support and the front light assembly maintain the fuel tank in raised position and remove the four handlebar U bolt retaining screws Move the h...

Page 314: ...he dedicated tool Execute two complete rotations to the left and two to the right Loosen the ferrule by executing a 90 rotation and then apply the definitive tightening torque Specific tooling 020884Y...

Page 315: ...eering plate cen tral closure screw applying the pre defined torque Tighten the upper steering plate nut again applying the predefined torque After refitting the handlebars apply a dynamometer to the...

Page 316: ...g the shock absorber has an adjuster screw 1 for adjusting the rebound hy draulic braking a ring nut for adjusting the spring preload 2 and a locking ring nut 3 CAUTION CARRY OUT MAINTENANCE OPERATION...

Page 317: ...g A Once the adjustment is done screw the ring nut 3 Use the screw 1 to adjust the shock absorber rebound hydraulic braking SET SPRING PRELOADING AND SHOCK ABSORBER RE BOUND DAMPING ACCORDING TO THE V...

Page 318: ...d 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...

Page 319: ...INDEX OF TOPICS CHASSIS CHAS...

Page 320: ...Flanged hex head phonic wheel and brake discs fixing screws M8x20 12 30 Nm 22 13 lb ft Pre impregnated screws Removal Position the motorcycle on the central and rear stand so that the front wheel is...

Page 321: ...ides loosen the screws on the fork feet Slide out the pin from the left hand side of the motorcycle Remove the wheel See also Front mudguard Retrieve the spacer present on the left hand side SHIVER 90...

Page 322: ...axial play Axial play minimal axial play is permitted Radial none If one or both bearings are not conformant Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH C...

Page 323: ...AR WHEEL Pos Description Type Quantity Torque Notes 1 Wheel axle nut M25x1 5 1 120 Nm 88 51 lb ft 2 Button head hex socket screw used for fastening the sensor to the brake calliper support M5x16 1 6 N...

Page 324: ...these op erations we recommend removing the chain guard Remove the external screw 1 Access the left hand side of the motor cycle and loosen the internal screw 2 Detach the chain guard 3 from the in t...

Page 325: ...crews 6 in order to release the tension on the drive chain Rotate the wheel forwards and disen gage the drive chain 7 from the sprocket Remove then nut 4 and the spacer washer 8 Partially extract the...

Page 326: ...Remove the wheel shaft 10 com plete with guide 11 Remove the rear wheel 12 Remove the spacers from both sides 13 Remove the complete sprocket as sembly 14 Chassis SHIVER 900 CHAS 326...

Page 327: ...control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE Check the radial and axial play Axial play minimal axial play...

Page 328: ...REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bear...

Page 329: ...t ferrule 1 60 Nm 44 25 lb ft 4 Button head hex socket shoe cap fastening screws M5x12 3 6 Nm 4 43 lb ft 5 Button head hex socket screws used for fastening the chain guard on the chain guide shoe M6x3...

Page 330: ...ER AFTER REMOVING THE WHEEL OTHERWISE THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT RESULTING IN BRAKE FLUID LEAKAGE See also Removing the rear wheel With the specific box spanner un screw and remo...

Page 331: ...N See also Removing the rear wheel Drive chain Removing The transmission chain although closed has a different coloured hammerlock where provided which should be used to perform opening disas sembling...

Page 332: ...le and remove the chain proceed as follows Partially remove the pins 3 using a generic chain breaker Remove the outer plate 4 Remove the outer O ring rings 5 Remove the inner plate 6 Chassis SHIVER 90...

Page 333: ...e crown put the inner O rings 1 back onto the hammerlock pins 2 and connect the two ends of the transmis sion chain Place the outer O rings 3 on the pins Compress the outer plate 4 using the appropria...

Page 334: ...urn the pin of the specific tool 90 and re engage the link pin again checking riveting at points B Grease the chain and record the clearance Adjusting The vehicle has an endless chain without master l...

Page 335: ...need to adjust chain tension after the check Place the vehicle on its rear service stand OPT Loosen the nut 1 completely Loosen both lock nuts 4 Actuate on the adjuster screws 5 and adjust the chain c...

Page 336: ...PROPER WORKING ORDER THE DRIVE CHAIN HAS SEAL RINGS BETWEEN THE LINKS WHICH KEEP THE GREASE INSIDE BE EXTREMELY CAREFUL WHEN ADJUSTING LUBRICATING WASHING AND REPLACING THE CHAIN CLEANING AND LUBRICA...

Page 337: ...footrest sup port to the frame plates M8x25 4 18 Nm 13 28 lb ft Loct 243 3 Button head hex socket screws used for fastening the luggage rack to the rider s footrest support M6x12 4 8 Nm 5 90 lb ft 4...

Page 338: ...he complete footrest To dismantle the footrest proceed as follows Remove the two screws 2 used to fasten the heel guard plate Remove the heel guard plate 3 Remove the seeger ring 4 Chassis SHIVER 900...

Page 339: ...Extract the pin 5 and remove it Remove the pedal complete with spring 6 Remove the two screws 7 used to fasten the rubber pad Separate the pedal 8 from the rubber pad 9 SHIVER 900 Chassis CHAS 339...

Page 340: ...w 1 from the brake pipe retaining plate in order simplify the mounting operations Remove the two fastening screws 2 Position the cloth in order to protect the frame from scratches and remove the two r...

Page 341: ...rom the pin that blocks the brake pump control rod Rotate the pin 5 to release the brake pump control rod and slide it out in or der to remove it Remove the brake switch 6 Remove the complete footrest...

Page 342: ...er return spring 7 and remove it After unscrewing the pin 8 it is possi ble to remove the complete brake lever 9 The pin 8 consists of the following elements An external washer 10 An O ring 11 An inte...

Page 343: ...peg 15 from the lever complete with rubber protection pad Unscrew the brake lever spring cou pling pin 16 and remove it Remove the two screws 17 used to fasten the heel guard plate Remove the heel gu...

Page 344: ...Remove the seeger ring 19 Extract the pin 20 and remove it Remove the pedal complete with spring 21 Remove the two screws 22 used to fasten the rubber pad Chassis SHIVER 900 CHAS 344...

Page 345: ...r pad 24 Remove the pin 25 PASSENGER FOOTRESTS THE FOLLOWING OPERATIONS ARE VALID FOR BOTH FOOTRESTS Remove the two screws 1 used to fasten the support bracket Remove the support bracket 2 com plete w...

Page 346: ...move the complete pedal Check that the plates 5 are aligned correctly be fore dismantling the pedal taking care not to lose the spring 6 and the ball 7 Remove the two screws 8 used to fasten the rubbe...

Page 347: ...te M10x1 25 1 10 Nm 7 38 lb ft 3 Low profile nut used for fastening the stand to the plate M10x1 25 1 30 Nm 22 13 lb ft 4 Cyl head hex socket screws used for fastening the stand switch M5x16 2 7 Nm 5...

Page 348: ...Release the spring coupling plate 2 and remove it Unscrew the nut 3 and remove it complete with washer 4 Unscrew the pin 5 and remove it Remove the stand 6 Chassis SHIVER 900 CHAS 348...

Page 349: ...g the shock absorber pro tection M4x6 2 3 Nm 2 21 lb ft 4 Manifold fastening clamps M6 2 7 Nm 5 16 lb ft 5 Terminal fastening clamp M6 1 7 Nm 5 16 lb ft 6 Flanged hex head screws used for fastening th...

Page 350: ...r plate support Loosen the clamp between the ex haust end and the manifold Remove the two support bracket fas tening screws 2 and retrieve the spacer washers Slide the exhaust terminal 3 off from the...

Page 351: ...ing the exhaust manifold FRONT MANIFOLD Remove the lower fairing and cut the upper clamp 1 that fastens the front lambda probe wiring harness to the ABS pump support frame Remove the lower clamp 2 Dis...

Page 352: ...manifold with the central manifold Remove the two nuts 5 used to fasten the front manifold to the head Remove the front manifold 6 Loosen the lower clamp 7 that con nects the rear manifold to the cen...

Page 353: ...ve the central manifold 9 REAR MANIFOLD Remove the clamp 10 that fastens the rear lambda probe wiring harness to the rear frame Remove the clamp 11 that fastens the rear lambda probe wiring harness to...

Page 354: ...Remove the two nuts 12 used to fas ten the rear manifold to the head Remove the rear manifold 13 sliding out from underneath the motorcycle Chassis SHIVER 900 CHAS 354...

Page 355: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 356: ...ged hex head screw used for fastening the ABS control unit on the support M6x25 2 10 Nm 7 38 lb ft Loct 270 4 Flanged hex head screws used for fastening the spacers on the ABS support M6x12 3 10 Nm 7...

Page 357: ...Foreword Key 1 Rear brake calliper 2 Modulator 3 Front bleed valve 4 Front brake reservoir 5 Front brake callipers 6 Rear brake pump 7 Rear brake reservoir SHIVER 900 Braking system BRAK SYS 357...

Page 358: ...Operating diagram Key 1 Instrument panel 2 Ignition switch 3 Main injection relay 4 ABS control unit Braking system SHIVER 900 BRAK SYS 358...

Page 359: ...onic Control Unit pin out PIN1 Power ground 1 PIN2 Power ground 2 PIN3 PIN4 Ignition switched live PIN5 CAN H line PIN6 CAN L line PIN7 PIN8 PIN9 PIN10 PIN11 Rear ABS sensor positive PIN12 Rear ABS se...

Page 360: ...r one The ABS inlet valve 10 12 is normally open and it is closed only when the system inter venes to avoid wheel locking The exhaust valve 13 15 is normally closed and it is opened only when the syst...

Page 361: ...ssure restoration by opening the inlet valve 10 12 momentarily the pressure of the callipers 8 9 is increased until maximum deceleration is reached Then the system gives the control over the braking b...

Page 362: ...he ABS system could take this as a dangerous situation In this case 2 things may occur the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed o...

Page 363: ...tion is highlighted in red Briefly moving to left or right deactivates the func tion Off This function allows you to disable the ABS system that is normally active On To return to the main MENU select...

Page 364: ...iagnosed one or more conditions must persist within a given time If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no longer able t...

Page 365: ...Notes Speed of the front wheel km h Speed of the rear wheel km h Quality test of the sensors When turning the wheel or acting on the brake a variation of parameters must be detected ACTIVATION screen...

Page 366: ...A1 the signal changes in irregular manner Rear speed sensor Functional fault 5DA2 the signal becomes weak periodically Rear wheel speed sensor 5DA3 Rear wheel speed sensor 5DA4 signal plausibility Rea...

Page 367: ...nosis Go to the page Error codes Select an error and show the Ambient parameter error where provided Repeat the operation by selecting each error and showing the corresponding Ambient parameter error...

Page 368: ...free programs ask the infor mation systems to install it Name the file with a name that contains the main information of the vehicle and the analysed component e g CN1200 Chassis0465 Instrument panel...

Page 369: ...ne at the next key ON Modulator MODULATOR REMOVAL Remove the fairing lug Release clamp 1 and disconnect con nector 2 By unscrewing the nuts remove and plug the brake oil pipes following this sequence...

Page 370: ...cription Type Quantity Torque Notes 1 Special brake pipe coupling fasten ing screw M10x1 1 10 Nm 7 38 lb ft 2 Button head hex socket screws used for fastening the brake pipe pro tection M5x9 1 4 Nm 2...

Page 371: ...e Quantity Torque Notes 1 Flanged hex head screws for fas tening the brake callipers to the fork stanchions M10x1 25 4 50 Nm 36 88 lb ft 2 Special screws for fastening the brake pipe to the callipers...

Page 372: ...16 1 6 Nm 4 43 lb ft 3 DAX nut for fastening the crown gear on the hub M10x1 25 5 50 Nm 36 88 lb ft 4 Cyl head hex socket screws used for fastening the cush to the wheel M10x30 5 50 Nm 36 88 lb ft Pre...

Page 373: ...C D E See also Rimozione Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI FICATIONS OF THE SYSTEM The following operations are to be car ried out with b...

Page 374: ...Type Quantity Torque Notes 1 Wheel axle nut 1 80 Nm 59 00 lb ft 2 Flanged hex head phonic wheel and brake discs fixing screws M8x20 12 30 Nm 22 13 lb ft Pre impregnated screws Removal Remove the front...

Page 375: ...CE SPECIFICATIONS OF THE SYSTEM The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by mea...

Page 376: ...BRAKE FLUID LEAKAGE Installing Insert two new pads placing them so that the holes are aligned with the calliper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED IN SI...

Page 377: ...clip Unscrew and remove the pin Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID L...

Page 378: ...important to ensure that there is always a sufficient quantity of brake fluid in the tank These operations may be simplified by using a bleeding device when carrying out the Re placing the brake fluid...

Page 379: ...ghten the bleeder screws applying the correct torque See also Front Rear REPLACING THE ABS CONTROL UNIT PREPARING THE VEHICLE Connect the bleeder bottles to the front and rear calliper bleeder screws...

Page 380: ...E AS DESCRIBED AT THE END OF THE CHAPTER Fill the tank up to the MAX level mark and replace the plug Check the stroke and sensitivity of the brake pedal and lever If the brake pedal or lever stroke is...

Page 381: ...ure check the braking system for leaks and if none are found bleed the system using PADS as de scribed Disconnect the flexible bleeder pipes and re tighten the bleeder screws applying the correct torq...

Page 382: ...HE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY BUT ARE VALID FOR BOTH THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED WHILE BLEEDING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NEC...

Page 383: ...E HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR CONVENTIONAL AIR PURGING SYSTEM Remove the...

Page 384: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS...

Page 385: ...ch actuator cylinder M6x75 1 8 Nm 5 90 lb ft Perform two tight ening cycles 5 Countersunk hex socket screws used for fastening the clutch actuator cylinder M6x20 2 8 Nm 5 90 lb ft Perform two tight en...

Page 386: ...om the clutch system and after re moving the rubber clamp 1 remove the pump pipe retaining screws 2 Disconnect the clutch switch connec tors 3 Unscrew and remove the two clutch pump U bolt 5 fastening...

Page 387: ...e clutch system and remove the retaining screw 1 from the control cylinder pipe Undo and remove the three control cyl inder fastening screws 2 Remove the complete cylinder 3 and replace the rubber o r...

Page 388: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 389: ...ad screw used for fastening the trellis radiator M6x25 1 10 Nm 7 38 lb ft 3 Button cyl head screw used for fas tening the electric fan to the radiator 4 2x20 3 3 Nm 2 21 lb ft 4 Flanged hex head screw...

Page 390: ...Key Yellow Air purge Orange Refilling Red From engine Blue To the pump Key 1 Front cylinder 2 Rear cylinder 3 Thermostat 4 Direction of travel of vehicle Cooling system SHIVER 900 COOL SYS 390...

Page 391: ...move the electric fan See also Removing the radiator Coolant replacement Remove the right side fairing Unscrew and remove the screw and remove the protection Place a container of suitable capacity Loo...

Page 392: ...ECAUSE DURING THE AS SEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LU BRICATION OF THE SAME IS REQUIRED IN ORDER TO PREVENT DAMAGE Refit both sleeves place the corresponding clamps and tighten their scre...

Page 393: ...en ing the chain tensioner slider M6x12 1 9 Nm 6 64 lb ft Loct 242 7 Pump support fastening screw M6x30 3 12 Nm 8 85 lb ft Removal Based on the engine design development there are two types of water p...

Page 394: ...nd remove the five wa ter pomp cover fastening screws Loosen the clip and remove the cover REMOVING THE PUMP ROTOR Remove the H2O pump cover Unscrew the rotor and remove it not ing the left hand threa...

Page 395: ...2O pump and extract the control chain NOTE WHEN REMOUNTING THE PUMP REPLACE THE O RINGS Installing MOUNTING THE COMPLETE H2O PUMP Insert the control chain and position the H2O pump in its housing Inse...

Page 396: ...AVOID DAMAGING THE O RINGS Removing the radiator Remove the fuel tank Locate a suitable recipient for collect ing the coolant Remove the filler cap Access the left hand side of the motor cycle loosen...

Page 397: ...ect the horn from its connec tors and remove it Disconnect the electric fan connector Release the clamps of the pipes that connect the radiator to the expansion tank and disconnect them from the ra di...

Page 398: ...the chassis Removing the expansion tank Remove the right side fairing Unscrew and remove the screw and remove the protection Loosen and move the clamp Slide off the pipe Undo and remove the screw and...

Page 399: ...ds 2 Outlet to short circuit direct to the pump 3 Outlet to radiator Thermostat specifications Characteristic Temperature at start of stroke 85 2 Valve stroke at 100 7mm Valve tightness pressure 2 bar...

Page 400: ...INDEX OF TOPICS BODYWORK BODYW...

Page 401: ...addle 2 Move the saddle 2 so that the front retainers fasten correctly Press on the middle of the saddle 2 at the rear fasteners to insert them correctly Press down and push the saddle 2 forwards enga...

Page 402: ...ten the direction indica tors M5x16 2 3 Nm 2 21 lb ft 3 Self locking flanged direction indica tor fastening nuts M5 2 2 Nm 1 48 lb ft 4 Flanged self locking upper headlight fastening nuts M6 2 10 Nm 7...

Page 403: ...tors After removing the lower front light as sembly fastening nut remove the pin taking care to retrieve the T bushings from both sides See also Instrument cluster support Remove the complete front li...

Page 404: ...2 2 Nm 1 47 lb ft 4 License plate light fastening M5 1 5 Nm 3 69 lb ft 5 Button head hex socket lower tail light fastening screw M5x25 1 4 Nm 2 95 lb ft Remove the saddle and the rear wiring harnesses...

Page 405: ...trieve the T bushing 4 Remove the rear light assembly 5 License plate holder Remove the saddle and the rear light assembly Unscrew the three upper screws 1 and remove them Remove the two screws 3 that...

Page 406: ...plate light wiring har ness we recommend removing the rear light assembly in order to remove the clamp 2 used to fasten the wiring harness to the number plate support frame Remove the license plate h...

Page 407: ...48 lb ft 5 SWP screws used to fasten the filter box side cover 5x20 3 2 Nm 1 48 lb ft 6 SWP wiring harness support bracket fastening screws 5x20 3 2 Nm 1 48 lb ft 7 SWP control unit cover fastening sc...

Page 408: ...remove them Remove the air filter 5 Remove the starter relay 6 from the support present on the base of the filter box Detach the Ride by Wire control con nector 7 from the support present on the vase...

Page 409: ...n injection relay 9 from the support present on the base of the filter box Detach the front ABS speed sensor connector 10 from the support present on the base of the filter box Remove the secondary in...

Page 410: ...rt present on the base of the filter box Remove the two instrument cannister support fastening screws 14 Remove the two clamps 15 used to fasten the main wiring harness to the cannister support Discon...

Page 411: ...o fas ten the cover 17 Remove the tenth screw used to fasten the cover 18 positioned in corre spondence with steering headstock Remove the metallic cable clamp 19 taking care to retrieve the washer 20...

Page 412: ...rs Disconnect the connectors and re move the sensors Remove the two clamps 23 used to fasten the wiring harness to the throttle body NOTE DURING REASSEMBLY REPLACE THE CLAMPS IN THE POSITIONS IDENTIFI...

Page 413: ...LIC CLAMPS ARE POSITIONED CORRECTLY SO AS TO GUARANTEE THEY ARE TIGHTENED PROPERLY WHEN REPOSITIONING THE THROTTLE BODY Disconnect the throttle body and re move the injector connectors 27 CAUTION THE...

Page 414: ...amps 31 in order to de tach the wiring harness from the base of the filter box Remove the two screws 32 that fas ten the plate used to connect the filter box to the frame Unscrew the nut 33 in order t...

Page 415: ...Remove the two screws 35 used to fasten the control unit cover Slide the control unit cover 36 off ver tically Disconnect the two connectors 37 from the control unit SHIVER 900 Bodywork BODYW 415...

Page 416: ...n the control unit support to the base of the filter box Remove the clamp 40 from the con trol unit support and release the wiring harnesses Detach the support 41 from the pin present on the base of t...

Page 417: ...clamps 44 that fasten the filter box rubber manifolds to the aluminium manifolds on the heads NOTE DURING REASSEMBLY MAKE SURE THAT THE METALLIC CLAMPS ARE POSITIONED COR RECTLY SO AS TO GUARANTEE THE...

Page 418: ...ness Remove the base from the filter box 50 Lower cowl FRONT MUDGUARD ENGINE FAIRING Pos Description Type Quantity Torque Notes 1 Button head hex socket screws used to fasten the mudguard to the calli...

Page 419: ...gine fairing to the support M6x20 4 10 Nm 7 38 lb ft After positioning the vehicle on the side stand unscrew and remove the lower fairing fastening screws working on both sides of the vehicle Remove t...

Page 420: ...l tank M5x30 4 5 Nm 3 69 lb ft 6 Cyl head hex socket for fastening the saddle to the tail fairing M5x16 4 4 Nm 2 95 lb ft FUEL TANK COVER Pos Description Type Quantity Torque Notes 1 Button head hex s...

Page 421: ...ANK pos Description Type Quantity Torque Notes 1 Flanged hex head front fuel tank fastening screws M6x30 2 6 Nm 4 43 lb ft 2 Fuel pump fastening nuts M5 6 6 Nm 4 43 lb ft SHIVER 900 Bodywork BODYW 421...

Page 422: ...he tank M5x10 2 4 Nm 2 95 lb ft 5 Button head hex socket screws for fastening the conveyors to the brack et M5x12 2 4 Nm 2 95 lb ft 6 Self tapping screws used for fasten ing the tank fuel tank cover d...

Page 423: ...e side panel fixing screws before the radiator Remove the four screws fixing the side panels to the tank covers Release the side panels from the ducts Remove the duct front screws SHIVER 900 Bodywork...

Page 424: ...partially and remove the duct central fixing screws Remove the ducts Disconnect the vent pipes from the fuel collection tank and remove it Operating from the right side of the mo torcycle disconnect...

Page 425: ...ump connector Remove the fuel pump connector be low the chassis crosspiece so that the tank can be removed later Remove the nut and remove the cen tral fixing screw of the tank Remove the tank SHIVER...

Page 426: ...the front screws of the tank cover Remove the rear screws of the tank cover Remove the central screws of the tank cover Remove the three outer screws indica ted on the tank cap Bodywork SHIVER 900 BO...

Page 427: ...Carefully remove the inner screw of the tank cap so that it does not fall into the tank Remove the complete cap Remove the tank cover Front mudguard SHIVER 900 Bodywork BODYW 427...

Page 428: ...2 95 lb ft Loct 243 2 Button head hex socket screws for fastening the engine fairing to the support M6x20 4 10 Nm 7 38 lb ft Working on both sides of the vehicle undo and remove the four screws that...

Page 429: ...ps 3 NOTE DURING REASSEMBLY ENSURE THAT ALL THE CLAMPS AND THE WIRING HARNESS ARE IN THE CORRECT PO SITION Disconnect the license plate light 4 and rear light assembly 5 connector Remove the two self...

Page 430: ...Remove the two screws 7 complete with T bushings 8 Remove the four front screws 9 Remove the grab bar 10 taking care to retrieve the T bushings 11 Bodywork SHIVER 900 BODYW 430...

Page 431: ...er to the support plate 5x14 3 3 Nm 2 21 lb ft 3 Button head hex socket screws for fastening the steering plate to the in strument panel plate M6x16 2 10 Nm 7 38 lb ft 4 Special screws for fastening t...

Page 432: ...stening screws 3 Loosen the nuts used for fastening the special screws 4 so that it is possible to remove them Raise the instrument panel in order to remove the three screws 5 used for fastening metal...

Page 433: ...crews 8 in order to separate the instrument panel 7 from the plastic support 9 Tail guard REAR BODYWORK Pos Description Type Quantity Torque Notes 1 Button head hex socket screws used for fastening th...

Page 434: ...te holder to the number plate holder support M5x9 3 4 Nm 2 95 lb ft 5 Flanged hex head screws used for fastening the grab bar support to the grab bar and the saddle support M8x30 4 22 Nm 16 23 lb ft R...

Page 435: ...the ig nition switch assembly disconnect the saddle opening cable and remove it Copertura terminale Remove the saddle the rear grab bar the rear light assembly and the number plate support in order t...

Page 436: ...f the number plate support has not been removed remove the screw 3 and the respective washer and grom met Slide the cover 4 off from the rear See also Seat License plate holder Rear grab rail Tailligh...

Page 437: ...SHIVER 900 Bodywork BODYW 437...

Page 438: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 439: ...fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front...

Page 440: ...COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEG...

Page 441: ...nt Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noi...

Page 442: ...31 385 387 Coil 161 Connecting rods Connectors 184 coolant 391 Coolant 391 Crankcase 52 263 265 270 271 274 Crankshaft 52 263 270 272 274 Cylinder 51 236 237 242 251 254 258 260 266 386 387 D Diagnost...

Page 443: ...ce 8 65 Mudguard 321 427 O Oil filter 70 Oil pressure sensor 173 R Radiator 198 391 396 Rear wheel 323 330 331 Recommended products 67 Run Stop switch 183 S Scheduled maintenance 65 Shock absorber Sho...

Page 444: ...U Use 288 364 W Water pump 393 Wiring diagram 111...

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