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APRILIA SL 750 SHIVER, Service Station Manual, Page: 159 / 303

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APRILIA SL 750 SHIVER Service Station Manual Download Page 159

•

Screw the anticlockwise bolt of the

special tool on the external body.

•

Keeping the external body blocked and

gripping the key, screw the anticlock-

wise bolt so as to remove the flywheel

from the crankshaft.

Specific tooling

020713Y Flywheel extractor

•

Unscrew and remove the anticlockwise bolt of the special tool from the external body.

•

Undo the screw from the crankshaft.

Specific tooling

020713Y Flywheel extractor

•

Remove the flywheel together with the

freewheel.

•

Remove the start-up transmission

gear.

•

In case of malfunction, the start-up

transmission gear cannot be over-

hauled. Therefore, the complete trans-

mission gear should be replaced.

•

Collect the crankshaft woodruff key.

SL 750 SHIVER

Engine

ENG - 11

Summary of Contents for SL 750 SHIVER

Page 1: ...SERVICE STATION MANUAL 854146 SL 750 SHIVER ...

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

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

Page 4: ......

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

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 8: ...HEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have c...

Page 9: ...UT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IF THE ELEC TROLYTIC FLUID COMES INTO CONTACT WITH THE SKIN RINSE WELL WITH ABUNDANT FRESH WATER IT IS PARTICULARLY IM...

Page 10: ...Only use ORIGINAL APRILIA SPARE PARTS Comply with lubricant and consumables usage guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start from the ones with the largest section or from the internal ones moving diagonally Tighten nuts and screws in successive steps before ap plying the tightening torque Always replace self locking nuts washers sea...

Page 11: ...AY CAUSE ONE OF THESE COMPONENTS TO GET LOOSE AND EVEN DETACHED THUS BLOCKING A WHEEL OR OTHERWISE COMPROMISE VEHICLE HANDLING THIS CAN LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Engine run in is essential to ensure engine long life and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your driving speed during ru...

Page 12: ...ple shown below ZD4RA0000YSXXXXXX KEY ZD4 WMI World manufacturer identifier code RA model 000 version variation 0 digit free Y year of manufacture S production plant S Scorzè XXXXXX progressive number 6 digits ENGINE NUMBER The engine number is printed on the base of the left side engine crankcase Engine No CHASSIS NUMBER The chassis number is stamped on the right side of the headstock Chassis No ...

Page 13: ...tch with control on the left side of the handlebar Lubrication system Wet crankcase Pressure system regulated by tro choidal pump Air filter with dry cartridge filter Cooling Fluid GEAR Specification Desc Quantity Type Mechanical 6 speeds with foot lever on the left hand side of the engine Transmission GEAR RATIOS Specification Desc Quantity Gear ratio Gear primary drive 38 71 1st gear ratio 14 36...

Page 14: ... 10 Ah Main fuses 30A Auxiliary fuses 3A 10A 15A 20A Permanent magnet Generator 13 5 V 450 W at 6000 rpm SPARK PLUGS Specification Desc Quantity Standard spark plugs NGK CR7EKB Spark plug electrode gap 0 6 0 7 mm 0 024 0 028 in Resistance 5 kOhm BULBS Specification Desc Quantity Low beam light 12 V 55 W H7 High beam light 12 V 55 W H7 Front tail light 12V 5W x 2 Turn indicator lights 12V 10W Licen...

Page 15: ... mm 1 69 in stems Travel 120 mm 4 72 in Rear Oscillating swingarm and single adjustable hy draulic shock absorber Wheel travel 122 mm 4 80 in SIZES A AND B Specification Desc Quantity Size A 658 5 mm 25 93 in Size B 373 4 mm 14 70 in Brakes BRAKES Specification Desc Quantity Front Double floating disc Ø 320 mm 12 60 in radially mounted callipers with four plungers two of them Ø 27 mm 1 06 in the o...

Page 16: ...petrol minimum octane rating of 95 NORM and 85 NOMM Tightening Torques FRAME ASSEMBLY Name Torque in Nm TCEI screw fixing Shock Absorber Counterplate to right chassis bracket M10x30 1 50 Nm 36 88 lbf ft TCEI screw fixing Fairings to engine M12x282 3 80 Nm 59 lbf ft Self tapping nut fixing left Fairing to engine and Framework to chassis fairings M12 7 80 Nm 59 lbf ft TC TORX screw fixing Perimeter ...

Page 17: ... stand bushing M6x40 2 10 Nm 7 37 lbf ft TBEI screw fixing chain tensioner pad M5x12 3 3 Nm 2 21 lbf ft Self tapping TBEI screw fixing chain guard brake pipe protection and counterslider M5x9 5 4 Nm 2 95 lbf ft Calliper support lock pin M12 1 50 Nm 36 88 lbf ft Loctite 243 FRONT SUSPENSION UNIT Name Torque in Nm Stainless steel TCC screw fixing fork stems on up per and lower plates M8x30 6 25 Nm 1...

Page 18: ... screw fixing right left cover to silencer M6x20 4 10 Nm 7 37 lbf ft TBEI lower screw fixing Licence Plate Holder curved support M6x20 2 10 Nm 7 37 lbf ft COOLING SYSTEM UNIT Name Torque in Nm Self tapping TE screw fixing Radiator left side to frame and radiator bracket to engine M6x25 2 10 Nm 7 37 lbf ft Electric fan fixing screw 3 3 Nm 2 21 lbf ft Screw fixing air deflector to radiator right and...

Page 19: ...t RH light switch 1 2 5 Nm 1 47 lbf ft LH light switch 1 2 5 Nm 1 47 lbf ft TCEI screw fixing lower U bolt on fork plate M10x60 2 50 Nm 36 88 lbf ft Stainless steel TCC screw fixing upper to lower U bolt M8x25 4 25 Nm 18 44 lbf ft ELECTRICAL COMPONENTS UNIT Name Torque in Nm SWP Self tapping screw fixing Demand Support to Demand M5x14 4 3 Nm 2 21 lbf ft Self tapping TE screw fixing Demand sensor t...

Page 20: ...x16 2 7 Nm 5 16 lbf ft FINISHING SMALL PARTS UNIT Name Torque in Nm TCEI screw M8x40 1 25 Nm 18 44 lbf ft Self tapping TE screw M6x25 2 10 Nm 7 37 lbf ft TCE screw fixing fuel cap M5x16 4 5 Nm 3 69 lbf ft TCEI screw fixing fuel cap M5x30 3 5 Nm 3 69 lbf ft TCEI screw fixing saddle lock to tail section M5x16 2 4 Nm 2 95 lbf ft ENGINE UNIT Name Torque in Nm TCEI screw fixing Pin to gearbox lever and...

Page 21: ...G SYSTEM Name Torque in Nm Nut fixing camshaft gears pre tightening M15x1 4 30 Nm 22 13 lbf ft Nut fixing camshaft gears M15x1 4 90 Nm 66 38 lbf ft Screw fixing Timing system Gear M24x1 5 2 40 Nm 29 50 lbf ft 3M SCOTCH GRIP 2353 Special screw fixing Mobile Fixed Pads M8 4 19 Nm 14 01 lbf ft Loctite 242 Chain tensioner fixing screw M6 4 12 Nm 8 85 lbf ft Cylinder Plate fixing screw M6 4 12 Nm 8 85 ...

Page 22: ...utch spring fixing screw M6 6 12 Nm 8 85 lbf ft Self tapping TE screw fixing Pinion M10x1 25x55 1 50 Nm 36 88 lbf ft Connecting rod screw M10 4 20 50 70 Nm 14 75 36 89 51 63 lbf ft Lubricate threads before tightening FLYWHEEL COVERS CLUTCH Name Torque in Nm Screw fixing Stator Flywheel Cover M6 3 9 Nm 6 64 lbf ft Screw fixing Pick up Flywheel Cover M5 2 3 50 Nm 2 58 lbf ft Screw fixing Flywheel Co...

Page 23: ...f ft Loctite 242 rbw control unit fixing screw M5 2 3 50 Nm 2 58 lbf ft Loctite 242 Injectors fixing screw M6 2 12 Nm 8 85 lbf ft Loctite 242 Crosshead self tapping screw fixing cover filter casing M5x20 8 3 Nm 2 21 lbf ft Crosshead self tapping screw fixing partition filter casing M5x20 10 3 Nm 2 21 lbf ft Crosshead self tapping screw fixing side cover filter casing M5x20 3 3 Nm 2 21 lbf ft Cross...

Page 24: ...ting clearance 0 050 0 064 mm 0 00197 0 00252 in Crankcase crankshaft connecting rod Two types of crankcase 1 or 2 are determined according to the diameter of the bearing hole The types are written on the engine crankshaft with a felt tip pen and can be seen by removing the clutch cover and the flywheel cover Two letters representing the main bushings and the primary wheelbase are written on the c...

Page 25: ...e type 1 half bushings A red Main journal type 4 flywheel side crankcase type 2 half bushings B blue Main journal type 5 flywheel side crankcase type 1 half bushings B blue Main journal type 5 flywheel side crankcase type 2 half bushings C yellow Main journal type 7 clutch side crankcase type 1 half bushings A red Main journal type 7 clutch side crankcase type 2 half bushings B blue Main journal t...

Page 26: ...ected from seven types E1 E2 according to connecting rod weight CRANKSHAFT SELECTION TYPE Specification Desc Quantity Crankshaft type 1 Crank pin diameter 41 994 42 000 mm 1 65330 1 65354 in Crankshaft type 2 Crank pin diameter 41 988 41 994 mm 1 65307 1 65330 in Bushing selection The connecting rod has only one size category Therefore bushings are chosen only based on crank shaft type BUSHINGS Sp...

Page 27: ...E SAME TYPE See also Removing the clutch cover Removing the flywheel cover Recommended products chart RECOMMENDED PRODUCTS Product Description Specifications AGIP RACING 4T SAE 15W 50 Engine oil Use top branded oils that meet or exceed the requirements of API SJ CCMC G4 ACEA A3 04 JA SO MA specifications AGIP FORK 5W Fork oil SAE 5W AGIP MP GREASE Grease for bearings joints cou plings and levers A...

Page 28: ...Characteristics SL 750 SHIVER CHAR 22 ...

Page 29: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 30: ...e Description 020709Y Engine support 020710Y Engine plate AP8140187 Engine support stand 020711Y Engine pinion locking 020712Y Handle for Flywheel cover re moval 020713Y Flywheel extractor Special tools SL 750 SHIVER S TOOLS 2 ...

Page 31: ...n 020714Y Comparator support 020715Y Tone wheel removal 9100896 Clutch bell locking tool 020716Y Connecting rod locking 020717Y Piston ring driver AP8140302 tool for sealing ring fitting SL 750 SHIVER Special tools S TOOLS 3 ...

Page 32: ...0718Y Camshaft gear alignment pin 020719Y Timing pin 020720Y Timing tool AP8140179 Valve spring compressor 020721Y Adaptor for valve removal 020722Y Guide for oil seal 020376Y Punch adaptor Special tools SL 750 SHIVER S TOOLS 4 ...

Page 33: ...20629Y 8 mm 0 31 in guide 020412Y 15 mm Oil seal guide 020439Y 17 mm guide for oil seal 020263Y Sheath for fitting the driven pulley 020365Y 22 mm 0 87 in guide 020364Y 25 mm oil seal guide SL 750 SHIVER Special tools S TOOLS 5 ...

Page 34: ...ores code Description 020483Y 30 mm punch 020441Y Oil seal punch 020358Y 37 x 40 mm punch 020357Y 32 x 35 mm adaptor 020359Y 42 x 47 mm punch 020360Y 52 x 55 mm punch Special tools SL 750 SHIVER S TOOLS 6 ...

Page 35: ...or timing overhead camshafts 020724Y Gear control rod roller cage punch 020725Y Punch for water pump overall sealing 020726Y Extractor for bushings 020727Y Punch for bushings 8140180 Extractor for bushings SL 750 SHIVER Special tools S TOOLS 7 ...

Page 36: ...81 manometer for fuel oil com pression pressure 8140199 Tool panel 8202222 Generic adhesive film for panel 8140426 Hooks for panel XXXXXXX Tool for inserting the entire rotor shaft being coded Special tools SL 750 SHIVER S TOOLS 8 ...

Page 37: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 38: ... 625 MI Action Gearing chain Check and lubricate or replace if necessary Transmission cables and controls Check and clean adjust grease or replace if necessary Steering bearings and steering clearance Check and clean adjust grease or replace if necessary Control unit diagnosis Check Disc brakes Check and clean adjust or replace if necessary Engine oil filter Replace General vehicle operation Check...

Page 39: ...ce if necessary Cooling system check and clean adjust grease or replace if necessary Braking systems Check and clean adjust grease or replace if necessary Light circuit Check and clean adjust or replace if necessary Safety switches Check and clean adjust grease or replace if necessary Clutch lever fluid check and top up if necessary Brake fluid Check Coolant Check and top up Engine oil Change Ligh...

Page 40: ...EEDS REPLACING Remove the saddle Remove the side fairings In order to gain access to the spark plugs CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE THE ENGINE AND MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE FRONT SPARK PLUG Working on the left side of the vehicle undo and remove the screw and collect the washer Undo and remove the screw Maintenance SL 750 SHI...

Page 41: ...diator towards the vehicle right hand side and lower it so as to be able to work on the coil Undo and remove the screw Slide off the front coil Unscrew and remove the front spark plug SL 750 SHIVER Maintenance MAIN 5 ...

Page 42: ...nd collect the two collars Undo and remove the chamber fixing screws Slide off the too full and breather pipes from the chamber Lift the tank by turning it on the hinge Release the petrol pipe Disconnect the pump cable harness Working on the right side unscrew and remove the nut and slide off the bolt from the left side Maintenance SL 750 SHIVER MAIN 6 ...

Page 43: ...OT ATTEMPT TO READJUST THE ELEC TRODE GAP The gap between the electrodes should be be tween 0 7 0 8 mm 0 027 0 031 in Otherwise replace the spark plug 2 Make sure the washer is in good con ditions Installation Once the washer is fitted screw the spark plug 2 carefully to avoid dam aging the thread Tighten using the spanner supplied in the tool kit Make each spark plug 2 SL 750 SHIVER Maintenance M...

Page 44: ...LY DROP BELOW THE MIN MARK THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDED THAT THE ALARM WARNING LIGHT AND THE ENGINE OIL PRESSURE ICON ON THE DISPLAY DO NOT TURN ON SIMULTA NEOUSLY CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER A TRIP OR AFTER TRAVELLING APPROXIMATELY 15 km 10 m...

Page 45: ...rew 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 Replace the sealing washer of the drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Screw and tighten the drainage plug 2 Locking torques N m Oil drainage plug M16x1 5 19 Nm 14 01 lbf ft Replace the oil filter Fil...

Page 46: ...ir filter Remove the fuel tank Disconnect the air temperature sensor Undo and remove the eight screws Remove the clamp and slide off the blow by tube Remove the filter casing cover Maintenance SL 750 SHIVER MAIN 10 ...

Page 47: ... PLACED SO THAT UNFILTERED AIR DOES NOT FLOW IN DO NOT FORGET THAT EARLY WEAR OF THE PISTON RINGS AND THE CYLINDER CAN BE CAUSED BY A MAL FUNCTIONING OR MISPLACED FILTERING ELEMENT REFITTING Upon refitting pay attention when inserting intake ducts and check that the bayonet joint is released once every duct has been inserted and rotated Checking the valve clearance The following operation can be c...

Page 48: ... 0 0063 0 0091 in Remove one camshaft at a time Leave the other camshaft assembled and blocked by means of the timing pin CAUTION IF BOTH CAMSHAFTS ARE REMOVED THE ENGINE SPINS MAKING TIMING NECESSARY Remove the bowl tappets and the ad justment shims using a magnet NOTE GREASE THE BOWL TAPPETS AND THE AD JUSTMENT SHIMS PROPERLY EACH TIME THEY ARE REMOVED Replace calibrated pads with a pad thick en...

Page 49: ... 3 30 16 Calibrated pad 3 35 17 Calibrated pad 3 40 18 Calibrated pad 2 55 19 Calibrated pad 2 50 20 Calibrated pad 2 45 21 Calibrated pad 2 40 CAUTION BEFORE REFITTING HEAD COVERS CLEAN HEAD AND COVER SURFACES CAREFULLY Apply THREEBOND on the head cover perimeter along the gasket housing Apply THREEBOND on the head in the areas indicated in the figure See also Removing the head cover SL 750 SHIVE...

Page 50: ...Maintenance SL 750 SHIVER MAIN 14 ...

Page 51: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 52: ...L WINDOW IS SELECTED AND IS DISPLAYED PRESS THE KEY TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 ...

Page 53: ... to 15 NO note C 15 IN THE ENGINE PARAMETER READING SCREEN PAGE AND WITH ENGINE AT IDLE ARE FRONT THROTTLE CORRECTION PARAMETERS OR REAR THROTTLE CORRECTION WITHIN THE 0 4 0 4 RANGE AND IN THE SAME SCREEN PAGE ARE THE FRONT THROT POT 1 DEGREES AND REAR THROT POT 1 DE GREES PARAMETERS OR TO 0 5 WITH ENGINE AT IDLE CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT C...

Page 54: ...ITH THE CONTROL UNIT YES go to 3 NO go to 4 3 ACTIVATE ONE INJECTOR BY MEANS OF AXONE DEVICES ACTIVATION SCREEN PAGE INJECTOR ICON IS THE INJECTOR ACTIVATED YES go to 17 NO go to 12 4 WITH THE KEY TURNED TO OFF CHECK IF THERE IS VOLTAGE ON THE ORANGE RED CABLE OF THE MAIN INJECTION RELAY POLARISED 41 YES go to 6 NO go to 5 5 INSPECT IF THERE IS AN INTERRUPTION IN THE ORANGE RED CABLE FROM THE MAIN...

Page 55: ...O go to 19 18 WHEN THE KEY IS TURNED TO OFF CHECK CONTINUITY AND GROUND IN SULATION OF THE YELLOW PURPLE CABLE FROM THE RELAY TO PIN 62 VEHICLE CONNECTOR YES go to 22 NO go to 21 19 RESTORE THE CABLE HARNESS 20 CHECK THERE IS GROUND INSULATION FOR THE BLUE CABLE OF THE PUMP CONNECTOR OK go to 24 NOT OK go to 23 21 RESTORE THE CABLE HARNESS END 22 CHECK THE VEHICLE CONNECTOR OK go to 25 NOT OK go t...

Page 56: ...E PINK BLACK CABLE OF THE RETENTION RELAY START UP LOGIC 39 TO PIN 14 VEHICLE CONNECTOR OK go to 38 NOT OK go to 39 37 REPLACE THE RETENTION RELAY START UP LOGIC 39 38 CHECK THE VEHICLE CONNECTOR PIN 14 OK go to 40 NOT OK go to 41 39 RESTORE THE CABLE HARNESS 40 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS ENGINE REVOLUTION SENSOR FOLLOW THE TROUBLESHOOTING STEPS IN THE SECTION RE...

Page 57: ...0 OK go to 52 NOT OK go to 53 51 REPLACE THE RELAY END 52 PRESSING THE STARTER BUTTON CHECK IF THERE IS VOLTAGE TO THE YEL LOW RED CABLE OF THE START UP RELAY OK go to 54 NOT OK go to 55 53 REPLACE THE RELAY END 54 CHECK IF THE BLUE CABLE OF THE START UP RELAY 36 IS GROUNDED OK go to 56 NOT OK go to 57 55 RESTORE THE CABLE HARNESS END 56 WITH THE KEY TURNED TO OFF CHECK IF THERE IS VOLTAGE TO THE ...

Page 58: ... ANY DEVICE AND CHECK THE SUITA BLE INDICATION ON THE DEVICE STATUS ICON 0 1 SCREEN PAGE If MALFUNCTION is shown go to 71 If CORRECT OPERATION is shown go to 72 67 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSOR INDICATION ON AXONE ALWAYS STOP END 68 IS THE SENSOR VERTICAL YES go to 69 NO go to 70 69 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSO...

Page 59: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 60: ...Components arrangement Key 1 Revolution sensor 2 Intake air pressure sensor 3 Intake air temperature sensor Electrical system SL 750 SHIVER ELE SYS 2 ...

Page 61: ...THE RELAY CABLES RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the wiring diagram 9 Location on the vehicle under the fuel tank left side second relay starting from the front START UP RELAY Location on the wiring diagram 36 Location on the vehicle under the fuel tank right side fifth relay starting from the front below in relation to the line of the other rela...

Page 62: ...stallation INTRODUCTION Scope and applicability The position of the cable harnesses how they are fixed to the motorcycle and potential problems are defined on the following sections in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harness 1 Filter Casing Cable H...

Page 63: ...ENTRAL SECTION TABLE F 8 ECU and Ground Lead Connectors for the filter casing CENTRAL SECTION TABLE A 9 Fuel Pump Connector CENTRAL SECTION TABLE F 10 Key Connector Right Light Switch Connectors Left Light Switch Connectors Connectors inside the housing behind the radiator FRONT SECTION TABLE I THE CONNECTORS LISTED ARE CONSIDERED CRITICAL IN COMPARISON WITH THE OTHERS BECAUSE THE VEHICLE WILL STO...

Page 64: ...cap on the cable harnesses 1 and 2 of the switches TABLE B RIGHT SWITCH CABLE HARNESS RETAINER Fasten the right switch cable harness es with a rubber clamp TABLE C LEFT SWITCH CABLE HARNESS RETAINER Fasten the left switch cable harnesses with a rubber clamp Electrical system SL 750 SHIVER ELE SYS 6 ...

Page 65: ...BLE With a small clamp not pulled clamp fasten the clutch cable to the throttle cable TABLE E INSTRUMENT PANEL CABLES Fasten the instrument panel cable braid to the chassis with a medium clamp SL 750 SHIVER Electrical system ELE SYS 7 ...

Page 66: ...E Use a small clamp to fasten the air temperature connector and the front headlamp cable to the main cable har ness TABLE H COIL CABLE Fasten the coil cable with a small clamp TABLE I HOUSING AND CENTRAL CABLE GUIDE 1 The housing containing light switch and key connectors shall be placed freely over the branch with the clamp and not fixed 2 Place medium clamps on the central cable guide that holds...

Page 67: ... indicator connector and the main trunk 2 The immobilizer aerial connector is fitted between the plate and the instrument panel 3 Lift the external air temperature sensor upwards once it is connected Parte centrale CAUTION SL 750 SHIVER Electrical system ELE SYS 9 ...

Page 68: ...TABLE A CONTROL UNIT MAIN CABLE HARNESS HORN AND NEUTRAL SENSOR CABLES 1 ECU 2 Engine Connector 3 Vehicle Connector 4 ECU ground connection 5 Horn and neutral sensor cables 6 Main cable harness The horn and neutral sensor cables shall be laid over the water pipe upon installation TABLE B UNDER SEAT CABLE HARNESS 1 Use small clamps to fasten the cables 2 Use medium clamps to fasten the main cable h...

Page 69: ... with a small clamp under the cable harness main branch TABLE E CABLE HARNESSES UNDER THE TANK 1 Fasten the pipe with two medium clamps 2 The flywheel and side stand cables shall be laid through the cable guide screwed to the filter housing 3 Bunch the cables with clamps 4 Fasten with a clamp cables on the filter housing and the rear cylinder coil SL 750 SHIVER Electrical system ELE SYS 11 ...

Page 70: ...t 4 Fasten with a medium clamp TABLE G HANDGRIP SENSOR CONNECTOR 1 Fitting the connector in the handgrip sensor 2 Closing the connector block 3 During step 1 move the hook 3 forwards TABLE H LEFT SIDE CABLE HARNESS UNDER THE TANK Identify the regulator output with the WHITE belt 1 Fasten the cable harness with a clamp 2 Connector for resistance module Electrical system SL 750 SHIVER ELE SYS 12 ...

Page 71: ...lso the control unit upper branch TABLE I PICK UP AND ENGINE CONTROL UNIT CABLE HARNESSES 1 Cable harness path towards the engine control unit connectors 2 Pick up cable harness path TABLE J RIGHT SIDE SL 750 SHIVER Electrical system ELE SYS 13 ...

Page 72: ...d the pipe so that the oil and start up cable is tightened to the rear pipe 3 Fasten the cable with medium clamps TABLE K NEUTRAL SENSOR CABLE HARNESS Place the neutral sensor cable harness as shown and fasten it with a small clamp where indicated Electrical system SL 750 SHIVER ELE SYS 14 ...

Page 73: ... the chassis as indicated 1 medium clamp 2 small clamp TABLE M1 FILTER CASING CABLE HAR NESS Place both throttle valve position sen sors TABLE M2 SENSORS Place the two sensors TABLE M3 CLAMPS Fasten cable harnesses with clamps SL 750 SHIVER Electrical system ELE SYS 15 ...

Page 74: ... path drawn in figure that will not be visible on the vehicle once fully assembled As indicated above the ground lead is laid behind the filter casing pipe As regards the lower section the cable is laid behind the starter motor plate In the central position insert a small clamp joining the ground lead and the oil cable to the smallest pipe Electrical system SL 750 SHIVER ELE SYS 16 ...

Page 75: ... ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A REAR LIGHT CABLE HARNESS 1 Rear right turn indicator BLACK and RED cables 2 Left turn indicator BLACK and SKY BLUE cables 3 Fasten the rear lig...

Page 76: ...Electrical system SL 750 SHIVER ELE SYS 18 ...

Page 77: ...General wiring diagram Key 1 MULTIPLE CONNECTORS 2 RIGHT FRONT TURN INDICATOR 3 COMPLETE FRONT HEADLAMP 4 TAIL LIGHT BULB SL 750 SHIVER Electrical system ELE SYS 19 ...

Page 78: ...FT TURN INDICATOR 22 REAR RIGHT TURN INDICATOR 23 LICENSE PLATE LIGHT BULB 24 REAR TWIN LIGHT STOP LIGHT BULB 25 REAR LIGHT ASSEMBLY 26 REAR STOP SWITCH 27 FRONT STOP SWITCH 28 SPEED SENSOR 29 FALL SENSOR 30 NEUTRAL SENSOR 31 TIMING SENSOR OPTIONAL 32 AUXILIARY FUSES 33 FLYWHEEL 34 VOLTAGE REGULATOR 35 STARTER MOTOR 36 START UP RELAY 37 MAIN FUSE 38 BATTERY 39 RETENTION RELAY START UP LOGIC 40 CON...

Page 79: ...YLINDER PRESSURE SENSOR 56 FRONT CYLINDER PRESSURE SENSOR 57 REAR CYLINDER INJECTOR 58 FRONT CYLINDER INJECTOR 59 EFG 1X THROTTLE CONTROL UNIT MARELLI 60 REAR CYLINDER THROTTLE 61 FRONT CYLINDER THROTTLE 62 THROTTLE GRIP POSITION SENSOR 63 PICK UP 64 ECU 65 HAZARD BUTTON LIGHTING 66 HIGH BEAM LIGHT RELAY 67 RECOVERY LOGIC RELAY Colour key Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Br...

Page 80: ...t should be present and it is important to check terminal correct positioning on the connector i e all terminals aligned at the same depth and terminal integrity i e that termi nals are not loose open bent etc For connec tors whose terminals are not visible e g Marelli control unit use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the ...

Page 81: ... check if a cable is energised i e if it receives power supply from the battery or the control unit Tester set the tester on the direct current symbol and place the tester red probe on the cable being inspected and the black probe on the vehicle ground connection or on the battery terminal CAUTION IN CASE OF TEMPORAL MALFUNCTIONING CARRY OUT ALL DUE CHECKS LOOKING FOR FAILURES BY MOVING SLIGHTLY T...

Page 82: ...ors stored in its memory INSTRUMENT PANEL ERRORS In this mode a chart is displayed showing potential errors in the immobilizer and the sensors connec ted to it Instrument panel errors In this mode a chart is displayed showing potential errors in the immobilizer and the sensors connected to it DSB 01 Immobilizer failure key code read but not recognised DSB 02 Immobilizer failure key code not read k...

Page 83: ...NG RESET This function is used to reset vehicle servicing Using this function the odometer can be reset only once within the first 200 km 124 mi of the vehicle provided this has not been done by the Quality Check UPDATE This function is used to program the instrument panel again This screen page shows the software version currently loaded the LCD reads INSTRUMENT PANEL DISCONNECTED NOW CONNECT THE...

Page 84: ...ded this has not been done by the Quality Check In order to activate this function follow the instructions in the DIAGNOSIS section See also Diagnosis level indicators Fuel reserve sensor Check proper operation of the sensor by adding a 2W bulb in series to the sensor Place a bulb between the battery power supply cable and the connector terminal and connect the negative terminal to the ground conn...

Page 85: ...ate light 10A B Low beam high beam lights 15A C Live positive lead to EFG 1x control unit and to instrument panel Instrument panel diagnosis 10 A D Instrument panel Ride by wire 15 A E Permanent positive ECU power supply 3A F Lambda heater coils Start up logic Fan and injection relay Fuel pump Purge valve Injectors ECU Start up logic 20 A G Spare fuses 10 15 20 A MAIN FUSES H Spare fuses 30 A I Ba...

Page 86: ...ch 2_Power latch finished Engine mode Example value Indefinite_Start up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal Example value yes no Indicates whether the control unit has received the consent by the instrument panel regarding the im mobilizer coded key or user code entered manually Potential errors will be shown on the Instrument Panel Errors ...

Page 87: ... operational Error cause Replace injection ECU Level 2 safety reset P0608 Error cause As the level 2 safety system comparison between requested torque and calculated torque has detected a fault the control unit has reset engine C gravity Troubleshooting Continue failure search for the other errors detected Safety Engine Stop P0609 Error cause As the level 3 safety system control EEPROM has detecte...

Page 88: ...e valve position Connect to Axone and check that the status for Throttle Self learning is Carried out and the status for Throttle grip autodetection is Not carried out this last status entails Urgent service being dis played on the instrument panel If Throttle Self learning shows Not carried out go to stage 1 If it shows Carried out go to stage 2 Stage 1 current errors have probably been detected ...

Page 89: ... right side near the clutch cover connector on the sensor Pin out 1 Ground connection 2 Output signal 3 Supply voltage 5V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL CON CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE PARAMETERS Speed sensor Vehicle speed km h AXONE LOGIC ERRORS Sens...

Page 90: ...t approximately 5V if there is no voltage set the key to OFF and check that there is continuity between the ENGINE PIN 13 and PIN 3 If there is continuity replace the control unit if there is not restore the cable harness if there is 5V voltage set the key to OFF and check that there is continuity between the VEHICLE PIN 49 and the sensor PIN 2 if there is no continuity restore the cable harness I...

Page 91: ...sitive signal CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL CON CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE PARAMETERS Engine rpm AXONE STATUSES Synchronised panel Example value Start up_Lean_Rich_Fault due to rich value_Fault due to lean value If the probe connector is removed vol...

Page 92: ...n and the sensor is adequately placed in its fitting if not OK restore if OK replace the sensor Twistgrip position sensor THROTTLE GRIP POSITION SENSOR Function The throttle grip is the part to which the throttle control cables arrive its task is to translate the rider s power request Demand into an electrical signal to be sent to the electronic control unit Operation Operating principle The two t...

Page 93: ...ND SHOULD BE PLACED TO THE RIGHT AXONE PARAMETERS Left side throttle grip position sensor track A Example value 1107 mV Voltage value of the left potentiometer track A Left side throttle grip position sensor track B Example value 1107 mV Voltage value times 2 of the left potentiometer track B Right side throttle grip position sensor track C 3560 mV Voltage value of the left potentiometer track C R...

Page 94: ... to zero if the circuit is open short circuit to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable earth insulation from the throttle grip sensor connector or the control unit connector if the cable is not earth insulated restore the wiring...

Page 95: ...o positive check the value shown by the parameter of the right Throttle Grip position Sensor track C disconnect the right side connector and see the value displayed by the Axone if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open short circuit to negative check the throttle grip sensor connec...

Page 96: ...e signals have been detected at PINS 42 and 40 of the VEHICLE con nector tracks A B Troubleshooting Check the parameters of the left Throttle Grip Position Sensor tracks A and B if one of the two values clearly deviates from 600 1400 mV it means that this potentiometer is defective Check the throttle grip sensor connector and the control unit connector if not OK restore If OK check that cable resi...

Page 97: ...s which get to the throttle grip sensor are the same but they should NEVER be inverted Mark or check the connector marking before removing them blue stamp blue band REMOVAL When required disconnect the corre sponding connectors undo and re move the two screws and remove the throttle grip position sensor Intake pressure sensor INTAKE AIR PRESSURE SENSOR Function The pressure sensors one per cylinde...

Page 98: ...3 mbar Pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure Example value 1004 mbar Pressure estimated by the control unit according to the throttle position AXONE ELECTRICAL ERRORS Front cylinder air pressure sensor P0105 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltag...

Page 99: ... check that the voltage on sensor con nector PIN 1 is approx 5 V if this is not correct set the key to OFF and check continuity between the ENGINE connector PIN 15 and the sensor connector PIN 1 If not OK restore the cable harness if it is OK replace the control unit if there is 5V voltage at PIN 1 and with key set to ON check the continuity to ground of the sensor connector PIN 3 If not OK restor...

Page 100: ...en percentage this error is activa ted The most frequent causes can be abnormal resistance in the sensor circuit for example rusted terminals or sensor with poor performance Troubleshooting Check the filter casing large connector the Marelli control unit connector and the sensor connector if not OK restore If everything is OK check that cable resistance between VE HICLE connector PIN 34 and sensor...

Page 101: ...and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Estimation error for front cylinder intake manifold pressure P0215 pressure too high pressure too low Error cause A substantial difference between the estimated pressure and the measured pressure has been detected for example the pipe between sensor and t...

Page 102: ...re too low at rear cylinder manifold error P0218 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake...

Page 103: ...s to an open circuit AXONE ELECTRICAL ERRORS engine temperature sensor P0115 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 45 of the ENGINE connector If shorted to negative voltage equal to zero has been detected at PIN 45 of the ENGINE connector If the circuit is open shorted to positive check...

Page 104: ...sor P0116 signal not valid Error cause An excessive temperature variation has been detected for example the cause may be a contact resistance between the terminals Troubleshooting Check the sensor connector and the ENGINE connector of the Marelli control unit NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check thro...

Page 105: ...N 63 of the ENGINE connector If shorted to negative voltage equal to zero has been detected at PIN 63 of the ENGINE connector Troubleshooting If the circuit is open shorted to positive check the sensor connector and the Marelli control unit connector If they are OK check sensor continuity replace the sensor if not OK if it is OK check continuity between the ENGINE connector PIN 63 and the sensor P...

Page 106: ... OK check the sensor connector and the Marelli control unit connector Lambda sensor LAMBDA PROBE Function It tells the control unit whether combustion is lean or rich Operation Operating principle The Marelli injection control unit reads and inter prets a voltage generated by the difference in oxy gen content between the exhaust fumes and the ambient It does not require an external supply source b...

Page 107: ...ds to 25 In an open circuit the lambda probe signal is too low Therefore the control unit takes it as a lean combustion condition and will try to enrich it The value read will be 0 75 once this correction has been tried the value shifts to 1 00 fixed and the Lambda probe error is signalled AXONE STATUSES Lambda Example value Start up_Lean_Rich_Fault due to rich value_Fault due to lean value If the...

Page 108: ...hort circuit to negative check the continuity from probe connector PIN 3 and 4 towards the probe if not OK replace the probe if it is correct check the sensor connector and the Marelli control unit connector If not OK restore If OK and with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if there is not check the red black cable between the probe connecto...

Page 109: ...TTLE AIR EXCESSIVE PETROL DEFECTIVE PROBE Injector INJECTOR Function To supply the correct amount of petrol at the right timing Operation Operating principle Injector coil is excited for the petrol passage to open Level in wiring diagram Coils and injectors Location on the vehicle inside the filter casing connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C 68 F Pin out 1 Supply 2 G...

Page 110: ...d to positive disconnect the injector connector set key to ON activate the compo nent with Axone and check the voltage on the filter casing grey green cable on the filter casing small connector towards the Marelli control unit if there is voltage restore the cable harness between the filter casing connector and the Marelli control unit If there is no voltage reconnect the connector and check if th...

Page 111: ...ction on the grey red cable if there is restore the cable harness between the filter casing connector and the Marelli control unit if there is not reconnect the connector and disconnect the injector connector and check if there is a ground connection on PIN if there is voltage restore the filter casing cable harness If there is not replace the injector the circuit is open check the component corre...

Page 112: ...econds and the sky blue orange cable of the coil is closed to ground for 2 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are dis played in case of lack of activation Rear coil The auxiliary injection relay No 42 in the wiring diagram placed unde...

Page 113: ...coil connector or control unit connector If not OK restore the cable harness Rear coil P0352 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 19 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 19 of the ENGINE connector Troubleshooting If ...

Page 114: ...ced to activation If start up is attempted during this activation which requires 3 seconds the engine will not start Level in wiring diagram throttle control unit Location on the vehicle inside the filter casing connector on the throttle body Pin out 1 potentiometer signal 1 2 supply voltage 5V 3 throttle valve control 4 potentiometer signal 2 5 throttle valve control 6 ground connection CAUTION B...

Page 115: ...manifold the pressure read is different from the pressure estimated by the control unit and the system tries to reach an estimated situation by opening the throttle a little bit more therefore this parameter takes a value different from zero an acceptable value should be between 0 7º and 0 7º Front cylinder Limp home position Rear cylinder Limp home position Example value 800 mV 780 mV Voltage sto...

Page 116: ...lue short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN A5 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN A5 of the throttle control unit Troubleshooting if shorted to positive check the value shown by the parameter of the front throttle...

Page 117: ...ion P0127 Example value short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN B5 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN B5 of the throttle control unit Troubleshooting if shorted to positive check the value shown by the parameter o...

Page 118: ...ector set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection if it is there is a short circuit in the cable ground connection if it is not replace the throttle body open circuit overcurrent excessive inside temperature check the throttle body connector and the throttle control unit connector If not OK restore If everything is OK disconnect the throttle body connec...

Page 119: ... the throttle body open circuit overvoltage excessive inside temperature check the throttle body connector and the throttle control unit connector If not OK restore If everything is OK disconnect the throttle body connector PIN 3 and the throttle control unit connector C8 and check the circuit continuity between the two terminals if there is no continuity restore the cable har ness If there is con...

Page 120: ... one of the two circuits Troubleshooting Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 1 and the throttle control unit PIN 6A is a few tenths of an Ohm Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5A is a few tenths of an Ohm If one of th...

Page 121: ...d the throttle control unit PIN 6B is a few tenths of an Ohm Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5B is a few tenths of an Ohm If one of the two is different restore the cable harness If correct replace the complete throttle body Front throttle Limp Home autodetection P0160 test failed Error cause Throttle position kept by the spri...

Page 122: ...te errors hindering throttle self learning Front throttle position error P0167 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body Rear throttle Limp Home autodetection P0180 test failed Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does...

Page 123: ...ning process has not been successful or has not been carried out The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Delete errors hindering throttle self learning Rear throttle position error P0187 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body RES...

Page 124: ...r DSB 07 Error cause An oil sensor failure is signalled when with engine off it is detected that the sensor circuit is open The test is per formed only once when the key is set to ON This error is signalled by the bulb icon and the general warning light turns on as well Troubleshooting Check the sensor connector and the instrument panel connector PIN 17 If not OK restore If OK check the con tinuit...

Page 125: ...in neu tral or in gear Operation Operating principle for gear in neutral the circuit is closed to ground connection then via CAN the control unit sends the signal to the instrument panel which turns on the neutral speed warning light Level in wiring diagram start up enabling switches Location on the vehicle left side of the vehicle near flywheel cover connector upper part of the flywheel cover Ele...

Page 126: ... ENGINE connector PIN 16 if there is no continuity restore the cable harness If there is replace the instrument panel if the vehicle performance is correct the engine starts with gear in neutral but the neutral warning light is off or replace the control unit if the vehicle performance is not correct the engine does not start with gear in neutral Indication on the instrument panel always gear in n...

Page 127: ...able terminals on the connector and the correct connection of the cables on the terminals If they are not correct restore the cable harness if correct disconnect the two terminals from the sensor and with key set to ON check continuity to ground connection of PIN 2 if there is no con tinuity restore the cable harness if there is replace the sensor Indication on Axone always Pulled disconnect the t...

Page 128: ...BLESHOOTING CAREFULLY READ THE GENERAL CON CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE STATUSES Side stand Example value up down Indication on Axone always down check the connector if not OK restore if it is OK disconnect the two terminals from the sensor and check continuity to ground of PIN 1 if there is no ...

Page 129: ...NG OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE PARAMETERS Fall sensor Example value Normal Tip over Indication on Axone always Normal even when the sensor is inverted disconnect the connector and with sensor inverted check if there is continuity between the two PINS of the sensor if there is no continuity replace the sensor if there is check the connector If not OK re...

Page 130: ...UMENT PANEL DSB 06 Error cause The oil sensor failure is signalled when it is detected that the sensor circuit is open or short circuit to positive Troubleshooting Check the sensor connector and the instrument panel connector PINS 10 and 30 If not OK restore if OK check the continuity of the pink cable between the sensor connector and the instrument panel connector PIN 10 if not OK restore the cab...

Page 131: ...nt Operation Operation Operating principle When the control unit detects a temperature of approx 102 C it closes the fan control relay pickup circuit to ground Level in wiring diagram electric fan Location the relay is located under the fuel tank left side first front relay CHECK however the identification of the relay with the colour of the cables Electrical characteristics relay normally open dr...

Page 132: ...s are correct by disconnecting it from the cable harness If they are not correct replace the relay if correct restore the cable harness pink blue cable If the circuit is open check the relay connector and the Marelli control unit VEHICLE con nector If not OK restore if OK restore the cable harness red blue cable RUN STOP switch Run stop switch Function It tells the control unit if the driver wishe...

Page 133: ... check if there is voltage to the red black cable if there is no voltage restore the cable harness if there is check the yellow grey cable earth insulation if there is continuity to ground restore the cable harness if it is correct take the key to OFF and check the VEHICLE connector is in good conditions and the continuity of the grey yellow cable between the sensor in question and the VEHICLE con...

Page 134: ... connector 9 3 Revolution sensor input Engine connector 23 4 Vehicle speed input Vehicle connector 49 5 Throttle grip input Track A Vehicle connector 42 6 Throttle grip input Track B Vehicle connector 40 7 Throttle grip input Track C Engine connector 30 8 Throttle grip input Track D Engine connector 44 9 Front cylinder intake pressure sensor input Vehicle connector 34 10 Rear cylinder intake press...

Page 135: ...elay control output Vehicle connector 59 30 Lambda heater control output Engine connector 32 31 Lambda sensor input Engine connector 43 32 Lambda sensor input Engine connector 60 33 Purge Canister valve control output optional Engine connector 51 34 Control unit direct power supply Vehicle connector 16 35 Power ground connection 1 Engine connector 21 36 Power ground connection 2 Engine connector 5...

Page 136: ...NOTE THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNEC TOR Electrical system SL 750 SHIVER ELE SYS 78 ...

Page 137: ...throttle body PIN 2 12 4B Firmware reprogramming power supply 13 5B Input for rear throttle potentiometer 2 signal Rear throttle body PIN 4 14 6B Input for rear throttle potentiometer 1 signal Rear throttle body PIN 1 15 7B Rear throttle reset signal input 16 8B Battery power supply input 17 1C Front throttle motor control Front throttle body PIN 3 18 2C Ground connection 19 3C Ground connection F...

Page 138: ...DY PIN 15 16 GREY BODY Indicator reset PIN 16 17 GREY BODY Oil sensor input PIN 17 18 GREY BODY 750 1200 Selection PIN 18 19 GREY BODY PIN 19 20 GREY BODY K Line PIN 20 21 BLACK BODY Battery PIN 21 22 BLACK BODY Front left turn indicator acti vation PIN 22 23 BLACK BODY Front right turn indicator acti vation PIN 23 24 BLACK BODY Aerial 2 PIN 24 25 BLACK BODY PIN 25 26 BLACK BODY CAN H PIN 26 27 BL...

Page 139: ... PIN 51 VEHICLE problem on the whole network for example battery cut off or short circuited or shorted to ground Troubleshooting Check the Marelli control unit VEHICLE connector if not OK restore if OK check the earth insulation of the two CAN lines from PIN 20 and PIN 51 of the VEHICLE connector If not OK restore the cable harness if OK check continuity of the two CAN lines from the Marelli contr...

Page 140: ...nel CAN line to the throttle control unit U1705 no signal Error cause No signal is received by the throttle control unit Troubleshooting Check the filter housing large connector and the throttle control unit connector if not OK restore if OK check the continuity of the two lines from the filter housing large connector to the VEHICLE connector of the Marelli control unit if not OK restore the cable...

Page 141: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 142: ...ional under sump and rear wheel service stands Undo and remove the screw and move the coil Disconnect the engine temperature sensor connector Disconnect the horn connectors Disconnect the engine oil pressure sensor connector Disconnect the starter motor power supply cable Engine from vehicle SL 750 SHIVER ENG VE 2 ...

Page 143: ...the washer Disconnect the ground leads Move the breather pipe Disconnect the speed sensor connec tor Undo and remove the three screws Remove the clutch control cylinder Lock the plunger using a clamp SL 750 SHIVER Engine from vehicle ENG VE 3 ...

Page 144: ...remove the three screws fix ing the chain guide Remove the clutch pin CAUTION UPON REFITTING PROPERLY GREASE THE O RING INDICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT Disconnect the gear in neutral sensor connector Engine from vehicle SL 750 SHIVER ENG VE 4 ...

Page 145: ...on connecting rod keeping it linked to the gear shift lever through the rod Slacken the gearing chain tension Undo and remove the screw collect the washer and the spacer Slide off the pinion from the chain and remove Disconnect the generator connections SL 750 SHIVER Engine from vehicle ENG VE 5 ...

Page 146: ...de slightly slide off the three bolts Collect the spacers on the opposite side Check the spacer sizes so as not to in terchange them upon refitting Slide off the three bolts completely and collect their washers Lower the engine See also Vehicle preparation Installing the engine to the vehicle Place the engine on a suitable lower stand Lift the engine Place the engine so that the rear attachments o...

Page 147: ...REMOVED Working from the left side tighten the three nuts Release the engine from the belt and the hoist Refit the pinion and restore the gearing chain clearance Reconnect the electric connections and clamp the cable harnesses Carry out the vehicle preparation oper ations but in reverse order restore the correct level of all fluids and carry out the adjustments that may be required See also Vehicl...

Page 148: ...Engine from vehicle SL 750 SHIVER ENG VE 8 ...

Page 149: ...INDEX OF TOPICS ENGINE ENG ...

Page 150: ...tor lock 3 Selector sprocket wheel 4 M5x16 Screw 5 Sprocket wheel pawl 6 Spring 7 Pin for spring 8 Tone wheel 9 Complete transmission gear shaft 10 Forks 11 Fork shaft 12 Spring 13 Pin for spring 14 Gear selector 15 Fork shaft 16 Fork Engine SL 750 SHIVER ENG 2 ...

Page 151: ...d screw M6x15 22 Complete index lever 23 Spring Gearbox shafts Gearbox shafts diagram Key 1 Main gear shaft Z 14 2 2nd gear on primary Z 17 3 3rd 4th gear on secondary Z 20 22 4 5th gear on primary Z 23 5 6th gear on primary Z 24 6 Thrust washer 7 Circlip 8 Thrust washer 9 Thrust washer SL 750 SHIVER Engine ENG 3 ...

Page 152: ... 5th gear on secondary Z 26 17 6th gear on secondary Z 25 18 Thrust washer 19 Circlip 20 Thrust washer 21 Thrust washer 22 Thrust washer 23 Floating bushing 24 Floating bushing 25 Floating bushing Disassembling the gearbox Remove the gear selector as descri bed in the Crankcase Opening section Remove the two bolts of the forks Engine SL 750 SHIVER ENG 4 ...

Page 153: ...m con trol Remove the three gear selection forks CAUTION THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE Carefully rotate the engine support SL 750 SHIVER Engine ENG 5 ...

Page 154: ...emove the gear selector refer to the operations described under Crankcase opening Checking the gear selector Selector spring Make sure that the spring ends on the two shifting positions forward downshifting and backward up shifting are always in contact with the selector plate Make sure that the clearance between the end of the spring on the selector plate and the stop pin is almost null when in h...

Page 155: ... plate spring With a thickness gauge check that the spring is not deformed by over stretching Starter motor Removing the starter motor Disconnect the starter motor power supply cable Undo and remove the four screws and remove the starter motor SL 750 SHIVER Engine ENG 7 ...

Page 156: ...ear 4 Freewheel flange 5 Freewheel 6 Complete rotor 7 Complete stator 8 Flywheel cover gasket 9 Flywheel cover 10 TCEI low head screw M6x30 11 TBIC screw M5x12 12 TE flanged screw 13 Cap 14 Gasket 15 TCEI screw M6X18 16 Woodruff Key 17 TE flanged screw 18 Washer Engine SL 750 SHIVER ENG 8 ...

Page 157: ...oving the flywheel cover Remove the flywheel cover inspection cap Unscrew and remove the ten screws 1 2 NOTE THE FLYWHEEL COVER SCREW 2 IS SHORTER THAN SCREWS 1 Use the specific tool to remove the fly wheel cover Specific tooling 020712Y Handle for Flywheel cover removal SL 750 SHIVER Engine ENG 9 ...

Page 158: ...VED SIMULTANEOUSLY AS THEY ARE PART OF THE SAME ELECTRICAL BRANCH Magneto flywheel removal Remove the flywheel cover Undo and remove the screw and re move the retention plate Heat the magneto flywheel with the specific heater Lock the flywheel using the specific tool and loosen the screw Specific tooling 020713Y Flywheel extractor Engine SL 750 SHIVER ENG 10 ...

Page 159: ...Unscrew and remove the anticlockwise bolt of the special tool from the external body Undo the screw from the crankshaft Specific tooling 020713Y Flywheel extractor Remove the flywheel together with the freewheel Remove the start up transmission gear In case of malfunction the start up transmission gear cannot be over hauled Therefore the complete trans mission gear should be replaced Collect the c...

Page 160: ...the freewheel from the mag neto flywheel Installing the flywheel Insert the woodruff key on the crank shaft Insert the start up transmission gear after applying a layer of grease Insert the flywheel on the crankshaft Screw the screw together with the washer but without tightening Engine SL 750 SHIVER ENG 12 ...

Page 161: ...t Remove the special tool Specific tooling 020713Y Flywheel extractor Locking torques N m Screw fixing Rotor Crankshaft M12x1 25 1 120 Nm 88 51 lbf ft Place the retention plate Tighten the screw Clutch side Remove the water pump cover Undo and remove the eleven screws working in a diagonal sequence Collect the gasket SL 750 SHIVER Engine ENG 13 ...

Page 162: ... possible to remove the complete clutch assembly by removing only the clutch cover In this case carry out the following operations measure the clutch bell protrusion from the crankcase before removal during refitting first check that the measurement has not changed then tighten the clutch nut If it has changed rotate the crankshaft so that the oil pump control drive gear engages cor rectly with th...

Page 163: ...2 Washer 3 Clutch hub 4 Clutch pressure plate 5 Clutch spring 6 Washer 7 TCEI screw M6 8 Spacer 9 Anti juddering 10 Belleville spring 11 Anti juddering 12 Nitrided driven disc 13 Lathed drive disc 14 Drive disc 15 Driven disc SL 750 SHIVER Engine ENG 15 ...

Page 164: ...oosening them 1 4 of a turn at a time operate in stages and diagonally and collect the washers and the clutch springs Remove the pressure plate Remove the mushroom rod for clutch control Remove the discs Remove the spacer and the belleville spring Engine SL 750 SHIVER ENG 16 ...

Page 165: ...Specific tooling 9100896 Clutch bell locking tool Unscrew and remove the clutch hub nut and collect the washer Remove the clutch hub Collect the special washer between the clutch hub and the bell Collect the clutch bell SL 750 SHIVER Engine ENG 17 ...

Page 166: ...lowed 0 20 mm 0 0079 in Measure the driving plate thickness at four positions replace them all if not complying with specifications CAUTION THE STEEL DISCS MUST SHOW NO SCORES OR TEMPERING COLOUR Measure the thickness of the clutch discs at four positions replace them if not complying with specifications Thickness of nine drive discs 2 5 mm 0 10 in Driven disc thickness 2 95 3 05 mm 0 116 0 120 in...

Page 167: ... Remove the clutch bell Remove the seeger ring Remove the oil pump control gear UPON REFITTING THE GEAR COLLAR MUST ALWAYS BE FACING THE CLUTCH BELL Remove the rotation locking pin from the oil pump control gear Check the clutch bell for damage and wear that may result in clutch irregular operation Deburr the teeth or replace the bell MAIN DRIVEN GEAR CHECK SL 750 SHIVER Engine ENG 19 ...

Page 168: ...ate Check the pressure plate and the bearing for dam age and wear If necessary replace the parts Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation If neces sary replace the bell Checking the springs Check the springs for damage and if necessary replace the them all togeth er Measure the clutch spring length when unloaded if necessary rep...

Page 169: ...lutch bell Make sure that the oil pump control drive gear of the clutch bell engages correctly with the oil pump driven gear Place the special washer correctly be tween the clutch bell and the hub CAUTION FIT THE SPECIAL WASHER WITH THE MA CHINING FACING THE BELL SL 750 SHIVER Engine ENG 21 ...

Page 170: ... drive gear engages cor rectly with the oil pump driven gear on the clutch bell Fit the washer and a new clutch hub nut Tighten the clutch hub nut using the specific tool Specific tooling 9100896 Clutch bell locking tool Tighten the nut and proceed to caulk Insert the flat ring 1 Insert the cupped ring 2 CAUTION BE CAREFUL WITH THE CUPPED RING FITTING SIDE THE RING CONE SHALL BE DIRECTED TOWARDS T...

Page 171: ...eel discs Position all friction material discs with their teeth aligned in one of the long slots of the clutch bell Place the control rod Place the pressure plate Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally Replace the gasket upon refitting Head and timing SL 750 SHIVER Engine ENG 23 ...

Page 172: ...d collect the rubber rings Remove the head cover Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Remove the head cylinder unit Undo and remove the screw on the in let side Undo and remove the screws on the outlet side Engine SL 750 SHIVER ENG 24 ...

Page 173: ...ollect the washer See also Removing the cylinder Cylinder head Key 1 Complete cylinder head 2 Inlet valve 3 Outlet valve 4 External valve spring 5 Internal valve spring 6 Upper cap 7 Lower cap 8 Stud bolt M8X3X46 SL 750 SHIVER Engine ENG 25 ...

Page 174: ...haft Remove the clutch side crankcase half Rotate the crankshaft until the rear cyl inder reaches the TDC First remove the rear head cover in order to re move the rear head camshafts First remove the front head cover in order to re move the front head camshafts Mark the head camshafts the corresponding sprocket wheels and cam caps in order not to in terchange them upon refitting Undo and remove th...

Page 175: ...ove the camshafts with the gears Removing the valves When removing the valve mark the components according to the position and the cylinder they belong to in order to refit the components to their correct positions Remove the bowl tappets and the ad justment shims using a magnet SL 750 SHIVER Engine ENG 27 ...

Page 176: ...the spring compressing tool Specific tooling AP8140179 Valve spring compressor 020721Y Adaptor for valve removal Remove the cotters using a magnet Release the valve springs Remove the valve spring fittings plus the springs Slide off the valves Engine SL 750 SHIVER ENG 28 ...

Page 177: ... mm 1 4232 in b 28 mm 1 1023 in Outlet a 35 13 35 17 mm 1 3831 1 3846 in Limit 35 00 mm 1 3779 in b 28 mm 1 1023 in Fasten the camshaft in horizontal po sition as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the component Camshaft eccentricity maximum limit 0 040 mm 0 0016 in Valve check CAUTION REPLACE THE VALVES ONE AT A TIME DO NOT MIX TH...

Page 178: ...y allowed 0 05 mm 0 00197 in Check that the fixing grooves 5 of the valve cot ters are in proper conditions VALVE SPRINGS Carry out a measurement and a visual inspection of the valve springs for damage distortion or loss of tension Measure the spring length at release position Valve springs minimum wear limit 6 42 5 mm 1 673 in Valve springs minimum wear limit 7 38 mm 1 496 in Checking the cylinde...

Page 179: ...3 mm 0 0012 in Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn replace the defective part s Installing the overhead camshaft The camshaft refitting procedure is described in the Timing section See also Timing Timing Key 1 Camshaft front inlet 2 Camshaft front outlet 3 Axial restraint 4 Complete timing system gear 5 Complete front timing system gear 6 Compl...

Page 180: ...ain 15 Chain guide slider 16 Chain tightener rod 17 Camshaft rear inlet 18 Camshaft rear outlet 19 Left nut M15x1 20 Spacer screw Removing the chain tensioner Undo and remove the screw and col lect the washer and the internal spring Undo and remove the two screws Remove the chain tightener and collect the gasket Engine SL 750 SHIVER ENG 32 ...

Page 181: ... ing chain intermediate gear paying at tention not to damage the O ring Collect the washer Remove the timing chain intermediate gear Slide off the timing chain from the crankshaft NOTE IT IS ADVISABLE TO MARK THE CHAIN IN OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTATION IS MAINTAINED See also Removing the chain sliders Removing the chain tensioner SL 750 SHIVER Engine ENG 33 ...

Page 182: ... the head to remove it Undo and remove the fixed chain ten sioner pad screw First remove the head in order to re move it REAR HEAD First remove the flywheel in order to remove the chain sliders from the front head Undo and remove the movable chain tensioner pad screw Slide it off from the head to remove it Undo and remove the fixed chain ten sioner pad screw First remove the head in order to re mo...

Page 183: ...replace the parts Installing the chain tensioner Refit the removed timing system chain tensioner on the cylinder head Fit the timing chain on the crankshaft and on the intermediate gear Remove the screw and collect the washer and the spring Fit the chain tensioner body on the cyl inder and insert a new paper gasket Tighten the two screws to the prescri bed torque Insert the spring and tighten the ...

Page 184: ...ANTICLOCKWISE NUT FOR BOTH REAR CYL INDER SHAFTS AN ANTICLOCKWISE AR ROW HAS BEEN PUNCHED ON IT Collect the washer Remove the timing system gear from the camshaft Clean gears surfaces camshaft cone and gear cone with System MC 217 spray metal cleaner Pre fit the gear on the camshaft so that it can turn freely Place the two camshafts in the head seats and align the two camshaft holes with the head ...

Page 185: ...he cam cap Pre tighten the eight screws in the se quence indicated to the prescribed tor que Tighten the eight screws in the se quence indicated to the prescribed tor que Carry out camshaft timing with the ap propriate dowels Specific tooling 020719Y Timing pin Locking torques N m Cam cap head fixing screws M6 16 Pre tight ening 4 90 6 86 Nm 3 61 5 06 lbf ft Tight ening 9 81 12 75 Nm 7 24 9 40 lbf...

Page 186: ...g camshaft gears M15x1 4 90 Nm 66 38 lbf ft Remove the gear alignment tool Specific tooling 020718Y Camshaft gear alignment pin Release the crankshaft from the specific special tool Rotate the crankshaft in the riding direction until the rear cylinder piston reaches the top dead centre Lock the crankshaft with the specific special tool Carry out the timing operations performed for the front cylind...

Page 187: ...sket 9 Plate 10 TE flanged screw 11 Complete chain tensioner 12 TE flanged screw 13 Head cylinder gasket 14 11 8X10 Pin Removing the cylinder Remove the timing chain Undo and remove the two head fixing screws located inside the timing chain compartment Undo and remove the external screw SL 750 SHIVER Engine ENG 39 ...

Page 188: ...inder head to the discharge and in take sides Remove the gasket between the cylin der and the crankcase See also Chain removal Disassembling the piston Remove the head and cylinder Take out the pin locking ring Lock the connecting rod using the spe cific tool Slide off the pin and remove the piston Specific tooling 020716Y Connecting rod locking Engine SL 750 SHIVER ENG 40 ...

Page 189: ...ing circlips FOR SAFETY REASONS COVER THE CRANK CASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE Remove the top ring the intermediate ring and the three oil scraper rings SL 750 SHIVER Engine ENG 41 ...

Page 190: ... CYLINDER LINER ARE EVIDENT REPLACE THE CYLINDER AND THE PISTON Clean off lime scales on the cylinder cooling slots Measure the cylinder bore at a dis tance of 10 43 90 mm 0 39 1 69 3 54 in from the head coupling sur face the highest value should be considered to estimate wear limits Cylinder bore C 92 000 mm 3 6220 in C D1 or D2 max Cylindricity tolerance 0 020 mm 0 00079 in Replace the cylinder ...

Page 191: ... and from the rings themselves Measure the piston ring side clearance and replace the piston and the piston rings all together if not complying with specifications Piston ring side clearance Top ring 1st slot 0 030 0 065 mm 0 0012 0 0026 in Intermediate ring 2nd slot 0 020 0 055 mm 0 0008 0 0022 in Oil scraper ring 3rd slot 0 010 0 045 mm 0 0004 0 0018 in Fit the piston ring to the cylinder Level ...

Page 192: ...ameter a and if not complying with specifica tions replace the pin Pin outside diameter 22 00 21 97 mm 0 8661 0 8650 in Limit 21 96 mm 0 8646 in Measure the pin housing diameter b and replace the piston if not complying with specifications Pin housing diameter b 22 010 22 015 mm 0 8665 0 8667 in Calculate the clearance between pin and pin hole and if not complying with specifications replace both ...

Page 193: ...ton Inside the piston there is a stamped arrow that indicates the exhaust side To refit the sealing rings on the piston position the arrow stamped on the piston external surface facing the operator The piston rings are all different and are fitted with the N mark facing up Fit the oil scraper ring on the piston with its opening facing the exhaust side Fit the remaining sealing rings on the piston ...

Page 194: ... 0236 in The silicone side should be facing the crankcase CAUTION IF THE ORIGINAL GASKET THICKNESS CAN NOT BE CHECKED OR SHOULD THE CYLIN DER BE REPLACED REFER TO THE BASE GASKET SELECTION SECTION Before fitting the cylinder place the chain sliders and the timing chain on the crankshaft fit the timing chain on the crankshaft from the base side NOTE BEFORE FITTING THE CYLINDER CAREFUL LY BLOW AIR I...

Page 195: ...crew the two head fixing screws lo cated inside the timing chain compart ment Check that the intermediate gear pin lubrication holes are clean With a hook hold the timing chain Fit the timing chain on the intermediate gear Slide in the pin together with a new O Ring and a washer SL 750 SHIVER Engine ENG 47 ...

Page 196: ...s following the procedure described in the Tim ing section See also Selecting the base gasket Selecting the base gasket Place the specific special tool on the piston which should have sealing rings and be fitted on the connecting rod Lock the special tool with the clamp Specific tooling AP8140302 tool for sealing ring fitting Temporarily fit the piston to the cylin der without base or head gasket ...

Page 197: ...culate the difference between the two measurements using the chart be low identify the thickness of the cylin der base gasket to be used upon refitting By correctly identifying the cyl inder base gasket thickness an ade quate compression ratio can be main tained Remove the specific tool and the cyl inder Specific tooling 020720Y Timing tool BASE GASKET Specification Desc Quantity Measured protrusi...

Page 198: ...uple the cylinder and the head Screw without tightening the two screws on the outlet side Screw without tightening the screw on the intake side Tighten the cylinder head fixing screws to the prescribed torque Place the cylinder head unit on the crankcase stud bolts Installing the head cover CAUTION BEFORE REFITTING HEAD COVERS CLEAN HEAD AND COVER SURFACES CAREFULLY Engine SL 750 SHIVER ENG 50 ...

Page 199: ...ter along the gasket housing Apply THREEBOND on the head in the areas indicated in the figure For the remaining operations follow the removal operations but in reverse order Crankcase crankshaft Key 1 Upper bushing SL 750 SHIVER Engine ENG 51 ...

Page 200: ...ring 20x30x5 15 Threaded cap 16 Oil spraying pipe 17 OR sealing ring 18 TCEI screw M5X16 19 Timing sensor 20 TE flanged screw 21 Seeger ring for hole 22 Special screw 23 Washer Splitting the crankcase halves Fit the special tool by fixing the four fix ing screws steadfastly on the crank case Using the special tool unscrew and re move the crankshaft locking nut and collect the washer Specific tooli...

Page 201: ... Using a commercial available extrac tor remove the crankshaft gear Remove the gear control rod and col lect the washer SL 750 SHIVER Engine ENG 53 ...

Page 202: ... speed sensor Carefully remove the speed sensor Heat the screws of the gear selector supporting plate Undo and remove the three screws fix ing the gear selector plate Remove the plate together with the se lector Engine SL 750 SHIVER ENG 54 ...

Page 203: ...he neutral sensor Remove the neutral sensor Collect the sensor contact together with its spring If the pinion has been removed refit and lock it with a special tool Specific tooling 9100896 Clutch bell locking tool SL 750 SHIVER Engine ENG 55 ...

Page 204: ...gh temperatures Remove the speed sensor catch with the specific special tool Reposition the tone wheel and seal it with high strength Loctite upon refitting Specific tooling 020715Y Tone wheel removal Undo and remove the gear selector drum fixing screw Remove the gear selector drum Engine SL 750 SHIVER ENG 56 ...

Page 205: ...ide off the clutch control rod Working on the left side undo and re move the nine M8 screws fixing the crankcase Working on the left side undo and re move the nine M6 screws fixing the crankcase SL 750 SHIVER Engine ENG 57 ...

Page 206: ... engine and the engine sup port into horizontal position Undo and remove the pin tighten it again one turn to allow for crankcase clearance and check sealing CAUTION PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUPPORT STABILITY AND MAKE SURE THE ENGINE TO PLATE FIXING IS RE LIABLE Remove the two screws fixing the sup port Engine SL 750 SHIVER ENG 58 ...

Page 207: ... Separate the crankcase halves by giv ing a few taps with a rubber hammer Open the crankcase halves Fix the two screws to the engine sup port again SL 750 SHIVER Engine ENG 59 ...

Page 208: ... See also Removing the cylinder Magneto flywheel removal Disassembling the clutch Removing the crankshaft Key 1 Complete crankshaft 2 Complete connecting rod 3 Connecting rod screw 4 Bushing half shell 5 Main transmission gear 6 Woodruff Key 7 Water pump gear Engine SL 750 SHIVER ENG 60 ...

Page 209: ...oth crankcase halves are not cracked or damaged Check that all threads are in proper conditions Check that all oil seals remaining in their position are not worn or damaged Check all ball bearings for clearance smoothness and potential distortions CAUTION LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING If the internal ring does not rotate smoothly and silently or if there is some n...

Page 210: ...s re move and thoroughly clean the nozzle that lubricates the piston crown REPLACE THE SPRAY NOZZLE O RING IF NECESSARY Replace the O ring on the oil passage duct Before refitting UPON REFITTING THE CRANKSHAFT GREASE THE SHAFT BUSHING CONNECTING ROD COUPLING Engine SL 750 SHIVER ENG 62 ...

Page 211: ...nd tolerance check the reference surfaces Specific tooling 020714Y Comparator support Assembling the connecting rod CAUTION TO FIT THE CONNECTING RODS CHECK THE COUPLING TYPES INDICATED IN THE CRANK CASE CRANKSHAFT CONNECTING ROD SECTION IN THE CHARACTERISTICS CHAPTER OF THE WORKSHOP MANUAL Installing the crankshaft Place the left side crankcase half on the engine support adequately Place the cran...

Page 212: ...e support pins CAUTION PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUPPORT STABILITY AND MAKE SURE THE ENGINE TO PLATE FIXING IS RELIABLE Fit the complete transmission gears unit Apply black sealing paste Threebond on the left crankcase half CAUTION BE CAREFUL NOT TO APPLY THREEBOND IN EXCESS AS IT MAY BLOCK OIL DUCTS THROUGH THE CRANKCASE HALVES Place the right crankcase half with the aid of a rub...

Page 213: ...e support into vertical position Working on the left side place the nine M6 screws fixing the crankcase Working on the left side place the nine M8 screws fixing the crankcase Tighten all the crankcase fixing screws both M6 and M8 type SL 750 SHIVER Engine ENG 65 ...

Page 214: ... the pinion Place the gear selector drum and check that it is correctly timed thrust the desmo drum axially from the fly wheel side so that the timing roller pro trudes Tighten the gear selector drum fixing screw Engine SL 750 SHIVER ENG 66 ...

Page 215: ...l Use Loctite medium strength for sealing Specific tooling 020715Y Tone wheel removal Tighten the pinion fixing nut using the special tool Specific tooling 9100896 Clutch bell locking tool Position the sensor contact together with the spring SL 750 SHIVER Engine ENG 67 ...

Page 216: ... NOT TO DAMAGE THE O RING WHEN INSERTING THE SENSOR IN ITS POSI TION Tighten the two screws fixing the neu tral sensor Position the plate together with the se lector Tighten the three screws fixing the gear selector plate by applying Loctite medium strength Engine SL 750 SHIVER ENG 68 ...

Page 217: ...ary pin ion tapered pins crankshaft coupling surfaces Position the crankshaft gear Position the washer and the crankshaft lock nut Fit the special tool and fix it steadfastly to the crankcase by tightening the four fixing screws on the crankcase Tighten the crankshaft gear lock nut Specific tooling 020711Y Engine pinion locking SL 750 SHIVER Engine ENG 69 ...

Page 218: ...Lubrication Oil pump Removing Lock the pump gear with the commer cially available hook spanner and undo the screw collect the washer Engine SL 750 SHIVER ENG 70 ...

Page 219: ... Collect the shim washer Undo and remove the two screws fixing the oil pump Remove the entire pump Inspection Undo and remove the two fixing screws SL 750 SHIVER Engine ENG 71 ...

Page 220: ...tor and stator and re place the rotor stator unit if required clearance between rotor and stator 0 04 0 10 mm 0 0016 in 0 0039 in Slide off the shaft with the cover Collect the lock pin from the shaft Remove the oil pump rotor Engine SL 750 SHIVER ENG 72 ...

Page 221: ...THER MARKS Installing Follow the oil pump removal opera tions carefully align the stator and ro tor references upon fitting and check clearance with a thickness gauge If required replace the stator rotor unit Locking torques N m Screw fixing oil Pump with Gear M5 1 8 Nm 5 90 lbf ft Loctite 270 SL 750 SHIVER Engine ENG 73 ...

Page 222: ...Engine SL 750 SHIVER ENG 74 ...

Page 223: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 224: ...ONE ELECTRICAL ERRORS Fuel pump relay control P0230 Example value short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 62 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 62 of the VEHICLE connector Power supply SL 750 SHIVER P SUPP 2 ...

Page 225: ...trol cables arrive its task is to translate the rider s power request into an electrical signal to be sent to the electronic control unit The two throttle cables opening and closing actuate on a scroll mounted on a shaft and which is sent back to its home position by a return spring On the shaft covers there are 2 double track potentiometers 4 control tracks by means of which the torque demand is ...

Page 226: ...nd stabilised speeds D n For medium high throttle openings alpha n For temporary speed speed change alpha n The main parameters that correct the injection map are Engine temperature Atmospheric pressure calculated Lambda probe signal Air temperature 3 System safety checks The checks are structured in several levels Level 1 sensor correct operation Level 2 comparison between requested torque and es...

Page 227: ...g in safety the warning light turns on the message Urgent Service is displayed the engine stops running Removing the throttle body Remove the filter casing Working on both bodies undo and re move the four screws and slide off the filter support Remove the upper plate Remove both bodies UPON REFITTING REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE SL 750 SHIVER Power supply P SUPP...

Page 228: ... Remove the plate Working on both bodies undo and re move the screw and detach the body Working on the body in question re move the injector slide off the clip and the injector itself CAUTION NEVER UNDO THE SCREWS IN THE FIGURE Power supply SL 750 SHIVER P SUPP 6 ...

Page 229: ...s etc is available at the home page of the website www serviceaprilia com in the search section Axone Parameters The same parameters device status errors etc are grouped per type of component they refer to in the Electrical system chapter Checks and Controls SL 750 SHIVER Power supply P SUPP 7 ...

Page 230: ...Power supply SL 750 SHIVER P SUPP 8 ...

Page 231: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 232: ...nal spacer 4 Bearing 5 Sealing ring 30x47x7 6 Seeger ring 7 Front wheel right external spacer 8 Front brake disc 9 Washer 25 2x36x1 10 Wheel pin nut 11 TE flanged screw M8x20 12 Front wheel pin 13 Front cover 120 70 ZR 17 Hold the scooter front part Suspensions SL 750 SHIVER SUSP 2 ...

Page 233: ...ront mud guard and remove it Undo the screws fixing the front pliers and slide them off the disc Remove the wheel pin fixing nut Collect the sealing washer Loosen the screws on the wheel pin clamps SL 750 SHIVER Suspensions SUSP 3 ...

Page 234: ...he wheel CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS ESPECIALLY THOSE MENTIONED BELOW ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Replace both wheel bearings RADIAL AND AXIAL CLEARANCE CHECK Check the radial and axial clearance Axial clearance a minimum axial clea...

Page 235: ...wheel pin eccentricity If the eccentricity ex ceeds the limit value replace the wheel pin Characteristic Maximum eccentricity 0 25 mm 0 0098 in Using a dial gauge check that the ra dial A and the axial B eccentricities of the rim do not exceed the limit value An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim if after replacing the bearings the value is not wit...

Page 236: ...ch 4 Anti vibration weight terminal 5 Anti vibration weight 6 TCEI screw M6x40 7 Upper U bolt 8 Screw M8x25 9 Handgrips 10 Right rear view mirror 11 Left rear view mirror 12 Throttle opening cable 13 Throttle closing cable Front fork Suspensions SL 750 SHIVER SUSP 6 ...

Page 237: ... pumping member assembly 7 Left pumping member assembly 8 Sleeve cap assembly 9 O ring 10 Rubber ring 11 Nut 12 Snap ring 13 Stem right wheel holder assembly 14 Stem left wheel holder assembly 15 Dust guard 16 Seeger ring 17 Oil seal 18 Ring 19 Guide bushing SL 750 SHIVER Suspensions SUSP 7 ...

Page 238: ... wheel Support the fork stem and loosen the screws on the upper and then the lower plate Remove the fork stem Draining oil NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS NOTE BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE CAPACITY TO COLLECT THE OIL Remove the fork Suspensions SL 750 SHIVER SUSP 8 ...

Page 239: ...le capacity to collect fluids DO NOT DISPOSE OF OIL INTO THE ENVIRON MENT DISPOSE OF ENGINE OIL STORED IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM See also Removing the fork legs Disassembling the fork WARNING DO NOT INTERCHANGE THE STEMS THEY HAVE INTERNAL DIFFERENCES THE LEFT CAR TRIDGE 2 HAS A SLOT AT THE BOTTOM WHILE THE RIGHT ONE 1 HAS A SLOT...

Page 240: ...fork oil Place the fork stem on a work table in upright position Fit the special tool Specific tooling AP8140147 Spacer tool With the help of a second operator Hold the sleeve cap firmly Push the special tool down Take out the Seeger ring Suspensions SL 750 SHIVER SUSP 10 ...

Page 241: ...ial tool between the nut and the preloading pipe Specific tooling AP8140148 Spacer pumping element separat ing plate Loosen the nut Remove the sleeve cap Slide off the preloading pipe together with the spring centring SL 750 SHIVER Suspensions SUSP 11 ...

Page 242: ...he appropriate protec tions Specific tooling AP8140149 Protection for fitting operations Unscrew and remove the bottom screw and collect the special washer Slide off the pumping member together with the spring Remove the dust guard using a screw driver as a lever Suspensions SL 750 SHIVER SUSP 12 ...

Page 243: ... Checking the components Stem Check the sliding surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED...

Page 244: ...bushing guide bushing pumping member If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SUR FACE Replace the following components with new ones oil seal dust guard Reassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Fit the dust guard 1 Seeger ring 2 oil seal 3 rin...

Page 245: ... the oil seal Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in holes Push the oil seal fitting special tool hard applied towards the sleeve with the aid of the specific weight Specific tooling AP8140146 Weight Fit the Seeger ring on the sleeve seat Fit the dust guard SL 750 SHIVER Suspensions SUSP 15 ...

Page 246: ...ing the stem in wheel carrier M10x1 5 2 20 Nm 14 75 lbf ft Filling oil NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Place the fork stem on a work table in upright position Fill the sleeve with the adequate quality and type of oil indicated on the recommended prod ucts table WARNING MOVE THE PUMPING ELEMENT SEVERAL TIMES UNTIL AIR BUBBLES ARE SEEN ON THE OIL SURFACE THE SLEEVE MUST ...

Page 247: ...ng Fit the special tool Specific tooling AP8140147 Spacer tool With the aid of a second operator hold the pumping member rod firmly lower the spacer retention tool insert the stop ring and the plate separating the spacer pumping member between the ring and the nut Specific tooling AP8140148 Spacer pumping element separat ing plate SL 750 SHIVER Suspensions SUSP 17 ...

Page 248: ... Being careful not to damage the fork stem when placing it in a vice in verti cal position using the appropriate pro tection Specific tooling AP8140149 Protection for fitting operations Tighten the sleeve cap Suspensions SL 750 SHIVER SUSP 18 ...

Page 249: ...ut 7 Headstock cap washer 8 Headstock cap 9 TCEI screw M10x60 10 Cap 11 Rubber ring 12 Lower U bolt 13 Fork upper plate 14 Screw M8x30 15 Spacer 10 1x14 1x38 Adjusting play Place the vehicle so that the front wheel is off the ground Shake the fork in the riding direction SL 750 SHIVER Suspensions SUSP 19 ...

Page 250: ... Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out Unscrew and remove the top bolt on the headstock and collect the washer Operating from both sides loosen the screws fixing the fork stems to the up per plate Suspensions SL 750 SHIVER SUSP 20 ...

Page 251: ...Slide off the fork upper plate by moving it towards the instrument panel Adjust the steering bearings preload ing by tightening the ring nut with the specific tool When refitting the U bolt position the two referen ces facing the front part of the vehicle Rear SL 750 SHIVER Suspensions SUSP 21 ...

Page 252: ...55 ZR 17 6 Anti vibration rubber buffer 7 Tubeless valve 8 Rear wheel spacer 9 Pin 10 Lower self locking nut M10 11 Sprocket carrier assembly 12 Anti vibration buffer spacer 13 Bearing 30x55x13 14 Seeger ring for hole 15 Sealing ring 30x52x7 16 Internal spacer 17 Seeger ring 18 10x20 Pin 19 Bearing Suspensions SL 750 SHIVER SUSP 22 ...

Page 253: ...n from the crown gear Unscrew and remove the nut on the wheel pin Collect the thrust washer and the right chain tensioner slider Working on the right side hit the wheel pin lightly so as to take out the head from its housing Working on the left side slide off the wheel pin together with the chain guide slider Remove the wheel by freeing the disc from the brake calliper Collect the spacer from the ...

Page 254: ... maintenance ta ble See also Adjusting Checking the rear wheel CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS ESPECIALLY THOSE MENTIONED BELOW REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Su...

Page 255: ...E BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE REAR WHEEL PIN Using a dial gauge check the wheel pin eccentricity 1 If the eccentricity exceeds the limit value replace the wheel pin 1 Characteristic Maximum eccentricity 0 25 mm 0 0098 in REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An exc...

Page 256: ...rear wheel service stands Unscrew and remove the upper screw and collect the washer Loosen the under sump optional serv ice stand to lower the engine Undo and remove the lower screw and collect the nut Remove the shock absorber Suspensions SL 750 SHIVER SUSP 26 ...

Page 257: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 258: ...for hole 7 O ring 8 Sealing ring 9 Swing arm pin 10 Adjustment bushing 11 Swingarm pin internal bushing 12 Swingarm pin ring nut 13 Rear wheel bolt nut 14 Rear wheel pin washer 15 Left chain guide slider 16 Right chain guide slider 17 Chain tensioner set screw 18 Serpress nut M8 Chassis SL 750 SHIVER CHAS 2 ...

Page 259: ...port the vehicle by means of the engine service stand and a hoist with belts fastened to the rear section of the frame Remove the rear service stand Undo and remove the two lower swing arm screws Remove the cable guide Slide off the rear calliper holding plate keeping it linked to the brake pipe CAUTION DO NOT ACTUATE ON THE REAR BRAKE LEV ER AFTER REMOVING THE WHEEL OTHER WISE THE CALLIPER PLUNGE...

Page 260: ...OST CAUTION SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOWERING AND TO KEEP IT UPRIGHT Working on the right side unscrew and remove the swingarm bolt UPON REMOVING THE REAR SWINGARM PAY ATTENTION NOT TO JAM THE GEARING CHAIN See also Removing the rear wheel Chassis SL 750 SHIVER CHAS 4 ...

Page 261: ... Move the vehicle forward so as to check vertical oscillation in other posi tions too backlash should remain con stant during all wheel rotation phases ADJUSTMENT CAUTION TO ADJUST THE CHAIN GET THE APPROPRI ATE REAR SERVICE STAND OPT If you need to adjust chain tension after the check Place the vehicle on its OPTIONAL rear service stand Loosen the nut 1 completely Loosen both lock nuts 4 Actuate ...

Page 262: ...N ON A REGULAR BASIS PARTICULARLY IF YOU DETECT DRY OR RUSTY PARTS FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE ADJUST LUBRICATE WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION CLEANING AND LUBRICATION Do not wash the chain with water jets steam jets high pressure water jet...

Page 263: ...elf locking nut M8 5 Head exhaust gasket 6 Manifold exhaust gasket 7 Manifold clamp 8 Silencer 9 Silencer gasket 10 Silencer clamp 11 Lambda probe 12 TE flanged screw M8 x 35 13 Spacer bushing 14 Retroreflector supporting rubber ring 15 Washer 16 Muffler fixing rubber ring SL 750 SHIVER Chassis CHAS 7 ...

Page 264: ...o as not to spoil it while removing the exhaust end Keeping the plastic cover up undo and remove the two central screws and col lect the washers Then remove the exhaust end Removing the manifold tail pipe Remove the front exhaust manifold Remove the lambda probe Loosen the clamp of the rear exhaust manifold Chassis SL 750 SHIVER CHAS 8 ...

Page 265: ...in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down FRONT Unscrew and remove the two nuts on the head exhaust stud bolts Loosen the clamp Remove the exhaust manifold SL 750 SHIVER Chassis CHAS 9 ...

Page 266: ...d the exhaust end Unscrew and remove the two nuts on the head exhaust stud bolts See also Removing the manifold tail pipe Removing the lambda sensor Disconnect the lambda probe connec tor Unscrew and remove the lambda probe Chassis SL 750 SHIVER CHAS 10 ...

Page 267: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 268: ...calliper Key 1 Brake pump together with reservoir 2 Rear brake calliper 3 Rear brake lever 4 Rear brake lever pin 5 O ring 6 Washer 10 5x21x2 7 Brake lever pin 8 Rubber ring for lever 9 Seeger ring 10 Spring retaining pin 11 Rear brake lever spring 12 Micro switch 13 Fork Nut M6 14 Clips for gear fork Braking system SL 750 SHIVER BRAK SYS 2 ...

Page 269: ... stop pin 21 Oil pipe screw 22 Washer 10x14x1 6 23 Brake pipe protection 24 TBEI flanged screw M5x9 25 Rear brake pads pair 26 Screws Calliper springs 27 Air bleed 28 Oil reservoir assembly 29 REAR BRAKE DISC 30 TE flanged screw M8x20 31 O ring Front brake calliper Key 1 Left front brake calliper SL 750 SHIVER Braking system BRAK SYS 3 ...

Page 270: ... pads Removal Turn the pins and remove both split pins Remove both pins Collect the anti vibration springs Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Rear brake pads Braking system SL 750 SHIVER BRAK SYS 4 ...

Page 271: ...n the hydraulic system it acts as a bearing absorbing a large part of the pressure from the brake pump and minimising calliper efficiency during braking The presence of air is signalled by the sponginess of the brake control and poor braking efficiency CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE C...

Page 272: ... tainer This will release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before the lever reaches its end of stroke Repeat the operation until the fluid draining into the container is air bubble free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRA...

Page 273: ... brake oil reservoir cap Quickly press and release the rear brake lever several times and then keep it fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before the lever reaches its end of stroke Repeat the operation until the fluid drai...

Page 274: ...Braking system SL 750 SHIVER BRAK SYS 8 ...

Page 275: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS ...

Page 276: ...0x14x1 6 8 Clutch control cylinder 9 Bleeding Kit 10 TSPEI screw 11 TSPEI screw 12 Stop switch 13 Rubber ring CAUTION IF CLUTCH LEVER TRAVEL OR CLUTCH DISENGAGEMENT ARE IRREGULAR CHECK THE CLUTCH SYSTEM FOR AIR BUBBLES AND BLEED THE SYSTEM THROUGH VALVE 9 Clutch system SL 750 SHIVER CLU SYS 2 ...

Page 277: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 278: ... 6 Water pipe 7 Thermostat radiator pipe 8 Radiator pump pipe 9 Radiator filling pipe 10 Bleed pipe 11 Valve motor pump pipe 12 Bleed pipe 13 Y shape coupling 14 Oil pipe 6x12 15 Oil pipe 6x12 16 Thermostat valve unit 85 C 185 F 17 Pin 18 Spacer Cooling system SL 750 SHIVER COOL SYS 2 ...

Page 279: ... TE flanged screw M6x25 28 TE flanged screw M6x20 29 Fuel pipe 5 5x10 30 Radiator support 31 Clic clamp 32 From front cylinder 33 From rear cylinder 34 To rear cylinder Electric fan Remove the radiator Undo and remove the three screws and collect the washers remove the electric fan See also Removing the radiator SL 750 SHIVER Cooling system COOL SYS 3 ...

Page 280: ...he screw and re move the protection Place a container of suitable capacity Loosen the screw move the clamp and slide off the sleeve Remove the cap Empty the system into the specific con tainer Loosen the screw and move the clamp Cooling system SL 750 SHIVER COOL SYS 4 ...

Page 281: ... the front protection and tighten the screw Fit the right side fairing Water pump overhaul COVER REMOVAL Drain off the cooling circuit completely Undo and remove the five screws Remove the water pump cover PUMP ROTOR REMOVAL Remove the clutch side cover Lock the pump shaft with a universal wrench on the hexagonal insert on the shaft Unscrew and remove the anticlock wise nut fixing the rotor Remove...

Page 282: ...ITTING Upon refitting carry out the removal operations but in reverse order From the outside to the inside fit the rotor shaft plus the seal in the corre sponding hole on the cover Drive the shaft plus the seal on the cover using the specific tool and a hy draulic press Refill the expansion tank so that the level is between the MAX and MIN marks Fill the system through the radiator cap Cooling sys...

Page 283: ...mpletely covered and the water jet from the system breather pipe is continuous Removing the radiator Empty the cooling system before re moving the radiator Working on both sides undo and re move the screw and collect the wash er Undo and remove the screw and col lect the nut Remove both clamps and slide off the corresponding pipes SL 750 SHIVER Cooling system COOL SYS 7 ...

Page 284: ...r fixing side to the chassis and remove it by sliding it off toward the vehicle right hand side To install the radiator follow the operations explained above but in reverse order and re place all the clamps removed Restore the correct coolant level See also Coolant replacement Cooling system SL 750 SHIVER COOL SYS 8 ...

Page 285: ...e clamp Slide off the pipe Undo and remove the screw and col lect the washer Slide off the expansion tank Thermostatic valve Traditional circuit three way thermostatic valve 1 Hot water inlet from the heads 2 Outlet towards the short circuit direct to the pump 3 Outlet towards the radiator SL 750 SHIVER Cooling system COOL SYS 9 ...

Page 286: ...Cooling system SL 750 SHIVER COOL SYS 10 ...

Page 287: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 288: ...ttention to the belt position set the saddle 2 in its position and push until it clicks shut CAUTION BEFORE LOWERING AND LOCKING THE SAD DLE CHECK THAT THE KEY HAS NOT BEEN LEFT INSIDE THE GLOVE BOX TOOLKIT COMPARTMENT Headlight assy Remove the instrument panel Working from the vehicle left side un screw and remove the pin and collect the nut and the washer from the right side Disconnect the front...

Page 289: ...llight assy Remove the tail section Undo and remove the screw Collect the washer Remove the rear light by sliding it off toward the back See also Tail guard Side body panels The following operations refer to one side of the vehicle but apply to both SIDE FAIRINGS Undo and remove the two screws SL 750 SHIVER Bodywork BODYW 3 ...

Page 290: ... Remove the cover Undo and remove the screw Remove the side fairing Bodywork SL 750 SHIVER BODYW 4 ...

Page 291: ... wards remove the saddle Undo and remove the two screws Slide off the lower fairing See also Seat License plate holder Remove the saddle Remove the helmet compartment Undo and remove the screw Undo and remove the two screws SL 750 SHIVER Bodywork BODYW 5 ...

Page 292: ...move the two screws col lect the spacers and the collars Slide off the license plate holder towards the back See also Seat Tail guard Air box Undo and remove the eight screws and remove the air filter Bodywork SL 750 SHIVER BODYW 6 ...

Page 293: ... Undo and remove the inner screw Undo and remove the screw Remove the filter support partition Slide off the start up relay SL 750 SHIVER Bodywork BODYW 7 ...

Page 294: ...le harness from the clamps Working from the left side undo and remove the screw to remove the cable guide Undo and remove the two screws after loosening the front and rear manifold clamps Bodywork SL 750 SHIVER BODYW 8 ...

Page 295: ...he clamp and slide off the oil vapour re covery pipe Working on the left side disconnect the two control unit connectors CAUTION THE CONNECTORS ARE MARKED BY THE LETTERS V VEHICLE AND E ENGINE DO NOT INTERCHANGE THEM WHEN REFIT TING Undo and remove the screw and re move the ground lead SL 750 SHIVER Bodywork BODYW 9 ...

Page 296: ... check the following parameters a take the vehicle temperature to 90 C 194 F or above b front cylinder throttle valve correction between 60 and 60 b rear cylinder throttle valve correction between 60 and 60 c potentiometer 1 front throttle valve value is 0 5 or above d potentiometer 1 rear throttle valve value is 0 5 or above e the difference of throttle valve correction values between the front a...

Page 297: ...nd collect the two collars Undo and remove the chamber fixing screws Slide off the too full and breather pipes from the chamber Lift the tank by turning it on the hinge Release the petrol pipe Disconnect the pump cable harness Working on the right side unscrew and remove the nut and slide off the bolt from the left side SL 750 SHIVER Bodywork BODYW 11 ...

Page 298: ...al fuel leaks with a cloth disconnect the quick coupler Remove the recovery chamber NOTE UPON REFITTING THE TANK KEEP THE FUEL PIPE CONNECTING THE PETROL PUMP TO THE FILTER HOUSING IN THE POSITION INDICATED BY THE FIGURE Front mudguard Operating from both sides undo and remove the two screws Remove the front mudguard Bodywork SL 750 SHIVER BODYW 12 ...

Page 299: ...d remove the two front screws Working on both sides loosen the nut and the screw and remove them Working from both sides tilting the front headlight forward undo and re move the screw and collect the nut SL 750 SHIVER Bodywork BODYW 13 ...

Page 300: ...strument panel rear cov er Disconnect the instrument panel connector Remove the clamp and disconnect the air temperature sensor Slide off the instrument panel from its support Tail guard Working from both sides of the vehicle undo and remove the screw and re move the lateral air intake Bodywork SL 750 SHIVER BODYW 14 ...

Page 301: ...e vehi cle undo and remove the two screws Operating from both sides of the vehi cle undo and remove the screw Undo and remove the 4 screws Undo and remove the two screws and remove the rear light cover SL 750 SHIVER Bodywork BODYW 15 ...

Page 302: ... Remove the clamp Slide off the auxiliary fuses box Remove the helmet compartment Remove the two clamps Bodywork SL 750 SHIVER BODYW 16 ...

Page 303: ...nnectors Operating from both sides slide the exhaust cover tail upward and off Working on the right side remove the right tail Working on the left side remove the saddle lock and the left tail SL 750 SHIVER Bodywork BODYW 17 ...

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