Ducati MULTISTRADA 1200S ABS 2015 Page 836 Workshop Manual Download

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Removing the air filter

Remove the fuel tank (

Removing the fuel tank

Loosen screws (19) and remove cover (18).

Remove the airbox (20).

Summary of Contents for MULTISTRADA 1200S ABS 2015

Page 1: ...pension Rear wheel Front suspension Front wheel Cooling system Gearbox Cylinder piston Crankshaft Timing system valves Transmission Colours General Overall dimensions Dimensions Fuel lubricants and ot...

Page 2: ...filter cartridge Check engine oil level MTS E4 05 Fairings Rear view mirrors Refitting the headlight fairing Removing the headlight fairing Refitting the panel Removing the panel Fairings Refitting th...

Page 3: ...light Handlebar controls controls Right hand switch Left hand switch Safety and protection sensors controls Horn Checking the fuses Side stand switch Air temperature sensor Engine temperature sensor C...

Page 4: ...level setting Customising the Riding Mode DTC level setting Customising the Riding Mode Engine setting Customising the Riding Mode Parameter storage Customising the Riding Mode Setting MENU Fog lights...

Page 5: ...the rear brake control Removing the rear brake control ABS system information ABS system deactivation ABS system operation information Operating principle ABS system components Routing wiring harnesse...

Page 6: ...ing the swinging arm shaft Removing the swinging arm Refitting the rear wheel eccentric hub and rear wheel shaft Removing the rear wheel eccentric hub and the rear wheel shaft Final drive Lubricating...

Page 7: ...ving refitting the complete engine Refitting the engine Removing the engine Lubrication system Oil pump Refitting the oil pump Reassembling the oil pump Disassembling the oil pump gear Removing the oi...

Page 8: ...rhauling the cylinder piston components Removing the cylinder piston assembly Clutch assembly Clutch Refitting the clutch Checking and overhauling the components Removing the clutch Description of the...

Page 9: ...the timing gears Refitting the external components Removing outer components Crankcase Casings Closing the crankcase Shimming the shafts Reassembling the crankcase halves Main bearings Overhauling the...

Page 10: ...ycle and its components Note This symbol indicates additional useful information for the current operation Smaltimento This symbol supplies information on the disposal of a substance material Product...

Page 11: ...e 243 LOCK 3 High strength threadlocker for threaded parts Loctite 270 LOCK 4 Surface sealant resistant to high mechanical stress and solvents Resists high temperatures up to 200 C and pressures up to...

Page 12: ...r Loctite 401 LOCK 12 Instant adhesive gel offering tensile shear strength Loctite 454 gel DUCATI sealing compound Three bond 1215 Sealing compound Exhaust pipe sealing paste Self sealing paste harden...

Page 13: ...he rear wheel slipping control and settings vary through eight different levels that are programmed to offer a different tolerance level to rear wheel slipping Each Riding Mode features a pre set inte...

Page 14: ...nals thereby optimising the efficiency of all these systems regardless of motorcycle position Ducati Cruise Control Multistrada 1200 features a system for maintaining the cruise speed the Ducati Cruis...

Page 15: ...to be repaired Note that the disassembly procedures in this manual describe the most efficient way to reach the part to be repaired General advice on repair work Always use top quality tools When lif...

Page 16: ...e hot even after engine is switched OFF pay particular attention not to touch exhaust system with any body part and do not park the motorcycle next to inflammable material wood leaves etc Used engine...

Page 17: ...r and make sure your clothing does not snag on the fan Battery Warning The battery gives off explosive gases never cause sparks or allow naked flames and cigarettes near the battery When charging the...

Page 18: ...ordering spare parts DATA STAMPED ON THE FRAME Example ZDM 12 BWW B Following is the table with the frame part numbers VERSION 1 2 3 4 5 6 Frame ZDM 12 BWWW B 1 Manufacturer Ducati Motor Holding 2 Ty...

Page 19: ...Examples 2BW Following are the tables with the frame part numbers VERSION 1 2 3 Engine version 2BW 1 Engine type 2 Model Year F for 2015 models 3 Progressive production no...

Page 20: ...indicators Lamp type RY10W amber halogen 12V 10W Number plate light Lamp type C5W 12 V 5 W Fuse box key Fuse box A key El item Rat 1 KEY EMS ABS IMU 5 A 2 KEY DSB BBS 15 A 3 KEY Lights 15 A 4 5 KEY A...

Page 21: ...Injection system Make Type Control unit BOSCH ME7921...

Page 22: ...mpatible with fuel having a maximum content of ethanol of 10 E10 Using fuel with ethanol content over 10 is forbidden Using it could result in severe damage to the engine and motorcycle components Usi...

Page 23: ...Ignition system Reference Technical specifications Starting Type Electric starter motor 12 V 0 7 kW Spark plugs Make and type NGK MAR10A J Electrode gap 0 8 0 1 mm...

Page 24: ...tery Voltage 12 V Charge 10 Ah Type Sealed type maintenance free Generator Denso Hi Frequency Capacity 12 V 500 W 1500 rpm Active voltage 27 5 V Minimum voltage 25 2 V Maximum voltage 33 V 2500 rpm Ac...

Page 25: ...e M50 Calliper cylinder diameter 30 Pad friction material TT2182 Master cylinder Type PR 16 19 Master cylinder diameter 16 mm REAR Brake disc Type Fixed drilled disc Thickness 5 mm 4 5 mm min Flange m...

Page 26: ...Rear suspension Reference Technical specifications Type SACHS Progressive with electronically adjustable monoshock Shock absorber Stroke 59 5 mm Wheel travel 170 mm...

Page 27: ...In the most worn part 2 mm Tyre pressure Cold 2 5 bar rider only 2 9 bar with pillion rider and or bags Swinging arm shaft runout On 100 mm 0 2 mm Wheel rim runout Radial 0 8 mm 2 mm Axial 0 5 mm 2 mm...

Page 28: ...erence Technical specifications Type SACHS upside down fork completely adjustable in rebound and compression electronic control Travel on leg axis 170 mm Fork S Version 252 5 cc active fork leg 642 5...

Page 29: ...alue Service limit Minimum tread depth In the most worn part 2 mm Tyre pressure Cold 2 5 bar rider only 2 5 bar with pillion rider and or bags Wheel shaft runout On 100 mm 0 2 mm Wheel rim runout Radi...

Page 30: ...ications Type Liquid cooling with two closed circuit radiators with twin bent radiator twin fan and mixing thermostat Coolant capacity 2 5 litres Thermostat Starts opening at 65 C 2 C Electric fan ena...

Page 31: ...ference Standard value Service limit Gearbox shafts End float 0 05 0 20 mm Selector drum End float 0 10 0 40 mm Gear selector fork Fork slider thickness 3 90 4 00 mm Fork to gear clearance 0 070 0 285...

Page 32: ...ection C 105 905 mm 105 915 mm 105 915 mm 105 925 mm 105 925 mm 105 935 mm Connecting rod Connecting rod big end diameter 49 mm Crankshaft class Connecting rod class Bearings colour Big end bearing pa...

Page 33: ...Crankshaft Reference Standard value Service limit Crankshaft Oval 0 005 mm Taper 0 005 mm Main journals alignment 0 01 mm on diameter...

Page 34: ...T D C Intake valve diameter 43 5 mm Exhaust valve diameter 34 5 mm Valve lift With 0 mm valve clearance Intake 12 2 mm Exhaust 11 2 mm Opening rocker arm intake 0 13 0 18 mm Opening rocker arm exhaust...

Page 35: ...es Clutch control Hydraulic Gearbox 6 speed Primary drive 33 61 Drive ratio 1 84 Final drive 15 40 Gearbox type With constant mesh spur gears operated by a lever on the left side of the motorcycle Tra...

Page 36: ...last Red Stoner SF Frame Racing Black Subframe Mercury Gray Rims Glossy Black L0040652 Lechler LMC06017 Lechler Iceberg White Primer Dual Primer White Clear coat Tixo Klarlack Frame Racing Black Subfr...

Page 37: ...Hydraulic upside down fork adjustable through electric inputs from the instrument panel Only the RH fork leg is equipped with an external adjuster for setting the preload of the inner spring Leg diam...

Page 38: ...tastretta with DTV system twin cylinder L type 4 valves per cylinder Bore 106 mm Stroke 67 9 mm Displacement 1198 4 cu cm Compression ratio 12 5 0 5 1 Timing system Toothed belt type with two overhead...

Page 39: ...Dimensions...

Page 40: ...en oil free surface and sleeve end with sleeve in fully lowered position and without spring and preload tube inside fork leg Important Do not use any additives in fuel or lubricants Using them could r...

Page 41: ...OCKET Sprocket retaining nut M25x1 5 186 5 GREASE B Sprocket cover retaining screw M6x1 6 LOCK 2 LIGHTS Headlight to front subframe retainer M5x0 8 5 LOCK 2 Tail light retaining screw M5x0 8 5 Rear tu...

Page 42: ...Accelerometer bracket to left fork bottom end fastener M5x0 8 5 Kahaba fork bottom end clamp retainer M8x1 25 19 GREASE B LH accelerometer bracket to left fork bottom end fastener M5x0 8 5 ELECTRICAL...

Page 43: ...ment retainer M18x1 3 Rear brake STOP switch to support M8x1 5 Power socket to headlight fairing retainer M18x1 3 Starter motor cable retainer M6x1 5 GREASE D Screw securing ground cable to crankcase...

Page 44: ...Rear brake calliper holder plate locking pin M12x1 25 33 LOCK 8 Accelerometer to brake line protection fastener AF5 2 5 HANDLEBAR CLUTCH CONTROL Clutch master cylinder retaining screws M6x1 10 Sequen...

Page 45: ...rvoir hose tie on reservoir fastener Ties clamps 1 Water hose clamp on radiator fastener Ties clamps 3 Horizontal cylinder bleed tie Ties clamps 1 Water bleeder cap on left casing Ties clamps 15 FOOTP...

Page 46: ...er Brake disc retaining screw M8x1 27 pre applied threadlocker Right and left rear wheel retaining screw 230 Silentblock retaining nut M10x1 44 LOCK 2 Rear wheel valve retaining hexagon nut M8x1 25 9...

Page 47: ...aesthetic support retaining screws M5x0 8 4 High seat support retaining screws M5x0 8 4 Rider seat adjustment eccentric retaining screw M5x0 8 2 Passenger rider seat spacer retaining screw M5x0 8 2 S...

Page 48: ...ottle body assembly to airbox fastener M5x0 8 5 Blow by to airbox retainer AF5 3 Wiring cover to airbox fastener AF5 3 Upper to lower airbox retainer AF5 3 Airbox filter cover retainer AF5 3 Blow by p...

Page 49: ...fastener M6x1 10 Sump guard LH bracket to crankcase fastener M6x1 10 LH and central RH sump guard retainer M5x0 8 5 Right and left sump guard to brackets fastener M5x0 8 5 Sump guard to footpeg holder...

Page 50: ...90 Nm Angular backlash manual check Nut for head cylinder stud bolt M10x1 5 Snug torque 20 GREASE C on nut underhead and on stud bolt thread Preload torque 40 38 42 Tightening torque 60 57 63 Camshaf...

Page 51: ...p bearing retaining screw M6x1 10 9 11 Timing inspection cover screw M6x1 5 4 5 5 5 Alternator cover closing screw M6x1 13 12 5 14 5 Water pump cover closing screw M6x1 13 12 5 14 5 Water pump closing...

Page 52: ...g screw M6x1 10 9 11 Secondary bearing chain side stopper screw M6x1 10 9 11 LOCK 2 or TB1324 Primary bearing clutch side stopper screw M6x1 10 9 11 LOCK 2 or TB1324 Casing jointing screw in idle gear...

Page 53: ...ng by 360 2 sec Snug torque 20 Nm to 30 rpm Snug torque 35 Nm to 10 rpm Tightening 65 1 at 14 rpm Torque check 70 113 Nm Gear selector control Gearbox drum positioning screw M16x1 5 30 27 33 Gearbox p...

Page 54: ...2 11 13 Rotor to flywheel retaining screw M5x0 8 13 11 15 Pre applied threadlocker on new part LOCK2 for reuse Oil pump Oil pump retaining screw M8x1 25 26 23 29 Oil pump assembling screw M6x1 10 9 11...

Page 55: ...IMAGE 28620441A PC HASP DDS2 0 wrench 979000252 DDS 2 Ducati Diagnosis System 2 0 979000253 Belt tensioning 979000254 Diagnosis and power supply cable 979000255 Diagnosis and power supply cable CAN 97...

Page 56: ...wheel shaft wrench 88713 1058 Wrench to fit steering tube plug 88713 1062 Steering tube bearing installation tool 88713 1074 Swingarm shaft removal tool 88713 1515 Frame engine support 88713 2409 Ball...

Page 57: ...88713 3211 Eccentric hub adjusting wrench 88713 3396 Engine repair work bench 88713 3501 Tank level sensor plug tightening wrench 88713 3526 Frame ring nut wrench...

Page 58: ...installation tool 88713 0870 Water pump front seal counter washer installation tool 88713 1010 Exhaust gas suction fitting 88713 1749 Puller for driving pulley and cover 88713 1805 Driving pulley tigh...

Page 59: ...rm shaft puller 88713 2011 Tool to block crankshaft at Top Dead Centre TDC 88713 2103 Bearing surface for head installation 88713 2442 Tool to install seal ring on valve guide 88713 2834 Snap ring ins...

Page 60: ...7 Spark plug wrench 88713 2906 Oil cartridge wrench 88713 3219 Reaction tool for pulley tightening 88713 3334 Selector fork positioning plate 88713 3352 Clutch plate positioning tool 88713 3367 Flywhe...

Page 61: ...ar sensor 88713 3408 F clutch housing reaction tool 88713 3417 Reaction wrench 88713 3497 Wrench to tension the belt mobile tensioner 88713 3521 Seal ring installation tool 88765 1000 88765 1005 88765...

Page 62: ...tioning tool 88765 1657 Degree wheel holder tool 88713 4964 Cylinder head nut tightening tool 88713 4965 Camshaft O ring installation tool 88713 4966 Pressure control nozzles 88713 4967 Lever to relea...

Page 63: ...88713 5009 TDC control tool 8876 1737 Camshaft locking tool...

Page 64: ...entation and the Service Booklet appropriately filled in Bike pre delivery Check of bike conformity with the purchase agreement version model no aesthetics flaws Check of accessory presence and their...

Page 65: ...e panniers and top case their opening and closing if present Maintenance schedule OIL SERVICE 1000 ANNUAL SERVICE OILSERVICE and additional DESMO SERVICE operations with relevant indications on instru...

Page 66: ...6 Check engine oil level Check brake and clutch fluid level Check tyre pressure and wear Check the drive chain tension and lubrication If necessary contact dealer for adjustment Check brake pads If n...

Page 67: ...ge timing belts 60 Change the spark plug Change air filter Clean air filter Clean plugs with metal mesh filters on heads Check brake and clutch fluid level 12 Change brake and clutch fluid 36 Check pa...

Page 68: ...itches engine stop switch gear neutral sensor 12 Check the indicators and lighting 12 Reset the Service indication through the DDS 2 0 Road test of the motorcycle testing the safety devices ex ABS and...

Page 69: ...Fill the reservoir with specified fluid taken from an intact container Important During the operation fluid level must remain at a suitable level at all times The end of the transparent plastic hose...

Page 70: ...a turn and operate the clutch lever several times until the fluid flows out of the bleed valve 3 Pull the lever fully and then loosen the bleed valve by at least 1 4 of a turn Wait for a few seconds t...

Page 71: ......

Page 72: ...lutch slave cylinder bleed valve 3 Note Follow the manufacturer s instructions when using a commercial clutch bleeding tool Remove the cover 1 with the membrane from the clutch fluid reservoir 2 Open...

Page 73: ...by 1 4 of a turn Operate the clutch lever until all the fluid has been drained To help fully drain the circuit it is recommended to remove the clutch slave cylinder Undo the screws 4 and slide out the...

Page 74: ...Push the internal piston to force out all the fluid from inside the cap Reassemble as described in chapter Refitting clutch slave cylinder...

Page 75: ...res Dispose of waste in compliance with the prevailing local and national standards European Waste Catalogue Codes recommended for waste disposal as indicated by Decision No 2001 118 EC CER 13 02 05 M...

Page 76: ...to allow fluid to flow out Warning During the filling operation always keep the fluid level above the MIN mark to avoid any air bubbles in the circuit Allow the fluid to flow from the bleed valve 3 u...

Page 77: ...ing to proper preload to improve motorcycle handling and keep safe clearance from the ground You may find that rebound damping needs adjusting as well The shock absorber is adjusted by electric impuls...

Page 78: ...n this motorcycle has rebound compression and spring preload adjustment Put the motorcycle on the side stand and make sure it is stable Fork is adjusted by means of electric impulses output by the ins...

Page 79: ...e 1 and slacken the lock nuts 2 and 3 Fit an open end wrench to hexagonal element of linkage 1 and rotate until setting pedal in the desired position Tighten both lock nuts onto linkage To adjust the...

Page 80: ...inder push rod in the following mode Slacken off the check nut 7 on the cylinder pushrod Screw the rod into the fork 8 to increase play or unscrew it to reduce play Tighten the check nut 7 to a torque...

Page 81: ...to increase lever distance Turn the adjuster counter clockwise to decrease lever distance When the clutch lever 1 is operated drive from the engine to the gearbox and the drive wheel is disengaged Us...

Page 82: ...versions Check through the slot between the two calliper halves and make sure that at least 1 mm of the friction material on pads is visible Important Change both pads even if just one of them is wor...

Page 83: ...Remove the brake pads 3 by pushing the calliper pistons fully inside their seats...

Page 84: ...Fit the new pads Insert pin 2 and fix it by means of the safety split pin 1...

Page 85: ...o that the pads firmly bed in against the disc thanks to the brake fluid pressure Check that the fluid level inside reservoir 4 is between the MIN and MAX marks If this is not the case unscrew the plu...

Page 86: ...by Decision No 2001 118 EC CER 16 01 12 Brake pads other than those mentioned under item 16 01 11 Note It should be noted that the above mentioned CER code is a general and non binding provision prov...

Page 87: ...nt On handing over the motorcycle after changing the brake pads inform the Customer that the front brake must be used gently for the first 100 km to allow the pads to bed in completely Check through t...

Page 88: ...emove the front pads 1 Note Change pads that have a shiny or vitrified appearance Insert the calliper of the front disk and use the indicated product to lubricate the two screws 2 Tighten the two scre...

Page 89: ...e fluid reservoir 6 by loosening the screws 7 Top up with specified fluid until reaching the Max mark Warning Do not dispose of brake pads into the environment Smaltimento Do not dispose of waste into...

Page 90: ...product original composition and intended use The user is thus responsible for selecting the CER code most suitable to the concerned product based on product real use and taking into account any alter...

Page 91: ...between the centre of the chain pins and the aluminium section of the swingarm It must be A 38 40 mm To adjust the tension remove the rear splash guard Removing the splash guard Slacken off the two sc...

Page 92: ...nsmission components If the screws 1 are removed lubricate with specified grease underside and thread then tighten the screws 1 to a torque of 35 Nm 5 proceeding with sequence 1 2 1 Warning Correct ti...

Page 93: ...Refit the rear splash guard Refitting the splash guard...

Page 94: ...ws Loosen the clamp screw 1 that holds the steering tube to the steering head Slacken the clamp screws 2 securing the steering head to both fork legs Using the special tool A part no 88713 1058 lock t...

Page 95: ......

Page 96: ...ke system Remove the rear wheel Removing the rear wheel Remove the rear brake calliper by loosening the screws 1 Undo the screws 2 and remove the hose cover 3 Release hose 4 Bring the rear calliper in...

Page 97: ...Attach a transparent plastic tubing to the rear calliper bleed valve 5 and insert the other end of the tubing in a container placed on the floor Unscrew the cover 6 of the rear brake fluid reservoir 7...

Page 98: ...with new oil up to the MAX mark Refit the membrane without the plug on the reservoir to avoid brake fluid splashes during the following operations Operate the brake pedal to pressurise the circuit Ke...

Page 99: ...air bubbles in the circuit Note If bleeding tool is not available move back calliper pistons as well Repeat the above operations until finishing all the fluid contained inside package approx 250 cc M...

Page 100: ...ecommended for waste disposal as indicated by Decision No 2001 118 EC CER 13 02 05 Mineral based non chlorinated engine gear and lubricating oils waste Note It should be noted that the above mentioned...

Page 101: ...e paint Avoid contact with eyes and skin In case of accidental contact wash thoroughly with water Remove the cover 1 with membrane from the front brake fluid reservoir 2 by undoing the screws 3 Siphon...

Page 102: ...ck to do so loosen screws 4 that retain the callipers on the fork bottom ends Take calliper pads apart and during this operation be careful with the fluid level which must always be sucked out each ti...

Page 103: ...d back and all the fluid in the reservoir has been sucked out connect a transparent tube to the RH calliper bleed valve 5 and set the other end in a container placed on the floor Fill the front brake...

Page 104: ...n the hole of bleeder cap to remove any residues of fluid and then refit the rubber cap Loosen the bleed valve of the LH calliper and then take the lever through the whole stroke to allow fluid to flo...

Page 105: ...d in the brake system Warning After draining the old fluid from the reservoir and while filling the system always keep the fluid level above the MIN mark to avoid any air bubbles in the circuit Warnin...

Page 106: ...d on product original composition and intended use The user is thus responsible for selecting the CER code most suitable to the concerned product based on product real use and taking into account any...

Page 107: ...asing Removing the front half casing Place a container under the engine and set the motorcycle on its side stand Remove the water radiator plug Connect a clamp to the expansion reservoir water radiato...

Page 108: ...10 minutes Stop the engine and allow it to cool down so that all the air is expelled from the circuit Warning Keep your hands clothing and tools well clear of the radiator fan at all times this fan st...

Page 109: ...Refit the LH and RH panel Refitting the panel...

Page 110: ...than 30 of antifreeze will not provide sufficient protection against corrosion Warning Do not dispose of coolant into the environment Smaltimento Do not dispose of the waste into the environment do n...

Page 111: ...r filters Remove the fuel tank Removing the fuel tank Remove the wiring cover 1 by loosening the two retaining screws 2 Release the wiring from the airbox Loosen the four retaining screws 3 and remove...

Page 112: ...the prevailing local and national standards European Waste Catalogue Codes recommended for waste disposal as indicated by Decision No 2001 118 EC CER 15 02 02 Absorbents filter materials including oil...

Page 113: ...sition cover 4 and tighten the four retaining screws 3 to a torque of 3 Nm 10 Position the main wiring on the airbox Position wiring cover 1 and tighten the two retaining screws 2 to a torque of 3 Nm...

Page 114: ...ng belt covers Removing the timing belt external covers Loosen the screws 6 and remove the filter 7 Check the air filter 7 in the horizontal timing belt cover 8 Once the check has been carried out ref...

Page 115: ...Refit the fuel tank Refitting the fuel tank...

Page 116: ...g if measured value is different from the specified one or the spark plug shows clear signs of carbon deposits Warning Do not use spark plugs with inadequate heat rating or incorrect thread length The...

Page 117: ......

Page 118: ...sion No 2001 118 EC CER 16 01 22 components not otherwise specified Note It should be noted that the above mentioned CER code is a general and non binding provision provided based on product original...

Page 119: ...e engine removed from the frame Use tool no 88765 1523 to rotate the crankshaft in the vehicle direction of travel by looking the tool from the front side counter clockwise to bring the horizontal cyl...

Page 120: ...the timing is correct fit tool B no 88713 2011 to block the crankshaft On the vertical head install tool C part no 88765 1737 Check the variators alignment i e they must be flush with the head flat su...

Page 121: ...Fit the belt 7 as shown in the figure using a screwdriver to tension it...

Page 122: ...If previously removed fit the chain tensioner 8 washer 9 and tighten it by means of nut 10 Do not tighten to torque...

Page 123: ...Remove tool C part no 88765 1737 and fit it on the horizontal head...

Page 124: ...Check on the variators 11 that the references are aligned with the head flat surface Fit the belt 12 in the horizontal head as shown in the figure using a screwdriver to tension it...

Page 125: ...If previously removed fit the chain tensioner 13 washer 14 and tighten it by means of nut 15 Do not tighten to torque...

Page 126: ...point D Tension the belt according to the values indicated in the table Reference Assembly Value new belt Assembly Value used belt Cold belt tension adjustment DDS 2 90 5 Hz horizontal 90 5 Hz vertic...

Page 127: ...icated point E Tension the belt according to the values indicated in the table Reference Assembly Value new belt Assembly Value used belt Cold belt tension adjustment DDS 2 90 5 Hz horizontal 90 5 Hz...

Page 128: ...Remove all the previously installed tools Refit the cylinder head covers Refitting the camshafts Refit the external timing belt covers Refitting the timing belt external covers...

Page 129: ...ed to the cooling system Removing the water radiator Disconnect the coil caps Disconnect the secondary air units of the head covers Removing the secondary air system Remove the cylinder head cover Rem...

Page 130: ...paragraph Removing the valves and replace it with one of suitable height to obtain the prescribed clearance Note Opening rocker arm shims measuring 1 80 to 3 45 are available as spare parts the size...

Page 131: ...camshaft lobe B...

Page 132: ...cribed in paragraph Removing the valves and replace it with one of suitable height to obtain the prescribed clearance Note Opening rocker arm shims measuring 1 80 to 3 45 are available as spare parts...

Page 133: ...l and national standards European Waste Catalogue Codes recommended for waste disposal as indicated by Decision No 2001 118 EC CER 13 02 05 Mineral based non chlorinated engine gear and lubricating oi...

Page 134: ...torque of 20 Nm Min 18 Nm Max 22 Nm OIL CARTRIDGE FILTER Remove the oil sump filter cartridge 2 using service tool part no 88713 2906 Important Dispose of the used filter do not re use it Fit a new c...

Page 135: ...fore fitting it this enables the recommended oil level to be maintained without topping up Screw it into seat and tighten it to 11 Nm Min 10 Nm Max 12 Nm OIL MESH FILTER Every two oil changes clean th...

Page 136: ...Remove the filtering element 5 and check the O rings 6 and 7 and replace them if necessary Clean the filter with fuel and compressed air Take care not to damage the mesh...

Page 137: ...Position O ring 7 on the crankcase and O ring 6 on the mesh filter 5...

Page 138: ...Refit the mesh filter 5...

Page 139: ...Apply a bead of sealing compound to cover 7 as shown in the figure...

Page 140: ...eeting the following specifications JASO MA2 and API SM Refit the filler plug 8 Run the engine at idle speed for a few minutes Check that there are no oil leaks and that the engine oil pressure warnin...

Page 141: ...Refit the complete belly pan Refitting the belly pan...

Page 142: ...ehicle perfectly upright and the engine hot but off Oil level must be between the MIN and MAX marks Top up if the level is low Remove the filler plug 2 and top up with the recommended oil Ducati recom...

Page 143: ...e windscreen support 2 Tighten rod 1 to a torque of 2 Nm 10 Fit springs in stud bolts A Fit block 3 on the windscreen support 2 by engaging tabs B of the windscreen support block 3 in seats C of suppo...

Page 144: ...Fit clips 4 in the indicated areas of the central panel 5 Force ball joint 6 into its seat...

Page 145: ...n stud bolts E of the windscreen support 3 Note The washer sharp edge must be facing the windscreen support block Couple the windscreen support assembly 8 with the central panel 5 by inserting rod 1 i...

Page 146: ...threadlocker on the two screws 9 Fit the windscreen support assembly 8 to the central panel 5 tightening screws 9 to a torque of 3 Nm 10 Fit washers 10 onto two screws 11 Tighten the two screws 11 to...

Page 147: ...Fit two rubber plugs 12 in the indicated holes Insert plugs 13 in recesses 14...

Page 148: ...screw silent blocks 15 on instrument panel 16 Fit toothed washers 17 on silent block 15 threaded pins Fit cover 16 on the windscreen support assembly central panel 18 by tightening nuts 19 to a torque...

Page 149: ...FITTING THE HEADLIGHT FAIRING Position headlight fairing 4 on the front frame Start screws 3 and tighten them to a torque of 3 Nm 10...

Page 150: ...Connect connector 1 to instrument panel 2 Refit the light assembly Refitting the light assembly Refit the panel Refitting the panel...

Page 151: ...ng Remove the panel Removing the panel Remove the light assembly Removing the light assembly Disconnect connector 1 of instrument panel 2 Working on both sides of the headlight fairing loosen screws 3...

Page 152: ......

Page 153: ...f previously removed refit Plexiglas 9 by starting three screws 8 Tighten screws 8 to a torque of 3 Nm 10 Connect power socket 7 Fit the panel so as to engage retainer 3 in hook 4 on the headlight Eng...

Page 154: ...Fix the headlight fairing to the headlight by means of two screws 2 Tighten them to a torque of 3 Nm 10...

Page 155: ...Connect the immobilizer antenna by means of connector 1...

Page 156: ......

Page 157: ...Removing the panel Remove the tank cover Removing the tank cover Disconnect connector 1 from the immobilizer antenna Remove the retaining screws 2...

Page 158: ...Remove the panel by pulling the top part outwards and the tip downwards at the same time as shown in the picture In this way retainer 3 will be released from hook 4 and pins 6 from seats 5...

Page 159: ...Disconnect the power socket 7 and remove the panel...

Page 160: ...If necessary remove the Plexiglas as indicated below remove Plexiglas 9 by loosening the three screws 8...

Page 161: ...Refitting the tank fairings Check that the two vibration damping pads 8 and the four clips 9 are present on the tank cover 7 Fit gasket 10 on cover 7 so that ridge A engages in recess B...

Page 162: ...Apply the indicated lubricant on the gasket surface 10 in contact with the tank plug 11 Fit the tank cover on the tank Fit the ten clips 12 in the points indicated in the figure...

Page 163: ...Fix the tank cover by means of the upper screws 6 and lateral screws 5 with Nylon washer Tighten the screws to a torque of 4 Nm 10...

Page 164: ...Fit the side conveyor 4 by sliding it first forwards and then backwards so that tab C engages in slot D and U bolts E in tabs F...

Page 165: ...Fix the side conveyor 4 by tightening screws 3 to a torque of 2 Nm 10...

Page 166: ...Fit the Hands free cover 1 by inserting the cover pins in the tank vibration damping pads and press on tabs 2 until they engage into seat...

Page 167: ...U S A VERSION...

Page 168: ......

Page 169: ...Removing the tank fairings Remove the Hands Free cover 1 by pulling it upwards to release teeth 2 U S A VERSION...

Page 170: ...Loosen screws 3 and remove conveyor 4 Repeat this operation on the other conveyor...

Page 171: ...Loosen screws 5 from both sides of the tank cover 7...

Page 172: ...Loosen the two upper screws 6 Remove the tank cover 7 by sliding it upwards...

Page 173: ......

Page 174: ...emperature sensor 10 to the central conveyor 11 by means of two screws 12 with gasket 13 Tighten the two screws 11 to a torque of 0 9 Nm 10 Position the central conveyor 11 inside the conveyor upper c...

Page 175: ...Connect the temperature sensor 10 Position the conveyor upper cover B by inserting the two pins 16 in rubber elements 17...

Page 176: ...Fix the conveyor upper cover B to the tank cover by means of screws 9 by fitting a plastic washer between the screw and the cover Tighten them to a torque of 2 Nm 10...

Page 177: ...Insert the lower panel 8 of conveyor B and fix it with screws 7 Tighten screws 7 to a torque of 2 Nm 10...

Page 178: ...radiator of the retaining brackets 18 If not present fix them by tightening screws 19 to a torque of 6 Nm 10 Fit the vibration damper 5 Check that the damper is on support 2 If not lubricate with indi...

Page 179: ...Position support 2 by inserting U bolt 23 in tooth 24 of the tank cover on the upper side...

Page 180: ...rew 3 highlighted in the figure Tighten the screw 3 to a torque of 2 Nm 10 Insert the threaded bushing 25 in the rear hole of the vibration damper 5 Use the indicated product to lubricate the surface...

Page 181: ...Tighten the screw 4 to a torque of 5 Nm 10 Start the remaining screws 3 and tighten them to a torque of 2 Nm 10 Check that on the panel there are two clips 26...

Page 182: ...Position the panel on its support upper part tabs 27 in slots 28 and U bolts 29 in tabs 30 Fix panel A by tightening screws 1 to a torque of 2 Nm 10...

Page 183: ......

Page 184: ...fairing consists of two parts A side panels B conveyor upper cover Side panels The procedure below describes how to remove one side panel but it applies to both tabs Remove the two screws 1 securing...

Page 185: ...To remove support 2 loosen the three screws 3 Loosen the retaining screw 4 of rubber element 5 Remove support 2 from rubber element 5 Remove the two conveyors 6 Removing the tank cover...

Page 186: ...Conveyor upper cover Loosen the three screws 7 securing the conveyor B lower panel 8 Remove the lower panel 8...

Page 187: ...h sides the retaining screws 9 of conveyor B Pull conveyor B forwards by releasing its retainers During this operation pay attention not to damage the temperature sensor cable 10 Disconnect the temper...

Page 188: ......

Page 189: ...at 3 in the relevant housings 5 on vehicle frame Press seat 3 towards vehicle front and lock it Lubricate rear seat 2 pin 6 housing with indicated product Fit rear seat 2 pin 7 in housing 8 on frame P...

Page 190: ......

Page 191: ...nents and height adjustment If previously removed fit seat support 10 and tighten screws 9 to a torque of 4 Nm 10 Check for eccentric 13 presence if it needs to be fitted tighten screw 14 to a torque...

Page 192: ...o increase it by positioning the two shims 11 After positioning them fix them by tightening screws 12 to a torque of 4 Nm 10 In case of lowered seat configuration spacer B must be installed on passeng...

Page 193: ......

Page 194: ...he retaining screws 6 and tighten them to 18 Nm 10 following the indicated sequence and applying the specified threadlocker Insert the lock block 5 and fix it with screws 4 Side body panels Make sure...

Page 195: ...o special screws 15 and tighten them to a torque of 5 Nm 10 Position the side body panel 3 so that the two tabs 9 engage in the frame hooks 8 At the same time the two tabs 10 must engage under the tan...

Page 196: ......

Page 197: ...Start screws 1 with the relevant washer 2 and tighten them to a torque of 5 Nm 10...

Page 198: ...s and the tail guard Side body panels Remove the seat Removing the seat Loosen screws 1 securing side body panel 3 to the rear subframe collecting washers 2 Remove the side body panel by sliding it to...

Page 199: ...Tail guard Undo the screws 4 and remove the seat lock block 5 Loosen screws 6 that retain the tail guard Remove the tail guard 7 by prying in the indicated point...

Page 200: ......

Page 201: ...nsert key inside seat lock 1 and turn it clockwise until hook clicks To slide passenger seat 2 out of the front retainer push it forward lift it and remove it To remove rider seat 3 from vehicle pull...

Page 202: ......

Page 203: ...pan From disassembled sump guard LEFT SIDE SUMP GUARD Fit the vibration dampers 6 and 7 with spacer 8 Fit clip 9 RIGHT SIDE SUMP GUARD Fit the vibration dampers 10 and 11 with spacer 12 CENTRAL SUMP...

Page 204: ...ump guard inserting hose guide A in between Start screws 14 Do not tighten to torque Position the just assembled assembly and fix it by starting screw 2 on the lower LH footpeg holder plate and screw...

Page 205: ...Start screw 5 on the silent block Fit the RH sump guard by starting screw 4 on the lower RH footpeg holder plate and screw 3 on the RH sump guard support plate...

Page 206: ...Fix the RH sump guard A to the central sump guard B by starting screws 15 Tighten screws 4 and 2 to a torque of 20 Nm 10 Tighten screws 3 and 1 to a torque of 5 Nm 10...

Page 207: ...Tighten the screw 5 to a torque of 24 Nm 10...

Page 208: ...Tighten screws 14 and 15 to a torque of 5 Nm 10...

Page 209: ...mbled sump guard Position the assembled sump guard and start screws 1 2 3 4 and 5 Tighten the screws to the following torque values Screws 4 and 2 to a torque of 20 Nm 10 Screws 3 and 1 to a torque of...

Page 210: ...Tighten the screw 5 to a torque of 24 Nm 10...

Page 211: ...Removing the belly pan Loosen the two screws 1 and 2 on the vehicle left side Working on the vehicle lower side loosen screws 3 and 4 Undo the lower screw 5 and remove the belly pan...

Page 212: ......

Page 213: ...ithout the front mudguard fitted to avoid the risk of the brake hoses fouling the wheel when braking Refit sensors Refit sensor brackets 6 and secure them in place by tightening screws 5 to a torque o...

Page 214: ...Fit mudguard 2 by starting screws 1 with spacers Tighten the screws 1 to a torque of 3 5 Nm 10...

Page 215: ...FRONT MUDGUARD HALF KIT Refit half mudguard 8 by tightening screws 7 to a torque of 3 5 Nm 10...

Page 216: ...During assembly insert tabs 10 in the housing on front mudguard 2 Make sure that semi mudguard 8 profiles are aligned as shown in the figure...

Page 217: ...NO FRONT MUDGUARD HALF KIT Fit bracket 9 and fasten it by tightening screws 7 to a torque of 3 5 Nm 10...

Page 218: ...e front wheel Removing the front wheel The following pictures show the front mudguard with installed mudguard half Loosen front mudguard 2 retaining screws 1 keeping the relevant nylon washers Loosen...

Page 219: ...Loosen the two retaining screws 5 of left accelerometer holder bracket 6 Repeat the same procedure on right bracket...

Page 220: ...Loosen the two screws 7 and remove the half mudguard 8...

Page 221: ...If mudguard half 8 has not been installed remove bracket 9 by loosening screws 7...

Page 222: ......

Page 223: ...mble the chain guard 4 with rear splash guard 1 as shown in the figure Position the splash guard 1 with chain guard 4 on the swinging arm Apply the specified threadlocker to screws 2 and 3 Start and t...

Page 224: ......

Page 225: ...Removing the splash guard Remove the splash guard 1 with chain guard from the rear swinging arm by loosening screws 2 and 3 Remove splash guard 1 from chain guard 4...

Page 226: ......

Page 227: ...Refitting the rear mudguard Fit rear mudguard 2 on swinging arm and start screws 1 3 and 4 Tighten screws 1 3 and 4 to a torque of 5 Nm 10...

Page 228: ......

Page 229: ......

Page 230: ...Removing the rear mudguard Working on the vehicle RH side loosen the screws 1 that retain the rear mudguard 2 to the swinging arm From the vehicle LH side loosen screws 3 and 4 on the rear side...

Page 231: ......

Page 232: ...Branch 10 Cables not inserted inside main wiring Table 10A POS DESCRIPTION 1 Starter motor cable 2 Battery negative cable 3 Generator cable...

Page 233: ......

Page 234: ......

Page 235: ......

Page 236: ...Table 10B POS DESCRIPTION 4 Ground cable...

Page 237: ...Table 10C POS DESCRIPTION...

Page 238: ...4 Horizontal head spark plug 5 Horizontal head coils...

Page 239: ...Table 10D POS DESCRIPTION 6 Vertical head spark plug 7 Vertical head coils...

Page 240: ......

Page 241: ...ROUTING OF WIRING ON FRAME...

Page 242: ...nch 9 Table 9A POS DESCRIPTION 1 USB cable 2 Alarm presetting cable 3 12V power outlet 4 Solenoid starter cable Table 9B POS DESCRIPTION 5 Exhaust valve motor rear accelerometer cable FOR S VERSION ON...

Page 243: ...Table 9C POS DESCRIPTION...

Page 244: ...6 Rear shock absorber preload cable FOR S VERSION ONLY Table 9D POS DESCRIPTION 7 Rear speed sensor cable 8 Rear shock absorber regulator cable FOR S VERSION ONLY 9 Gear sensor cable...

Page 245: ......

Page 246: ......

Page 247: ......

Page 248: ...Table 9E POS DESCRIPTION 6 Rear shock absorber preload cable FOR S VERSION ONLY 10 Tail light cable...

Page 249: ...ROUTING OF WIRING ON FRAME...

Page 250: ...Branch 8 Table 8A POS DESCRIPTION 1 Vertical head knock sensor cable 2 Exhaust side vertical head timing regulator cable...

Page 251: ...ROUTING OF WIRING ON FRAME...

Page 252: ...h 7 Table 7A POS DESCRIPTION 1 ECU 1 cable 2 ECU 2 cable Table 7B POS DESCRIPTION 3 Injector wiring cable 4 Horizontal solenoid valve cable 5 Vertical solenoid valve cable 6 Vertical head map sensor c...

Page 253: ...DESCRIPTION 7 Exhaust side vertical head timing regulator cable 8 Intake side vertical head timing regulator cable 9 Exhaust side vertical head timing check cable 10 Intake side vertical head timing...

Page 254: ...ROUTING OF WIRING ON FRAME...

Page 255: ...Branch 6 Table 6A POS DESCRIPTION 1 Hands free cable 2 Airbox cable 3 Tank plug presetting cable 4 Ground jointing...

Page 256: ......

Page 257: ...ROUTING OF WIRING ON FRAME...

Page 258: ...Branch 5...

Page 259: ...Table 5A POS DESCRIPTION 1 Water temperature sensor cable 2 Pick up cable...

Page 260: ......

Page 261: ...Table 5B POS DESCRIPTION 3 Vertical oxygen sensor cable 4 Side stand cable...

Page 262: ......

Page 263: ...ROUTING OF WIRING ON FRAME...

Page 264: ...Branch 4 TABLE 4A POS DESCRIPTION 1 RH switch cable 2 Front brake switch cable 3 Throttle control cable 4 Heated handgrip cable IF ENABLED ONLY 5 Secondary air system valve cable...

Page 265: ...TABLE 4B POS DESCRIPTION...

Page 266: ...2 Front brake switch cable 3 Throttle control cable 4 Heated handgrip cable IF ENABLED ONLY 6 Right turn indicator cable...

Page 267: ...ROUTING OF WIRING ON FRAME...

Page 268: ...Branch 3 Table 3A POS DESCRIPTION 1 Purge valve cable...

Page 269: ...Table 3B POS DESCRIPTION 2 ABS control unit cable...

Page 270: ...Table 3C POS DESCRIPTION...

Page 271: ...3 Horizontal head knock sensor cable 4 Intake side horizontal head timing regulator cable 5 Intake side horizontal head timing check cable...

Page 272: ...Table 3D POS DESCRIPTION...

Page 273: ...5 Intake side horizontal head timing check cable 6 Exhaust side horizontal head timing check cable 7 Exhaust side horizontal head timing regulator cable...

Page 274: ...Table 3E POS DESCRIPTION 8 Horn cable 9 Horizontal map sensor cable...

Page 275: ...Table 3F POS DESCRIPTION...

Page 276: ...10 Horizontal oxygen sensor cable...

Page 277: ...Table 3G POS DESCRIPTION 11 LH fan cable...

Page 278: ...Table 3H POS DESCRIPTION...

Page 279: ...12 RH fan cable ROUTING OF WIRING ON FRAME...

Page 280: ...ed sensor cable 2 Front suspension cable FOR S VERSION ONLY 3 Front wheel accelerometer cable FOR S VERSION ONLY 4 Frame accelerometer cable FOR S VERSION ONLY 5 Clutch switch cable 6 Heated handgrip...

Page 281: ...Table 2B POS DESCRIPTION...

Page 282: ...1 Front speed sensor cable 3 Front wheel accelerometer cable FOR S VERSION ONLY 4 Frame accelerometer cable FOR S VERSION ONLY...

Page 283: ...Table 2C POS DESCRIPTION...

Page 284: ...2 Front suspension cable FOR S VERSION ONLY 5 Clutch switch cable 6 Heated handgrip cable IF ENABLED ONLY 7 Turn indicator cable 8 LH switch cable...

Page 285: ...Table 2D POS DESCRIPTION 9 Fuel pump cable 10 Bluetooth cable IF ENABLED ONLY...

Page 286: ...ROUTING OF WIRING ON FRAME...

Page 287: ...1A POS DESCRIPTION 1 Instrument panel TABLE 1B POS DESCRIPTION 1 Instrument panel 2 Oil temperature sensor cable 3 Oil pressure switch cable 4 GPS presetting cable 5 Air temperature sensor cable 6 12...

Page 288: ...TABLE 1C POS DESCRIPTION 5 Air temperature sensor cable...

Page 289: ...TABLE 1D POS DESCRIPTION 6 12V power outlet...

Page 290: ...TABLE 1E POS DESCRIPTION 2 Oil temperature sensor cable 3 Oil pressure switch cable...

Page 291: ...ROUTING OF WIRING ON FRAME...

Page 292: ...ROUTING OF WIRING ON FRAME MAIN BRANCHES...

Page 293: ...MAIN WIRING POSITIONING Position main wiring as shown in the figure...

Page 294: ......

Page 295: ...Air temperature sensor cable 12V power outlet Branch 2 Front speed sensor cable Front suspension cable FOR S VERSION ONLY Front wheel accelerometer cable FOR S VERSION ONLY Frame accelerometer cable F...

Page 296: ...gulator cable Horn cable Horizontal map sensor cable Horizontal oxygen sensor cable LH fan cable RH fan cable Branch 4 RH switch cable Front brake switch cable Throttle control cable Heated handgrip c...

Page 297: ...side vertical head timing regulator cable Branch 9 USB cable Alarm presetting cable 12V power outlet Solenoid starter cable Exhaust valve motor rear accelerometer cable FOR S VERSION ONLY Rear shock...

Page 298: ...valve motor 30 Rear stop light 31 Vehicle control unit BBS 32 Fuel level 33 Rear suspension adjustment preload 34 Fuse box 2 35 Fuse box 1 36 ABS 37 Rear speed sensor 38 Front speed sensor 39 Fuel pu...

Page 299: ...nder IN timing sensor 73 Horizontal cylinder EX timing sensor 74 Horizontal cylinder IN timing sensor 75 Vertical cylinder EX timing connector 76 Vertical cylinder IN timing connector 77 Horizontal cy...

Page 300: ...orcycle not leaning over The Multistrada 1200 ABS also features a cornering function that widens ABS functionality to the conditions where the motorcycle is leaning over thus preventing wheel lockup a...

Page 301: ...ons used in the manual ABS Antilock Braking System BBS Black Box System CAN Controller Area Network LIN Local Interconnect Network DSB Dashboard DTC DUCATI Traction Control DWC DUCATI Wheelie Control...

Page 302: ...attery is fully charged the current value will be lower Important Check the charging current by using the DDS diagnosis instrument Removing the regulator To remove the regulator see the procedure expl...

Page 303: ...ignition key to OFF before replacing the fuse to avoid possible short circuits Warning Never use a fuse with a rating other than the specified value Failure to observe this rule may damage the electri...

Page 304: ...ambient temperature 20 C Attention Before testing disconnect the generator wiring from the electrical system when the ignition key is set to OFF Rpm Active voltage Minimum voltage Maximum voltage 1500...

Page 305: ...A Refitting the flywheel generator assembly and the generator cover Refitting the generator cover Refit the cooling system pipes Refitting the cooling system hoses and unions and restore the fluid lev...

Page 306: ...7 and battery solenoid starter 6 wiring Tighten the screw 5 to a torque of 10 Nm 10 Position ground cable 4 and tighten screw 3 to a torque of 10 Nm 10 Secure battery mounting bracket 2 with screw 1...

Page 307: ...er or terminals are broken or if the valve cover has been tampered with IT IS ABSOLUTELY NECESSARY TO REPLACE THE BATTERY Important If the motorcycle is left unused for more than 30 days remove the ba...

Page 308: ......

Page 309: ...ed Do not inhale the gases produced during recharging KEEP OUT OF REACH OF CHILDREN Warning Do not dispose of exhausted battery into the environment Smaltimento Do not dispose of waste into the enviro...

Page 310: ...ttery cells Warning Do not peel or perforate the sealed areas Place the electrolyte container 2 upside down Align the six sealed elements with the six filler holes on the battery Push the container 2...

Page 311: ...utes If no bubbles emerge from one of the holes tap gently on the bottom of the respective container Important Never move the container away from the battery Do not cut or puncture the container Make...

Page 312: ...automatic battery charger ensure that the charger current ampere is equal to or higher than the value of the standard charging system STD indicated on the battery itself Press firmly downwards with bo...

Page 313: ...ous substances Note It should be noted that the above mentioned CER code is a general and non binding provision provided based on product original composition and intended use The user is thus respons...

Page 314: ...y if the battery becomes too hot to the touch Leave to cool before resuming charging Use only constant voltage battery chargers Check that battery terminals are properly connected to the battery charg...

Page 315: ...Checking the battery charging system Perform checks on the system as indicated in the following paragraphs Recharging the battery Topping up the electrolyte Generator Rectifier regulator...

Page 316: ...t Removal procedure Disconnect the solenoid starter connector 2 from the wiring Slide out solenoid starter from its seat Remove protection 3 Undo the screws 4 taking care to collect the spring washers...

Page 317: ...ty If there is no electric continuity ensure that the terminals are not oxidised and apply water repellent spray Change the solenoid starter if the malfunction persists Refitting procedure Lay down th...

Page 318: ......

Page 319: ...oad applied to the shaft Warning Secure the starter motor to a test bench making sure not to damage the casing Warning Use a fully charged 12 V battery for the test Use battery motor connection cables...

Page 320: ...Electric starting system The electric starting system consists of a solenoid starter 1 and a starter motor 2...

Page 321: ...lacing the tail light bulbs The tail light 1 on this motorcycle is a LED light In case of malfunctions or breakage it will be necessary to replace the entire tail light 1 Removing the number plate hol...

Page 322: ...Tail light The tail light 1 on this motorcycle is a LED light In case of malfunctions or breakage it will be necessary to replace the entire tail light 1 Removing the number plate holder...

Page 323: ...with the longitudinal axis of the motorcycle Note If possible perform this check in dim light Switch on the low beam The height of the upper limit between the dark area and the lit area must not be m...

Page 324: ......

Page 325: ...Replacing the headlight bulbs This model features a full LED headlight so in case of failure the whole headlight will have to be replaced Removing the headlight...

Page 326: ...Headlight This S version features a LED headlight so in case of malfunction of a bulb the whole headlight must be replaced...

Page 327: ...ble right hand switch 1 see chapters Removing the handlebar and Refitting the handlebar CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connected to control unit diag...

Page 328: ...ble left hand switch 1 see chapters Removing the handlebar and Refitting the handlebar CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagn...

Page 329: ...ected between the two poles threaded pins of the solenoid starter check for electric continuity If there is no electric continuity ensure that the terminals are not oxidised and apply water repellent...

Page 330: ...s described in paragraph Removing the seat To expose the fuses lift the box protective covers Mounting position and ampere capacity are marked on box cover Refer to the table below to identify the cir...

Page 331: ...key Pos El item Rat 1 30 EMS LOAD RELAY 25 A 2 30 FUEL PUMP RELAY 10 A 3 30 Starter RELAY 7 5 A 4 30 Instrument panel 10 A 5 30 Black Box System BBS 10 A 6 30 ABS UBMR 25 A 7 30 ABS UBVR 15 A Fuses 8...

Page 332: ...FUSES To reach the main fuses and the ABS fuses remove the seat as described in paragraph Removing the seat The two main fuses A one is the spare fuse are located on solenoid starter B Remove protecti...

Page 333: ...Main fuses key Pos El item Rat A Main fuse 30 A A Spare 30 A ELECTRIC DIAGRAM...

Page 334: ...lown fuse can be identified by breakage of the inner filament F Important Switch the ignition key to OFF before replacing the fuse to avoid possible short circuits Warning Never use a fuse with a rati...

Page 335: ...to the control unit The detected signal is output to the control unit which shares it with the instrument panel CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connec...

Page 336: ...sary CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket A which is positioned inside electrical components compartment to rea...

Page 337: ......

Page 338: ...e electrical components compartment to reach it remove the seat After selecting the proper items on the menu read the engine coolant temperature value among the different displayed engine parameters w...

Page 339: ...t circuit or open circuit inside the control unit memory check the electric system parts connecting sensor to control unit If this section of the electric system is not faulty no open circuit no short...

Page 340: ...ront brake lever is operated there must be electric continuity between the terminals of the corresponding switch No electric continuity should be available when brakes are not operated If these tests...

Page 341: ...tside the specified range check the lubrication circuit components and service as necessary Switch on the instrument panel without starting the engine disconnect the electrical terminal from the press...

Page 342: ...ELECTRIC DIAGRAM...

Page 343: ...ned on the vehicle rear RH side CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket A which is positioned inside electrical co...

Page 344: ...e rear 1 STOP switch use a multimeter when the rear brake lever is operated there must be electric continuity between the terminals of the corresponding switch No electric continuity should be availab...

Page 345: ......

Page 346: ...STOP switch use a multimeter when the front brake lever is operated there must be electric continuity between the terminals of the corresponding switch No electric continuity should be available when...

Page 347: ......

Page 348: ...emoving the side panels Release exhaust valve motor cable as described in chapter Removing the exhaust system REMOVAL PROCEDURE Remove the three screws 1 of exhaust valve motor support 2 collecting wa...

Page 349: ...Fasten exhaust valve motor 6 using the two screws 4 and positioning the two washers 5 in between Tighten the two screws 4 to a torque of 2 Nm 10 Fasten support 2 to the frame using the three screws 1...

Page 350: ...ntrol unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket A which is positioned inside electrical components compartment to reach it remove the seat...

Page 351: ......

Page 352: ...s are indicated in chapter Cooling system REMOVAL REASSEMBLY To work on the solenoid valves move the radiator from the front side as described in chapters Removing the radiator and Refitting the radia...

Page 353: ...ELECTRIC DIAGRAM...

Page 354: ...alue that allows the spark creation in the spark plug Four coils are fitted on the vehicle two for the horizontal cylinder 1 and 2 and two for the vertical cylinder 3 and 4 REMOVAL PROCEDURE To reach...

Page 355: ...aps as described in paragraph Replacing the spark plugs Remove vertical cylinder coil 4 Disconnect the connector 9 Disconnect caps as described in paragraph Replacing the spark plugs Loosen the two sc...

Page 356: ...ove the two screws 10 Remove coils 1 and 2 ELECTRIC CHECKS Primary winding resistance 0 6 Ohm PIN OUT Function PIN 1 Control signal to negative PIN 2 Positive to battery DIAGNOSIS CHECKS Check control...

Page 357: ...socket A which is positioned inside electrical components compartment to reach it remove the seat ELECTRIC DIAGRAM Vertical cylinder coils Horizontal cylinder coils...

Page 358: ......

Page 359: ...ounted to frame swinging arm REMOVAL PROCEDURE Front mudguard sensor For sensor removal please refer to chapters Removing the front mudguard Bottom yoke front sensor To remove sensor 1 located on bott...

Page 360: ...E Front mudguard sensor For sensor refitting procedure refer to chapter Refitting the front mudguard Bottom yoke front sensor If it has been previously removed proceed as follows to refit it Fit front...

Page 361: ...g the two screws 2 Rear sensor Insert sensor 4 in its support and fix it with two screws 6 Refit exhaust valve motor position sensor as described in chapter Refitting the side panels Fasten sensor 4 t...

Page 362: ...correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket A which is positioned inside electrical components compartment to reach it remove the seat ELECTRIC DI...

Page 363: ...Bottom yoke front sensor Rear sensor...

Page 364: ......

Page 365: ...ting remove the instrument panel first Removing the panel and Refitting the panel Remove the Bluetooth control unit 1 by sliding it upwards Disconnect the connector 2 CONTROLS Check control unit corre...

Page 366: ...ELECTRIC DIAGRAM...

Page 367: ...e sensor is installed in its definitive position This because upon Key On the sensor checks the signal plausibility If the sensor is not in its correct position it will trigger a signal error that can...

Page 368: ......

Page 369: ...rs 1 In case of faulty combustion the ignition advance is progressively reduced CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic s...

Page 370: ...Vertical head...

Page 371: ...eives information on throttle twistgrip position activation dynamics To remove the APS follow the instructions in chapter Removing the throttle control CONTROLS Check control unit correct operation wi...

Page 372: ...le is provided with two lambda sensors one per cylinder oxygen sensor 1 for horizontal cylinder exhaust oxygen sensor 2 for vertical cylinder exhaust If necessary reach the oxygen sensor connectors as...

Page 373: ...ELECTRIC DIAGRAM Horizontal oxygen sensor Vertical oxygen sensor...

Page 374: ......

Page 375: ...h motorcycle inclination above 7 with respect to the vertical axis For removal and refitting please refer to chapters Removing the light assembly and Refitting the light assembly CONTROLS Check contro...

Page 376: ...control For removal and refitting please refer to chapters Removing the handlebar and Refitting the handlebar CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connecte...

Page 377: ...y identifies a vehicle family model country serial number This code can be stored in the instrument panel and read through the DDS 2 with suitable KWP2000 inputs When replacing one of the above contro...

Page 378: ...are Front wheel speed Rear wheel speed Inertial platform via CAN line For removal and refitting please refer to chapters Removing the ABS control unit and Refitting the ABS control unit CONTROLS Chec...

Page 379: ......

Page 380: ...or signals are shared by both electronic units Sensors are connected to closer electronic unit instrument panel or engine control unit which sends the signals to the network to be processed by the con...

Page 381: ...sensor is installed in its definitive position This because upon Key On the sensor checks the signal plausibility If the sensor is not in its correct position it will trigger a signal error that cann...

Page 382: ......

Page 383: ...sensor 2 the control unit can control vehicle traction according to the speed difference between the two wheels CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connec...

Page 384: ...To remove and refit the speed sensors refer to chapters Replacing the front phonic wheel sensor and Replacing the rear phonic wheel sensor ELECTRIC DIAGRAM Front sensor Rear sensor...

Page 385: ......

Page 386: ...ap of two teeth as reference for the first cylinder TDC Position 1 the pick up sensor detects the full area i e the tooth Position 2 the pick up sensor detects the empty area i e the gap between the t...

Page 387: ...l unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket A which is positioned inside electrical components compartment to reach it remove the seat ELEC...

Page 388: ...Throttle Position System TPS In the Multistrada the TPS is integrated in the ETV...

Page 389: ...the ETV but it is necessary to replace the complete throttle body Once replaced reset the TPS as described in chapter Throttle position potentiometer CONTROLS Check control unit correct operation with...

Page 390: ...VERTICAL ETV WIRING DIAGRAM 1 To remove and refit the ETV refer to chapters Removing the airbox and throttle body and Refitting the airbox and throttle body...

Page 391: ...if enabled In Signals Front wheel accelerometer Bottom yoke accelerometer if enabled Level sensor Preload position if enabled Shock absorber position sensor if enabled EXVL valve position Rear stop li...

Page 392: ...3 Disconnect the connector 4 REFITTING PROCEDURE Refitting is the reverse of removal CONTROLS Check control unit correct operation with the DDS 2 diagnosis instrument connected to control unit diagno...

Page 393: ......

Page 394: ...antity of intake air in the cylinders and based on the preset stoichiometric ratio determines the correct quantity of fuel to be delivered to the injectors The air fuel ratio is therefore always excel...

Page 395: ...V Map REMOVAL REASSEMBLY To remove and refit the MAP sensor refer to chapters Removing the airbox and throttle body and Refitting the airbox and throttle body...

Page 396: ...isted below APS Gear sensor Vertical and horizontal cylinder ETV Vertical and horizontal cylinder lambda sensor Pick Up sensor Vertical and horizontal cylinder Map Sensor Vertical and horizontal cylin...

Page 397: ...ECU 1 connector ECU 2 connector To remove and refit the ECU see the procedure described in chapter Removing the airbox...

Page 398: ...ou press the button 2 the displayed number increases by one 1 up to 9 and then starts back from 0 3 each time you press the button 1 the displayed number decreases by one 1 up to 1 and then starts bac...

Page 399: ......

Page 400: ...eys he she still has The Ducati authorised service centre will program all new and old keys The Ducati authorised service centre may ask to the customer to prove to be the motorcycle owner The codes o...

Page 401: ...ll of the grip by pushing it forward and lifting it as shown in the figures After separating the plastic shells remove the battery protection sheath 2 Remove battery 3 and install a new one Install th...

Page 402: ...Reinstall the rear plastic shell and push slightly as shown in the figure Make sure shells close properly and that the key is well closed...

Page 403: ...n Note In this case replace the battery as soon as possible When the charge level goes below a certain limit the key can only work in passive mode like the passive key in this case the instrument pane...

Page 404: ...on every Key Off The grip of each ignition key contains an electronic device that modulates the output signal from a special antenna in the headlight fairing when the ignition is switched On The modul...

Page 405: ...e left turn indicators press button 10 in position I to activate the right turn indicators press button 10 in position L Turn indicators can be cancelled by pressing button 10 on LH switch If the turn...

Page 406: ...rd function has higher priority compared to normal operation of the single turn indicators this means that as long as it is active it will not be possible to activate the single right or left turn ind...

Page 407: ...types of Smartphones depending on supported Bluetooth profiles This is why Ducati cannot guarantee multimedia player proper operation for any earphones not coming with the Ducati Kit part no 98102949...

Page 408: ...MANUAL System automatically highlights DELETE indication for the first associated device and user can delete one or several devices refer to Deleting associated devices or quit the Bluetooth Setting M...

Page 409: ...tting Menu during pairing you will find the indication CONNECT ON NAVI which will go out as soon as connection between control unit and device is successfully established Note If user does not complet...

Page 410: ...ressing button 4 at DEVICE item From the list of associated devices user can select the device by pressing button 1 or button 2 Then press button 4 for at least two seconds at DELETE item to delete it...

Page 411: ...ct EXIT and press button 4 Setting the units of measurement Speed This function allows to change the units of measurement of speed and hence even the ones of distance travelled You open the UNITS SETT...

Page 412: ...press CONFIRM MENU button 4 You open the TEMPERATURE menu When you enter the function the current unit of measurement is displayed followed by the list of the possible units C F Press buttons 1 and 2...

Page 413: ...ired unit of measurement and then press the CONFIRM MENU button 4 to confirm the selected unit is stored and the EXIT option is highlighted The selected unit of measurement will be used by the instrum...

Page 414: ......

Page 415: ...Once the desired backlighting option is highlighted press button 4 to confirm The instrument panel immediately activates the option selected by the user and highlights the corresponding name To exit t...

Page 416: ...NFIRM MENU button 4 The value will start flashing Select AM or PM option by pressing button 1 or 2 respectively Once you reach the value to be set press button 4 and the set value will stop flashing S...

Page 417: ...each the value to be set press CONFIRM MENU button 4 and the set minutes will stop flashing Storing the time Time is set automatically any time you quit each single setting and colon is flashing To ex...

Page 418: ...Once highlighted press CONFIRM MENU button 4 Year value starts flashing Press button 1 to decrease year value by 1 unit 2099 2098 2000 2099 Press button 2 to increase year value by 1 unit 2000 2001 20...

Page 419: ...o store set modified date select MEMORY using buttons 1 and 2 and press button 4 for 2 seconds The instrument panel will display MEMORIZED for two seconds and then automatically highlight EXIT If date...

Page 420: ......

Page 421: ...1 up to 9 and then starts back from 0 3 Each time you press the button 1 the displayed number decreases by one 1 up to 1 and then starts back from 0 4 To confirm the number press the button 4 Repeat t...

Page 422: ...ts of the PIN CODE When you press button 4 to confirm the fourth and last digit the instrument panel highlights the message MEMORY To save the new setting hold button 4 for two seconds while the messa...

Page 423: ......

Page 424: ...To perform this procedure the Authorised Ducati Dealer may ask you to demonstrate that you are the owner of the motorcycle Activating the PIN CODE To activate the PIN CODE function and enter your own...

Page 425: ...age is successful MEMORIZED will be highlighted in green for 1 second and then EXIT will be highlighted in green Once the first PIN CODE is stored this menu page is no longer available and is replaced...

Page 426: ...ated to all riding modes To gain access to this function enter the Setting Menu use button 1 or 2 to select RIDING MODE and press button 4 Then use button 1 or 2 to select ALL DEFAULT and keep button...

Page 427: ...m the drop down menu by pressing button 1 or 2 Once the desired mode is highlighted press button 4 You open the selected riding mode customisation Menu Select DEFAULT option by pressing button 1 or 2...

Page 428: ...evels 1 to 3 and status OFF Press buttons 1 and 2 to highlight the levels one by one in particular use button 1 to highlight the following item and button 2 to highlight the previous item Once the des...

Page 429: ...e desired parameter is highlighted press button 4 If the DTC is disabled set to OFF the DWC parameter can not be changed and is forced to level OFF When entering the function the currently set DWC lev...

Page 430: ...drop down menu by pressing button 1 or 2 Once the desired parameter is highlighted press button 4 When entering the function the currently set DTC level or status is indicated on the right e g ON LEV...

Page 431: ...highlighted press button 4 When entering the function currently set engine power is indicated on the right e g MEDIUM The central drop down menu lists the available customisation options HIGH MEDIUM...

Page 432: ...tons 1 and 2 to select the riding mode to change and press button 4 Then use buttons 1 and 2 to select MEM flashing and keep button 4 pressed for 2 seconds then the display will show WAIT for 2 other...

Page 433: ...on settings front fork rear shock absorber rider only rider with luggage rider and passenger rider and passenger with luggage DEFAULT Press buttons 1 and 2 to highlight the customisable parameters one...

Page 434: ......

Page 435: ...active Important For safety reasons it is recommended to use this Menu with the motorcycle at a standstill Press buttons 1 and 2 to highlight the customisable parameters one by one in particular use...

Page 436: ......

Page 437: ...rument panel activates the fog light warning light when the fog lights option are present and active In case of fog light fault the DSB displays the flashing Fog Light warning light and turns on the G...

Page 438: ...pen the icon SIDE STAND is displayed on a red background In case of Side stand sensor fault the instrument panel will display the stand down up indication with MIL light on If instrument panel does no...

Page 439: ...in real time Upon Key On in case of errors the instrument panel turns on the MIL light B in case of errors directly connected to the engine control unit or the Generic Error light A in case of any oth...

Page 440: ...ght turns on the small warning icon is not displayed on instrument panel until the Generic Error light stays on warnings will only be displayed within the first 10 seconds as a large size icon Conside...

Page 441: ...rning indicates that the Hands Free system has detected that the battery that permits the active key to communicate and turn the vehicle on is almost discharged Note In this case Ducati recommends cha...

Page 442: ...road but for off road use only Date setting This function prompts the user to enter the date via the Setting Menu Note In this case Ducati recommends to stop and enter the calendar date using the fun...

Page 443: ......

Page 444: ...e service threshold is reached the warning for the type of service required is triggered OIL SERVICE A SERVICE DATE B DESMO SERVICE C Required service warning is triggered and displayed in red until R...

Page 445: ...conds upon Key ON the count of the mileage in kilometres miles remaining before the next OIL SERVICE A 1000 km 600 mi earlier than the service threshold the count of the days remaining before the next...

Page 446: ...ing The first service warning is the OIL SERVICE zero and is triggered as soon as the odometer reaches the first 1 000 km 600 mi Warning is displayed until Reset by the Ducati authorised service centr...

Page 447: ...ice Centre The service warning indication can be reset only by the Authorised Ducati Service Centre during servicing There are 3 types of scheduled maintenance interventions OIL SERVICE ZERO service a...

Page 448: ...quested target speed has been reached for over 5 seconds the display will show the coolant temperature again Press RES button 6 to resume previous SET speed in case the Ducati Cruise Control was previ...

Page 449: ...activating the front brake activating the rear brake pulling the clutch The Ducati Cruise Control system controls the vehicle speed only between 50 Km h 30 mph and 200 Km h 125 mph...

Page 450: ...uttons Warning All data concerning the Infotainment Player access to Contact List Name of devices etc are managed for use of Western character sets If Bluetooth is active apart from the Bluetooth icon...

Page 451: ...the smartphone is connected to the bike to the moment it is disconnected the missed call symbol will be displayed The number of missed calls is not displayed In case there is at least one SMS MMS EMAI...

Page 452: ...time button is pressed The player can be turned off by quitting the player control pressing button 2 for 2 seconds and then pressing button 1 for 2 seconds under menu 1 item will be PLAYER OFF in pla...

Page 453: ...so the DUCATI MULTIMEDIA SYSTEM during the pairing phase will send an access request to such profile which can be notified to the user explicitly depending on the operating system by requesting acces...

Page 454: ...option control function This function allows enabling and adjusting the heated handgrips Press the heated handgrips button 12 and the instrument panel will display grip icon followed by OFF indicatio...

Page 455: ...crease and reach the actual user setting Note In case of Battery Off upon the following Battery On Key On the Dashboard sets this function by default to OFF Note This means that if heated handgrips ar...

Page 456: ...a string of three dashes is steadily displayed followed by the unit of measurement If the air temperature sensor is in fault the instrument panel will show three flashing dashes as air temperature va...

Page 457: ...shown depicts the function in TRACK layout Note It is possible to change the units of measurement of Speed and distance travelled as well from km h and km to mph and mi through the SETTING MENU using...

Page 458: ...running and the motorcycle is moving moments when the motorcycle is not moving when speed is equal to 0 and or when the engine is OFF are not considered When the calculation is not made a string of t...

Page 459: ...units of measurement of Speed and distance travelled as well from km h and km to mph and mi through the SETTING MENU using the UNITS SETTING function When TRIP1 is reset the value is reset and the fi...

Page 460: ...to 11 59 or p m from 12 00 to 11 59 In case of a power off Battery Off upon the following Key On the instrument panel displays 4 dashes steadily and with flashing colon until clock is set through the...

Page 461: ...starts again When the reading exceeds 511 00 511 hours and 00 minutes the meter is reset and automatically starts counting from 0 again Considering that the FULL and CORE layouts show the values for...

Page 462: ...f measurement If there is any function fault the instrument panel will display three flashing dashes If the instrument panel is not receiving RANGE information a string of three steady dashes is displ...

Page 463: ...ed is reset and the meter automatically starts counting from 0 again While the trip meter is displayed press button 1 for 2 seconds to reset TRIP 2 The TRIP2 counter is automatically reset in case the...

Page 464: ...velled is reset and the meter automatically starts counting from 0 again While the trip meter is displayed press button 1 for 2 seconds to reset TRIP 1 When TRIP1 is reset the average fuel consumption...

Page 465: ...of a power OFF Battery OFF Note If a string of flashing dashes is displayed within odometer function please contact a Ducati Dealer or Authorised Service Centre Odometer update When replacing the Ins...

Page 466: ...wing four layouts or modes TRACK FULL CORE OFF ROAD Available functions are Residual range RANGE Trip meter 1 TRIP1 Trip meter 2 TRIP2 Trip time TRIP TIME Instant fuel consumption CONS Average Fuel Co...

Page 467: ...ge 39 C 38 F to 39 C 102 F LO is displayed steadily within the range 40 C 104 F to 120 C 248 F the value is displayed steadily higher than or equal to 121 C 250 F HI is displayed flashing If the coola...

Page 468: ...oes further down the last mark will be red and flashing and the fuel pump symbol will be steady and red Considering that the FULL CORE and OFF ROAD layouts show the values for this function in a simil...

Page 469: ...d A string of flashing dashes is displayed if gear teach in procedure has not been carried out yet or if instrument panel is not receiving gear information If the gear sensor is in fault a string of d...

Page 470: ...te If DTC is set to OFF DWC is also forced to OFF The Ducati Wheelie Control system DWC supervises control of wheelie movement and settings vary through eight different levels that are calibrated to o...

Page 471: ...oneness to do wheelies and sensitively intervenes in case of wheelie NO 7 HIGH SAFE STABLE Level for all kinds of riders The system reduces the motorcycle s proneness to do wheelies and sensitively in...

Page 472: ...DWC sensitivity level that suits you best always try each level for at least two laps to allow the tyres to warm up Tips for use on the road Activate the DWC select level 8 and ride the motorcycle in...

Page 473: ...em the ABS lettering will flash Considering that the FULL CORE and OFF ROAD layouts show the values for this function in a similar to the TRACK layout the example shown depicts the function in TRACK l...

Page 474: ...long high gradient downhill road tracts shift down gears to use engine braking Apply one brake at a time and use brakes sparingly Keeping the brakes applied all the time would cause the friction mate...

Page 475: ...y and lift up control which is disabled in level 2 Level 2 provides for the front to rear combined braking and the cornering function ABS level 1 is specific for off road use and ABS is active only on...

Page 476: ...is a rider aid that can be used on the track on the road and off road The system is designed to make riding easier and to enhance safety but in no way relieves the rider of the obligation to ride resp...

Page 477: ...mmended by Ducati In particular OE tires for this motorcycle are Pirelli Scorpion Trail II in the following sizes 120 70ZR17 at the front 190 55ZR17 at the rear Using tires with different size and cha...

Page 478: ...ing style slightly to a more rough approach to cornering i e straighten up more rapidly on exiting the corner instead of immediately trying a different level setting Tips for use on the road We recomm...

Page 479: ...reen layout TRACK FULL CORE and OFF ROAD is associated to every riding mode it is set by Ducati or customised by the user from the setting functions the layouts set by Ducati are associated to the Rid...

Page 480: ...om 01 to 24 for the rear shock absorber Displayed information includes the values stored for each single Riding Mode The stored settings may be the factory ones Ducati default settings or the ones cus...

Page 481: ...nd and compression damping a specific rear shock absorber rebound and compression damping as well as a specific rear shock absorber spring preload Press button 2 for two seconds to activate the load m...

Page 482: ...set unit of measurement if speed is equal to 299 km h or 186 mph or if instrument panel is not receiving the speed value steady ON the rear speed sensor is in fault flashing Considering that the FULL...

Page 483: ...000 or higher number 8 is displayed bigger The range between 8500 and 10500 rpm pre warning area is displayed in orange both for the bargraph filling and for the indication of value 10 orange area The...

Page 484: ......

Page 485: ...ER Additional information LAP Infotainment Bluetooth Cruise Control Service indication SERVICE Warnings Alarms Heated handgrip optional Riding mode customisation RIDING MODE this menu allows customisa...

Page 486: ...eck routine and leave ON only the warning lights that are actually active at the moment The main screen can have four different layouts TRACK FULL CORE and OFF ROAD Data displayed on the main screen f...

Page 487: ...ndication 9 LOAD settings motorcycle setup 10 Gear indication 11 Clock 12 Rev counter 13 Menu 1 Range Trip 1 Trip 2 Trip time 14 Menu 2 Instant fuel consumption Average fuel consumption Average speed...

Page 488: ...th indication 16 Infotainment Menu Connected devices phone calls sms 17 Infotainment Menu Player calls Phone Recall 18 Infotainment Menu Player volume track selection 19 LAP indication only if active...

Page 489: ...itch to view Menu 2 information Lap time LAP only if active Average fuel consumption CONS AVG Instantaneous fuel consumption CONS I Average speed SPEED AVG Air temperature From the main screen with FU...

Page 490: ...CORE layout press button 1 on LH switch to view Menu 1 information RANGE TRIP 1 TRIP 2 TRIP FUEL when function is active PLAYER ON OFF active only with connected Smartphone Press button 2 on LH switch...

Page 491: ...ctual motorcycle speed is lower than or equal to 20 km h 12 mph to enter the Setting menu where you can set any function Important You can enter the SETTING MENU only when the actual vehicle speed is...

Page 492: ...ENTRY BUTTON Button used to confirm during MENU navigation 5 CRUISE CONTROL BUTTON ON OFF Button used to switch the Cruise Control function on off 6 CRUISE CONTROL BUTTON RES Resume more see Fig 1 Bu...

Page 493: ...d below 5 Km h 3 mph Light OFF Light flashing Light steady on DTC DWC enabled and functioning DTC DWC enabled but not yet functioning since initialisation is in progress or functioning with degraded p...

Page 494: ...Spark advance cut Light steady ON Injection cut Light steady ON 13 OVER REV IMMOBILIZER SYSTEM RED Over rev No intervention Light OFF First threshold N RPM before the limiter kicks in Light steady ON...

Page 495: ...been completed refit the wheel as follows Check the central spacer 8 is present on the wheel see Overhauling the front wheel On the right side lubricate seal 9 using the specified product Fit spacer 8...

Page 496: ...Fit spacer 7 in the wheel Apply the recommended grease on wheel shaft 6 thread included...

Page 497: ...Fit the complete wheel between the fork bottom ends Take pin 6 fully home into the wheel hub...

Page 498: ...Fit the washer 4 on the end of the wheel shaft Use the indicated product to grease the thread and underhead of the retaining nut 3 Fit nut 3 without tightening it to torque...

Page 499: ...ad and underhead of screws 2 retaining calliper 1 Pre tighten the two screws 2 to a torque of 2 Nm 10 Pull the brake lever many times Hold the lever pulled towards the handgrip and simultaneously tigh...

Page 500: ...underhead of screws 2 retaining calliper 1 Fit the two spacers A Pre tighten the two screws 2 to a torque of 2 Nm 10 Pull the brake lever many times Hold the lever pulled towards the handgrip and sim...

Page 501: ...Tighten the screws 5 on the vehicle right side to a torque of 10 Nm 5 following a 1 2 1 sequence Tighten nut 3 to a torque of 63 Nm 5...

Page 502: ...rque Lower the motorcycle to the ground and push up and down the handlebars to load the suspension so the fork bottom ends will become properly seated onto the wheel shaft Tighten the screws 5 on both...

Page 503: ...like those indicated in values A and B An excessive wear can cause vibrations and instability of the vehicle and therefore it is necessary to replace them To remove the bearings and the sealing rings...

Page 504: ...ve the latter fully into its seat Use the same method to install the sealing rings 9 Ensure that spacer 8 is fitted between the two wheel hub bearings Note Wheels must be rebalanced after repair maint...

Page 505: ...the rim as follows Visually inspect the rim for cracks scoring and deformation change the rim if damaged Insert the shaft in the wheel and position it on two fixed reference blocks Using a dial gauge...

Page 506: ...If the values measured are not within the tolerance limits replace the wheel...

Page 507: ...e bike so that the wheel to be removed is raised from the ground Remove front brake callipers 1 by loosening the two screws 2 securing the calliper to the fork leg without disconnecting them from the...

Page 508: ...Warning Do not operate the brake lever when the callipers are removed This can cause the brake pad pistons to come out Loosen and remove nut 3 on wheel shaft left side Collect washer 4...

Page 509: ...Loosen the wheel shaft retaining screws 5 on both fork bottom ends...

Page 510: ...Working from the left hand side use a plastic mallet to drive the wheel shaft 6 out from the opposite side and remove it Remove the wheel and collect spacers 7 and 8...

Page 511: ...Working on both sides remove the sealing ring 9...

Page 512: ......

Page 513: ...Refitting the rear wheel Lubricate the wheel shaft threaded end with indicated grease Fit the wheel shaft by matching holes A on the rear rim with pins B on the rear hub...

Page 514: ...the wheel and washer 3 Tighten the nut 2 to a torque of 230 Nm 10 checking that the hole on the nut is aligned with one of those on the wheel shaft Fit the clip 1 fitting the end into one of the holes...

Page 515: ...In case of tyre replacement fit the counter weights by respecting the values indicated in the figure...

Page 516: ......

Page 517: ...ing machine Overhauling the wheel rim Inspect the wheel rim as follows Visually inspect the rim for cracks scoring and deformation change the rim if damaged Fit the wheel rim on the service shaft no 8...

Page 518: ......

Page 519: ...silencer Place the motorcycle on the rear service stand and engage the 1st gear Remove the circlip 1 Using a suitable socket loosen the wheel nut 2 Fully unscrew the nut 2 and then slide out washer 3...

Page 520: ......

Page 521: ...y positioned hoses can affect brake operation and foul moving parts Position the component as shown in the figure After having aimed the hose unions 11 on the front brake callipers 13 and 14 tighten s...

Page 522: ...t the brake pads are brought into contact with the brake disc Hold the lever pulled towards the handgrip and simultaneously tighten the calliper screws 12 to a torque of 45 Nm 5 Refit the front brake...

Page 523: ...et 5 Tighten screw 3 to a torque of 10 Nm 5 If the speed sensor has been removed it will be necessary to adjust the AIR GAP There must be a gap between ABS sensor and phonic wheel of 1 3 mm to 1 9 mm...

Page 524: ...10 Nm 10 For the shimming use two feeler gauges A of 0 2 mm and 0 5 mm Warning Shim pack shall never exceed 3 mm Note Perform the test in three points of the phonic wheel at a distance of 120 one fro...

Page 525: ...roughly and apply the indicated threadlocker on the threads of retaining screws 1 LEFT SIDE Fit the phonic wheel 3 Tighten the screws 1 retaining the brake disc 2 to the wheel following this sequence...

Page 526: ...Refit the wheel on the motorcycle Refitting the front wheel...

Page 527: ...of this component Incorrect overhaul of this component could endanger rider safety Operations should be limited to replacement of the pads fasteners and the bleed valve assembly The brake disc must be...

Page 528: ...consist of an inner carrier which is mounted to the wheel and an outer rotor Both parts must be replaced together as a pair Remove the front wheel Removing the front wheel Undo the screws 1 securing t...

Page 529: ...hanging the front brake system fluid Remove the front brake master cylinder Removing the hydraulic front brake master cylinder Loosen the screws 1 and remove the protection 2 Undo the screw 3 and slid...

Page 530: ...Undo the special screws 8 and 9 from both callipers and collect the seals 10 Remove the front brake callipers from hoses 4 and 11...

Page 531: ...Loosen the two retaining screws 12 securing the left front brake calliper 13 to the fork leg Repeat the operation for the right brake calliper 14...

Page 532: ......

Page 533: ...rrosive and will damage paint Avoid contact with eyes and skin In case of accidental contact wash thoroughly with water For all maintenance operations wear check and replacement of brake pads and brak...

Page 534: ...bly 3 on the handlebar by inserting pin B in the relevant seat C of the handlebar Position U bolt 6 on the handlebar by starting the screws 5 as shown in the figure Tighten the fastening screws 5 to t...

Page 535: ...switch connector A to the main wiring harness Position the hose 4 and sealing washers 2 on the master cylinder unit 3 and secure with the special screw 1 without tightening Tighten the special screw 1...

Page 536: ...s For the positioning of the hose 4 and retaining ties see Section Routing wiring hoses Refit the RH switch Refit the rear view mirrors Refitting the rear view mirrors Fill in the braking system Chang...

Page 537: ...eplacement of the following parts control lever fluid reservoir assembly and relative fasteners and master cylinder fasteners Drain the braking system Changing the front brake system fluid Remove the...

Page 538: ...Undo the screws 5 securing the U bolt 6 and then remove the front brake master cylinder assembly from the handlebar...

Page 539: ...ighten special screw 1 to the torque of 23 Nm 10 If the speed sensor 6 is removed fit it to the calliper holder plate 9 with the spacer 8 and tighten the screw 7 to a torque of 10 Nm 10 If calliper ho...

Page 540: ...screw 7 fully home on sensor 6 every time you add or remove shims Once the shimming is completed tighten the sensor retaining screw to a torque of 10 Nm 10 For the shimming use two feeler gauges A of...

Page 541: ...Warning Shim pack shall never exceed 3 mm Note Perform the test in three points of the phonic wheel at a distance of 120 one from the other...

Page 542: ...c Position disc 2 on the flange and fix it with screws 1 after applying the indicated threadlocker Position the phonic wheel 4 apply the indicated threadlocker and fix using screws 3 Refit the rear wh...

Page 543: ...ar disc Remove the rear wheel Removing the rear wheel Remove the rear wheel shaft Removing the rear wheel shaft and hub Loosen screws 3 of phonic wheel 4 and remove it Loosen the retaining screws 1 an...

Page 544: ...r brake calliper and the corresponding seals 3 Remove the hose 2 Undo the two fastening screws 4 securing the rear brake calliper 5 to the calliper holder bracket and remove the brake calliper 5 If it...

Page 545: ...e lever 7 Bushing 10 must be at the same distance from the external edges of rear brake lever seat 7 Apply the indicated grease on the inner surface of the bush 10 and threadlocker on the shaft 6 Inst...

Page 546: ......

Page 547: ...3 Tighten the special screw 12 to a torque of 23 Nm 10 Note Pay particular attention to the hose routing and hose coupling on the rear brake master cylinder Apply the indicated threadlocker on shaft 6...

Page 548: ...Refit the rear brake control 7 and the bracket 5 that retains the rear stop light 1...

Page 549: ...ition the rear brake master cylinder 3 on the vehicle inserting the retaining screws 2 Insert the rod 4 inside the master cylinder 3 after applying the recommended grease Tighten screws 2 to a torque...

Page 550: ...Fill the rear braking system Changing the rear brake system fluid...

Page 551: ...the brake pedal 7 needs to be replaced grease the external surface and fit the new bush using a press to insert it The bush must be placed at the indicated value After performing an operation on the...

Page 552: ...tenance operations on these units are limited to replacement of the following parts control lever fluid reservoir assembly and relative fasteners and master cylinder fasteners Drain the rear braking s...

Page 553: ...Undo pin 6 securing the brake lever 7 collecting spring 8...

Page 554: ...Slide out the brake lever 7 and collect pin 6 bushing 11 and O rings 9...

Page 555: ...Undo the special screw 12 from master cylinder 3 by removing the hose clip 13 slide out hose 14 collecting the seals 15 and hose 16 Remove rear brake master cylinder 3 from vehicle...

Page 556: ...ABS system deactivation ABS Antilock Braking System intervention can be customised and possibly disabled To set and disable the ABS refer to ABS system operation information...

Page 557: ...the ABS control unit have been added to the Global Scan function providing the following information in case of IMU sensor and BBS ABS component replacement BBS setting indicates the setting of the B...

Page 558: ...ter the next key off key on cycle As a result always perform a key on key off cycle after any work on the ABS system interrupting and re establishing communication between the diagnostic instrument an...

Page 559: ...pressure to rear pump sensor fault Offset fault C1333 ABS pressure sensor fault Overvoltage C1015 ABS pump motor fault ABS pump motor fault C1059 ABS control unit Overvoltage ABS control unit Overvol...

Page 560: ...gnal IMU sensor wrong signal U2928 IMU sensor Timeout IMU sensor Timeout U100C IMU sensor Generic error IMU sensor Generic error U0121 CAN communication problem with ABS ABS_Data02 message timeout CAN...

Page 561: ...the front and rear brake systems depending on the vehicle lean angle with the purpose of preventing wheel lockup and slipping as much as possible within the physical limits allowed by the vehicle and...

Page 562: ...5A Rear calliper 5B Left front calliper 6B Right front calliper 7 Pressure transducer Brake system diagram Braking without ABS ABS 1 modulation braking...

Page 563: ...ABS 2 modulation pressure partial reduction on callipers ABS 3 modulation pressure total reduction on callipers...

Page 564: ......

Page 565: ...r to ABS control unit A B C E F 3 Hose from front master cylinder to ABS control unit A F 4 Hose from rear master cylinder to ABS control unit A F G H 5 Hose from rear calliper to ABS control unit C D...

Page 566: ...TABLE B...

Page 567: ...TABLE C...

Page 568: ...TABLE D...

Page 569: ...TABLE E TABLE F...

Page 570: ...TABLE G TABLE H...

Page 571: ......

Page 572: ...control unit 2 by tightening screw 14 to a torque of 5 Nm 10 Hoses 9 10 11 and 12 must be secured in place using new sealing washers 13 on unions Tighten screws 5 6 7 and 8 to a torque of 23 Nm 10 Co...

Page 573: ...ll be supplied with the secondary circuit already filled with fluid Control unit must thus be assembled and the system filled and drained as a traditional system Refit the seat Refitting the seat Refi...

Page 574: ...moving the tank Remove the airbox Removing the airbox Disconnect ABS control unit 2 connector 1 lift unit from the vehicle Loosen the special screws 5 6 7 and 8 that retain hoses 9 10 11 and 12 and re...

Page 575: ...en screw 4 and remove the ABS control unit 2 Important Do not open the ABS control unit if faulty replace it Should it be necessary to replace one or several hoses refer to Routing wiring harnesses ho...

Page 576: ...s Remove the rider seat Removing the seat Remove the rear mudguard Removing the rear mudguard Disconnect connector 1 of rear ABS sensor 2 from main wiring Open all the ties that retain the rear ABS se...

Page 577: ...Undo the screws 7 and remove the rear swinging arm cable cover 6 Remove the ties Loosen screw 8 and remove the speed sensor 2 Collect the calibrated seal 9...

Page 578: ...WHEEL SENSOR Fasten the sensor to the calliper holder plate by tightening screw 8 to a torque of 8 Nm 10 Reposition the speed sensor cable 2 as described in chapter Routing wiring harnesses hoses Posi...

Page 579: ...Connect the connector 1...

Page 580: ...Refit the rear mudguard Refitting the rear mudguard Refit the rider seat Refitting the seat...

Page 581: ...r A from main wiring Undo the retaining screw 2 and remove front ABS sensor 1 with calibrated gasket 3 sliding cable out from cable grommet 4 Before refitting make sure that contact parts between fron...

Page 582: ...ghten screw 2 to a torque of 10 Nm 10 Connect the connector A to main wiring Refit all the ties that retain the front ABS sensor cable 1 Refit the front half casing Refitting the front half casing Ref...

Page 583: ...hanging the front brake system fluid and Changing the rear brake system fluid Before bleeding a brake master cylinder move back the calliper pistons to let any air build up in the ABS control unit flo...

Page 584: ......

Page 585: ...ssembled and the system filled and drained as a traditional system Important Should it prove difficult to bleed the braking system it is possible to use a dedicated activation to operate the pump and...

Page 586: ...the front calliper ABS circuit rear part AV Prepare to open the bleed valve A on the rear calliper Still with DDS 2 0 start the second stage of the activation function that opens the rear outlet valve...

Page 587: ...2 0 to start the third stage of the activation function to open the rear outlet valves AV and HSV with activation of the ABS pump During this time open and close repeatedly the bleed valve A of the re...

Page 588: ...cement or refitting of the speed sensor 3 or 4 front replacement or refitting of the sensor holder bracket rear replacement or refitting of the calliper holder plate It is necessary to check the air g...

Page 589: ...FRONT Tighten securing screw 2 fully home on sensor 1 every time you add or remove shims REAR Tighten securing screw 7 fully home on sensor 6 every time you add or remove shims...

Page 590: ...exceed 3 mm Note Perform the test in three points of the phonic wheel at a distance of 120 one from the other Phonic wheels cleaning It is important to check that both phonic wheels 1 and 2 are always...

Page 591: ......

Page 592: ...pply the recommended threadlocker on the thread in view of screws 13 Refit the lower U bolt 14 and start screws 13 Tighten the screws 13 to a torque of 45 Nm 5 1 2 1 sequence Position handlebar 12 in...

Page 593: ...crews 10 Tighten screws 10 to a torque of 25 Nm 5 following a 1 2 3 4 3 sequence as shown Refitting the switches Following is the procedure to refit the LH switch The same procedure applies also to th...

Page 594: ...Fit switch 2 fully home on support 3 Check that the switch is actually blocked...

Page 595: ...Reconnect the connector Refitting the heated handgrips LH HANDGRIP Connect connector 7 to the main wiring located in the connector support B...

Page 596: ...Tighten screws 9 to a torque of 2 8 Nm 10...

Page 597: ...RH HANDGRIP For the RH handgrip refer to chapter Refitting the throttle control Connect connector 7 located on support B...

Page 598: ...Refit the front brake control Refitting the front brake master cylinder Refit the clutch hydraulic control Refitting the clutch hydraulic control Refit the hand guards Refitting the hand guards...

Page 599: ...r cylinder Remove the hydraulic clutch control Removing the clutch master cylinder assembly Removing the left handgrip Slide out the LH handgrip using a pressure air gun Repeat this operation on the o...

Page 600: ...Remove the two protection plugs 8 and loosen the two retaining screws 9 Slide the heated handgrip out of the handlebar...

Page 601: ...RH HANDGRIP The heating system of the RH handgrip is integrated in the throttle control Disconnect connector 7 located on the vehicle right side in support B...

Page 602: ...oving the throttle control Removing the switches To remove the switches it is necessary to use tool no 88713 4967 Following is the procedure to remove the LH switch The same procedure applies also to...

Page 603: ...Insert tool A inside seat 1 of switch 2 Push tool A until releasing switch 2...

Page 604: ...3 Remove the switch 2 Removing the handlebar Undo and remove the screws 10 securing the upper U bolt 11 Remove the upper U bolt 11 that retains the handlebar Remove the handlebar 12 from its seat on t...

Page 605: ...Remove the steering head Removing the steering tube components Undo the screws 13 remove the lower U bolt 14 and recover washers 15...

Page 606: ......

Page 607: ...he following procedure is the same for both hand guards Position the hand guard Tighten the two screws 4 of support 5 to a torque of 5 Nm 10 Fix the hand guard by tightening screw 2 to a torque of 10...

Page 608: ......

Page 609: ...emoving the hand guards The following procedure is the same for both hand guards Undo screws 2 of the hand guard 1 Disconnect the connector 3 Loosen the two screws 4 of support 5 Remove the hand guard...

Page 610: ......

Page 611: ...t screw 3 in the rear view mirror 2 Insert the rear view mirror 2 in the U bolt Tighten the screw 3 to a torque of 40 Nm 10 Insert plug 1 Important Pay attention to the different threading the left re...

Page 612: ...ove plug 1 from the rear view mirror 2 Undo screw 3 and remove the rear view mirror Repeat the described operations for the other mirror Important Pay attention to the different threading the left rea...

Page 613: ...the throttle control Position the throttle control on the handlebar by inserting the reference pin in the relevant seat Assemble the two parts of the throttle control Tighten screws 4 to a torque of...

Page 614: ...Connect the throttle control cable 3 to the switch...

Page 615: ...Position the hand guard 1 by tightening screw 2 to a torque of 10 Nm 10...

Page 616: ...the tank fairings Remove the front half fairings Removing the front half fairing Move hand guard 1 by loosening screw 2 Disconnect the throttle control cable 3 from the main wiring harness Loosen the...

Page 617: ......

Page 618: ...lace also the two O rings 8 Lubricate with the indicated product and reposition the clutch pushrod 7 with the two O rings 8 Position the anti rotation pin 10 so as to align it with holes A as shown in...

Page 619: ...Fit the anti rotation insert 12 into clutch slave cylinder 14 making sure to match part B of insert 12 with slot C on the actuator...

Page 620: ...Insert clutch slave cylinder 14 including anti rotation insert 12 on clutch pushrod 7 already positioned The anti rotation pin 10 must engage into the corresponding slots D on anti rotation insert 14...

Page 621: ...g screws 1 Tighten screws 1 to a torque of 10 Nm 10 by in the 1 2 3 1 sequence Note To bring the clutch slave cylinder internal surface near the casing cover as evenly as possible screw and tighten th...

Page 622: ...operations that can be performed on the slave cylinder regard the bleeding unit the seal and the complete piston Drain the clutch system Draining the clutch system circuit Undo screws 1 of the clutch...

Page 623: ...the two O rings 8 and replace them if necessary Refitting the clutch slave cylinder If the clutch pushrod 7 must be replaced it is necessary to replace also the two O rings 8 Lubricate with the indic...

Page 624: ...Position the anti rotation pin 10 so as to align it with holes A as shown in the figure Fit seals 13 on the anti rotation insert 12 Apply the recommended grease to the seal 13...

Page 625: ...Fit the anti rotation insert 12 into clutch slave cylinder 14 making sure to match part B of insert 12 with slot C on the actuator...

Page 626: ...including anti rotation insert 12 on clutch pushrod 11 already positioned The anti rotation pin 10 must engage into the corresponding slots D on anti rotation insert 14 In the picture below the rod is...

Page 627: ...0 Nm 10 by in the 1 2 3 1 sequence Note To bring the clutch slave cylinder internal surface near the casing cover as evenly as possible screw and tighten the retaining screws alternatively in steps Fi...

Page 628: ...Component A Component B...

Page 629: ......

Page 630: ...H handlebar by inserting centring pin A in hole B of the clutch master cylinder control Couple clamp 6 with the clutch master cylinder control and fix them with screws 5 Tighten the fastening screws 5...

Page 631: ...e special screw 1 without tightening Warning An incorrectly positioned hose can cause system faults and interfere with moving parts For the positioning of the clutch hose 4 and retaining clips refer t...

Page 632: ......

Page 633: ...owing parts control lever fluid reservoir assembly and relative fasteners and master cylinder fasteners Drain the clutch system Draining the clutch system circuit Remove the LH rear view mirror Removi...

Page 634: ......

Page 635: ...r reassembling follow the removal procedure in the reverse order In particular apply specified threadlocker to screws 2 and tighten them to a torque of 15 Nm 10 To position the wiring refer to Section...

Page 636: ...system wiring A from the main wiring If the electronic tank plug kit is installed it will be necessary to disconnect the tank plug wiring B Remove the clamp shown in the picture Disconnect the immobil...

Page 637: ......

Page 638: ...Insert the shaft 1 in the gear lever 2 and insert the other O ring 3 and the washer 4 Fit the gear lever 1 on the footpeg plate by inserting and tightening the shaft 1 to the specified torque of 23 Nm...

Page 639: ...Fit the gear change unit inserting the lever 7 on the gear control pin apply threadlocker on the screw 6 and insert it on the lever 7 Tighten screw 6 to a torque of 10 Nm 10...

Page 640: ...rive the new bush into place using a press The bush must be seated 2 mm below the outer face of the pedal Warning After working on the gear change control check the position of the gear pedal To adjus...

Page 641: ...osen and remove the pin 1 securing the gear pedal 2 and collect the O rings 3 the washer 4 and bush 5 Undo and remove the screw 6 securing the gear lever 7 to the gearbox shaft Remove the lever 7 comp...

Page 642: ...Note Mark the position of lever with respect to the gear selector shaft To remove lever 7 from gear transmission rod assembly 8 loosen screw 9 then slide out lever 7...

Page 643: ...0 1 mm Position fork legs 5 and 6 on bottom yoke 4 and steering head 3 Fasten fork legs by tightening screws 1 to 10 Nm 5 and screws 2 to 16 Nm 5 retaining bottom yoke 4 and steering head 3 tighten s...

Page 644: ...ting the front wheel Refit the front half fairings Refitting the front half fairing Refit the front brake callipers Refitting the front brake system Warning Do not use the motorcycle when front mudgua...

Page 645: ...sleeve 1A using tool no 88713 4302 Release the spring preload by rotating the adjustment nut counter clockwise Warning Write down the number of performed rotations so as to tighten the nut by the same...

Page 646: ...upper plug 3A while holding lock nut 2A with a wrench Slide the following components out of the outer sleeve 1A in the following sequence 1 upper plug 3A 2 spring preload tube 4 3 washer 5 4 washer 6...

Page 647: ......

Page 648: ...n to let oil flow out Work several times on the damper rod 7 to let the oil completely flow out Warning With this movement the fluid is pressurised and drained out of the fork leg Aim the fluid inside...

Page 649: ...the LH leg Lock with a vice the fork leg on outer sleeve 1 using tool no 88713 4302 Loosen the screw 9 fastening top cover 10 on upper plug 3 Slide the upper cover 10 and rubber block 11 out of the fo...

Page 650: ...Loosen the fork top plug 3B using tool no 88713 4303 Loosen the upper plug 3B while holding lock nut 2B with a wrench...

Page 651: ...Loosen ring nut 12 while holding with tool no 88713 4303 the plug upper part Loosen the lower part 13 of the plug from its upper part 14 while holding with tool no 88713 4303 the plug upper part...

Page 652: ...Slide out the plug upper part 14 from the bottom part 13 Loosen ring nut 12 from the plug bottom part 13 and slide it out Slide out spring 8B from outer sleeve 1B...

Page 653: ...n to let oil flow out Work several times on the damper rod 7 to let the oil completely flow out Warning With this movement the fluid is pressurised and drained out of the fork leg Aim the fluid inside...

Page 654: ...seals and dust seals Block in a vice the fork leg on the bottom end and slide out spring 15 that retains the dust seal and the latter 16 Warning During this operation pay attention not to damage the...

Page 655: ...Remove the circlip 17 Slide out fork leg 19 from fork leg 1...

Page 656: ...Remove the oil seal 18 from leg 19 Fit the new oil seal 20 and dust seal 21 on fork leg 19 and fit the outer sleeve 1 in the fork leg 19...

Page 657: ...no 88713 3204 Fit the circlip 17 fix the new dust seal 20 to the outer sleeve using tool no 88713 3204 Refit the spring 15 that retains the dust seal Important Lubricate the sliding edges with grease...

Page 658: ......

Page 659: ...tity 660 cc 5 cc for the RH leg Attention The amount of fluid affects the behaviour of the fork at the end of its compression travel A high fluid level increases the compression load a low level decre...

Page 660: ...Insert the preload tube 4 paying attention to keep the damper rod 7 as lifted as possible to fit a wrench on the nut Insert the upper plug 3A...

Page 661: ...Tighten the upper plug 3A on the damper rod while holding lock nut 2A with a wrench...

Page 662: ...to the outer sleeve using tool no 88713 4303 to a torque of 20 Nm 10 Restore the spring preload by rotating the adjustment nut clockwise Important Repeat the number of rotations performed during the d...

Page 663: ...left leg Attention The amount of fluid affects the behaviour of the fork at the end of its compression travel A high fluid level increases the compression load a low level decreases it Fit spring 8B...

Page 664: ......

Page 665: ...on its upper part 14 while holding with tool no 88713 4303 the upper part Screw ring nut 12 to the plug bottom part 13 bringing the ring nut fully home on the upper part 14 Hold with tool no 88713 430...

Page 666: ...Tighten the upper plug 3B on the damper rod while holding lock nut 2B with a wrench Tighten the top plug 3B to the outer sleeve 1B using tool no 88713 4303 to a torque of 20 Nm 10...

Page 667: ...Fit the upper cover 10 and rubber block 11 by routing the cable inside the components Tighten the screw 9 fastening top cover 10 on upper plug 3B...

Page 668: ......

Page 669: ...nt mudguard Removing the front mudguard Remove the front wheel Removing the front wheel Remove the front half fairings Removing the front half fairing Loosen the screws 1 securing the fork legs to the...

Page 670: ...st the upper bearing race tighten the nut 11 and use a wrench to seat the outer rings 8 fully in the steering tube leave the tool fitted until the steering tube has cooled down to ensure that bearings...

Page 671: ......

Page 672: ...d with the larger diameter side of the race facing upwards Install the sealing ring 5 with the flat side facing upwards Tighten the adjuster ring nut 3 by hand until it seats against the sealing ring...

Page 673: ...tom yoke Refit the fork legs Apply recommended grease to the screw 1 Tighten screw 1 on steering head to a torque of 18 Nm 5 If previously removed position splash guard 13 onto bottom yoke 7 and secur...

Page 674: ...Refit the front brake callipers Refitting the front brake system Fill the braking system Changing the front brake system fluid...

Page 675: ...ding wiring and hoses can remain on the motorcycle provided they do not hinder the following operations Loosen the screw 1 securing the steering head 2 to the ring nut 3 Remove the steering head 2 Wit...

Page 676: ...e figure remove the inner ring A from the steering shaft taking care not to damage the seat Important The removed seals and bearings shall not be reused and must be replaced with similar new component...

Page 677: ......

Page 678: ...Steering angle adjustment Loosen the nuts 2 Screw or loosen dowel 1 so as to respect value X 6 6 5 mm Keep dowel 1 and screw nut 2 fully home...

Page 679: ...bearing clearance as explained under Section Adjusting the steering head bearing clearance If the problems found are not solved check the wear of steering bearings 1 and replace them if necessary as...

Page 680: ...Refitting the rear suspension Reposition the preload tube 2 and fix it with bracket 1 Reconnect the connectors 3 and 4...

Page 681: ...d underside of top screw 5 and bottom screw 6 Fit the shock absorber bottom end into the rear swinging arm and tighten screw 6 fit shock absorber top end to rear subframe and tighten screw 5 Tighten s...

Page 682: ...ting the rear mudguard Refit the rear wheel Refitting the rear wheel Refit the silencer Refitting the silencer Refit the rear LH side body panel Refitting the side body panels and the tail guard Refit...

Page 683: ...Overhauling the rear shock absorber Important For any problem concerning the shock absorber operation contact a SACHS authorised service centre...

Page 684: ...y panel Removing the side body panels and the tail guard Remove the exhaust silencer Removing the silencer Remove the rear wheel Removing the rear wheel Remove the rear mudguard Removing the rear mudg...

Page 685: ...To remove the rear shock absorber from the vehicle undo the upper 5 screw and the lower screw 6 Then slide the rear shock absorber out with the electronic preload tube...

Page 686: ......

Page 687: ...hydraulic monoshock absorber that is completely adjustable The shock absorber can be adjusted both in rebound by means of adjuster 1 and in compression by means of adjuster 2 located under plug 3 It...

Page 688: ......

Page 689: ...ly the indicated threadlocker on screw 12 and tighten it to 5 Nm 10 Chain guard Apply indicated threadlocker on screws 10 position chain guard 11 and fix it by tightening screws 10 to a torque of 5 Nm...

Page 690: ...r on the three screws 7 and tighten them to a torque of 5 Nm 10 Check the bearing 14 movement they must move freely without faulty frictions or noise If they have to be replaced proceed as follows use...

Page 691: ...14 on both sides using the indicated product Lubricate the swingarm shaft with the specified product Calculate the allowed end float of the swinging arm Overhauling the swinging arm Centre the swinga...

Page 692: ......

Page 693: ...8 Nm 10 Refit the rear subframe Refitting the side plates Refit the splash guard Refitting the number plate holder Refit the rear eccentric hub Refitting the rear wheel eccentric hub Refit the rear mu...

Page 694: ...is not the case the available shim sizes are 0 20 mm and 0 10 mm with which it is possible to restore the specified play Example Measured play Left hand side shims Right hand side shims 0 10 no 1 shi...

Page 695: ...Warning The maximum swinging arm rear end play is within 1 mm...

Page 696: ...specting the swinging arm shaft Before refitting the swinging arm shaft 14 check it carefully for distortion Turn the shaft on a reference surface and measure distortion using a feeler gauge Rear whee...

Page 697: ...ake calliper Remove the shock absorber Removing the rear shock absorber Remove the rear mudguard Removing the rear mudguard Remove the rear eccentric hub Removing the rear wheel eccentric hub Remove t...

Page 698: ...ool no 88713 1074 fully extract the swinging arm shaft Pay attention to the two spacers 6 upon reassembly it will be necessary to calculate the end float Overhauling the swinging arm Remove the swingi...

Page 699: ...Lower chain sliding shoe Undo the screws 7 to remove the lower chain sliding shoe 8 from the swinging arm 9...

Page 700: ...Chain guard Undo the screws 10 to remove the chain guard 11 from the swinging arm 9...

Page 701: ......

Page 702: ...e of removal with attention to the following points If the calliper bracket locating pin 10 was removed apply the recommended threadlocker upon reassembly Tighten shaft 10 to a torque of 33 Nm 5 Befor...

Page 703: ...commended grease on seals 8 and position them in the seat of plate 7 Fit plate 7 to swinging arm pin 10 must be engaged in the plate 7 Refit the other washer 6 Fit the circlip 5 with the sharp edge fa...

Page 704: ...he eccentric hub 9 position to swinging arm 11 is with the horizontal axis D of the hub hole B below the horizontal axis C of the hub seat Apply an even coating of the recommended grease in the areas...

Page 705: ...haft 3 in the hub Ensure the wheel shaft 3 is seated in the hub Fit the inner ring 2 on the wheel shaft 3 Insert the inner ring 2 in the hub Apply recommended grease to screws A and tighten to 35 Nm 5...

Page 706: ...ng the rear brake calliper Refit the rear sprocket Refitting the rear sprocket Refit the rear wheel Refitting the rear wheel Refit the exhaust silencers Refitting the silencer Tension the chain as des...

Page 707: ...the exhaust silencers Removing the silencer Remove the rear wheel Removing the rear wheel Remove the rear sprocket Replacing the rear sprocket Remove the rear brake calliper Removing the rear brake ca...

Page 708: ...Remove the circlip 5 on the wheel side of the eccentric hub Remove the washer 6 and the calliper mounting bracket 7 with the O rings 8...

Page 709: ...Remove the second washer 6 Slide out the eccentric hub 9 from swinging arm chain side...

Page 710: ...Warning The rear hub is very important for vehicle dynamic safety it is available as a single spare part since you must not service its internal parts...

Page 711: ...ricated at regular intervals to protect metal parts of the chain and the O rings Lubrication also serves to keep the O rings soft and pliable to ensure the maximum sealing efficiency Using a brush app...

Page 712: ...O rings must be washed in oil diesel fuel or paraffin Do not use fuel trichloroethylene or other solvents which will damage the rubber O rings For the same reason use only sprays specifically formulat...

Page 713: ...sprocket flange 4 onto rear sprocket 5 engaging cush drive damper pins 7 Apply recommended threadlocker to the nut thread 8 Start nuts on cush drive damper pins threaded end 7 Tighten the nuts 8 to a...

Page 714: ...t silencers Removing the exhaust system Remove the rear wheel Removing the rear wheel Restrain wheel shaft against rotation Remove the circlip 1 Using a suitable socket wrench loosen nut 2 Fully unscr...

Page 715: ...Using a mallet tap the sprocket flange 4 with the cush drive damper 7 off the rear sprocket 5...

Page 716: ...er ring of the bearing Before refitting the front sprocket check that the spacer 6 is installed on the gearbox secondary shaft Check that the splines of the gearbox secondary shaft and the sprocket ar...

Page 717: ...nto the body C and the plate holder F Fit the body C onto the holder A which holds the chain in position Manually turn the bolt G until the plate holder F is seated against the plate itself Use wrench...

Page 718: ...o pins the figure shows the correct result of the procedure Tension the chain Adjustment of chain tension Apply the recommended threadlocker to the screws 2 Fit the sprocket cover 1 and tighten the sc...

Page 719: ......

Page 720: ...Remove the chain Remove the chain using tool X part no 88713 1344 The tool consists of a holder A a punch B a body C and two wrenches D and E Fit the link to be opened into the holder A Fit the punch...

Page 721: ...dy C and the wrench E onto the bolt Turn clockwise the bolt F until the pin comes out Remove the chain Engage a low gear and unscrew the nut 3 Remove the nut 3 and the lockwasher 4 on the sprocket Rem...

Page 722: ...Remove the spacer 6 with O ring 7 and washer 8 from the gearbox secondary shaft Important The O ring must be renewed upon removal...

Page 723: ...ear visually check the front sprocket 1 and the rear sprocket 2 If the teeth are worn as shown in the figure dotted line the final drive must be replaced Important Make sure that the rear sprocket fro...

Page 724: ...t RH footpeg is described in detail the LH footpeg can be removed following the same procedure Position spring 4 so that the end A rests on the footpeg 3 Position footpeg 3 inserting the end C of spri...

Page 725: ...g holder plate 6 as shown If necessary smear pin B retaining spring 12 with recommended grease in order to keep it in the correct position Insert the spring 10 into the special hole of the footpeg 3 F...

Page 726: ......

Page 727: ...Apply the recommended threadlocker to the screws 5 Position passenger rear footpeg holder plate 6 on frame and tighten screws 5 to a torque of 24 Nm 10...

Page 728: ...pin 2 while supporting the footpeg 3 Slide out footpeg 3 from its seat and collect spring 4 Removing the rear footpegs Note Removing of the rear RH footpeg is described in detail the LH footpeg can b...

Page 729: ...thereby releasing the pin 9 Slide out pin 9 from footpeg holder plate 6 holding the footpeg 3 and making sure that the ball 11 and the spring 10 are not released Slide out footpeg 3 from its seat and...

Page 730: ...Refitting the centre stand Insert pins 3 from both the left and the right side Tighten the two pins to a torque of 50 Nm 10 The picture shows only the left pin Connect the spring 1 to the stand 2...

Page 731: ...Removing the centre stand Release the spring 1 of the central stand 2 Loosen pins 3 on both sides Remove the stand The picture shows only the left pin...

Page 732: ...he side stand return springs 5 and 6 and attach them to fasteners B and C on bracket and stand Place the switch 1 on the plate on its pin 7 Fit the retaining screw 4 with recommended threadlocker and...

Page 733: ...Connect the side stand switch connector A to the main wiring...

Page 734: ......

Page 735: ...moving the side stand Disconnect connector A of the stand switch 1 from the main wiring Undo the two fastening screws 2 of the side stand support plate 3 to the engine and remove the complete side sta...

Page 736: ...Undo the retaining screw 4 and remove the side stand switch 1 Release stand return springs 5 and 6 disengaging them from retainers B and C Unscrew the pin 7 securing the side stand to the bracket and...

Page 737: ...tand to the plate and check that there is no excessive clearance Ensure that the ends of the side stand are not bent with respect to the shank A side stand which shows signs of cracking must be replac...

Page 738: ...crews 5 Tighten screws 5 to a torque of 25 Nm 10 Lay wiring front branch on headlight support 1 and position cable ring Secure wiring in place using clamps 4 Fit front light assembly 2 on headlight su...

Page 739: ...Refit the side panels Refitting the panel...

Page 740: ...en the screws 4 to a torque of 10 Nm 10 Refit the number plate holder Refitting the number plate holder Refit the rear wheel Refitting the rear wheel Reconnect the rear brake sensor Refit the rear foo...

Page 741: ...Refitting the structural parts and frame Check that on frame 1 there are clips 2 elements 3 and adjusters 4...

Page 742: ...t the following screw tightening sequence to the relevant torque by alternating screws on the left and on the right side of the vehicle POSITION DESCRIPTION TORQUE PRODUCT 1 Frame special screw 60 Nm...

Page 743: ...crew 42 Nm 10 GREASE B on thread and underhead 7 Rear shock absorber upper retaining screw 42 Nm 10 GREASE B 8 Shock absorber bracket retaining front screw 25 Nm 10 9 Adjuster screw Manually fully hom...

Page 744: ...Apply three drops of adhesive in the RH and LH plugs at 120 one from the other Remember to point the arrows B as shown in the figure Fit the tail guard Refitting the tail guard...

Page 745: ...the side stand Remove the sump guard Removing the sump guard Remove the rear footpegs Removing the rear footpegs Remove the rear wheel Removing the rear wheel Remove the rear shock absorber Removing...

Page 746: ...rew 5 and the swingarm shaft plug 6 Loosen screw 7 plug 8 of the adjuster and from the vehicle right side the two screws 9 retaining the shock absorber upper bracket Remove the front screw 10 that ret...

Page 747: ...Loosen ring nut 12 of the adjuster Remove the two lateral plates 13...

Page 748: ......

Page 749: ...ving the panel Loosen screws 3 and remove the front headlight assembly 2 from the front headlight assembly unit 1 Remove ties 4 and release the whole wiring from the headlight support 1 Loosen screws...

Page 750: ......

Page 751: ...x and throttle body Remove the secondary air system pipes and valve Removing the secondary air system Remove the supply system and the injectors from the intake manifolds Disconnect the caps from the...

Page 752: ...ws The number plate holder 5 consists of three parts 6 number plate holder 7 tail light 8 number plate holder cover Make sure that clips 9 and 10 are present on number plate holder 6 Fit the three rub...

Page 753: ...Fit the two turn indicators 14 and the wiring as shown in the figure A Left turn indicator B Right turn indicator C Number plate light D Tail light...

Page 754: ...Connect the tail light and fix it by means of screws 16 with washer 15 Fix the number plate holder 6 to cover 8 by means of screws 17...

Page 755: ...Fit the number plate holder plate 18 by tightening screws 19 USA version For this version fit also cat s eye 20 with brackets 21 in the number plate holder...

Page 756: ...Insert the number plate holder assembly 5 in the rear subframe and fix it with screws 4...

Page 757: ...Connect the connector 3...

Page 758: ...Refit the ignition relay 2 and the battery 1 Refit the rider and passenger seats Refitting the seat...

Page 759: ...ats Removing the seat Remove the battery 1 as described in paragraph Battery and the starter relay 2 Release the wiring from any tie and disconnect the tail light connector 3 Loosen the four upper ret...

Page 760: ...Remove the number plate holder 5...

Page 761: ......

Page 762: ...rd sheet 9 insert three screws 10 and washer 11 Fit on screws 10 the plastic heat guard 12 with washer 13 Tighten the heat guard sheet 9 with plastic heat guard 12 by means of nuts 15 and washer 14 Fi...

Page 763: ...Tighten the two screws 20 securing voltage regulator 21 Fit washer 22 and tighten with nut 23...

Page 764: ...ion damping pads 24 block them with the two nuts 23 and washers 22 Fitting the seat lock Fit the lock in the suitable seat 25 of the electrical components compartment by engaging the lock tabs in the...

Page 765: ...Fit plate 26 by engaging lock tabs A and B in the recesses...

Page 766: ...Fix the lock by starting nut 27 Tighten the nut to the specified torque Insert latch cable 28 and position its bracket 29 and fix it with screws 30...

Page 767: ...e heat guard on the compartment Position the heat guard and fix to the bottom part of the electrical components compartment by means of the two screws 31 In the upper part fix the heat guard with the...

Page 768: ...pports and hose clips Position supports 33 and cable rings 34 and fix them with screws 35 Position the remote control switch support 36 and fix it with the screw 37 Route the latch cable as shown in t...

Page 769: ...Position the electrical components compartment 8 inside the rear frame Fix the electrical components compartment 8 with screws 6 and washer 7 and with screws 4 in the bottom part...

Page 770: ...Fit the inertial platform 4 Fix it on the vibration damping pads 39 by tightening screws 38 to a torque of 10 Nm 10...

Page 771: ...Reposition relays 3 and the fuse boxes 2 Route the wiring as indicated in chapter Routing the electric wirings Tighten the two screws 1 of the lock control...

Page 772: ...after installing its support Reconnect the starter relay Install the battery and its mount Refit the side body panels Refitting the side body panels and the tail guard Refit the rider and passenger s...

Page 773: ...e the side body panels Removing the side body panels and the tail guard Remove the battery and its mount Remove the starter relay Disconnect the black box and remove it with its support Remove the loc...

Page 774: ...Release the wiring from the hose guides and clamps Loosen the two retaining lower screws 5 of the number plate holder cover Loosen the screws 6 and collect washer 7...

Page 775: ...Remove electrical components compartment 8...

Page 776: ...ition tank 8 on the frame by fitting the two forks on support 9 Fix the tank by means of screws 7 Check for the presence of the lower 14 and upper 13 blocks and spacer 12 Connect the two breather pipe...

Page 777: ...Reconnect the fuel pump connector 4 and hose 6 Grip and press flange A to insert hose 6...

Page 778: ...Reconnect the fuel level connector 3 and reposition the clips 1...

Page 779: ...Refit the tank fairings Refitting the tank fairings Refit the side body panels Refitting the side body panels Refit the seat Refitting the seat Positioning the fuel tank breather pipe...

Page 780: ......

Page 781: ...Positioning the fuel tank drain pipe...

Page 782: ......

Page 783: ......

Page 784: ...Positioning the fuel pipes...

Page 785: ......

Page 786: ...fectly clean Fit gasket 4 fully home on the pump 1 as shown in the figure Lubricate the gasket 4 with the indicated product and fit it in the fuel tank 2 Position the pump locking flange 5 on pump 1 c...

Page 787: ...sor Insert the fuel level sensor inside the tank Use the indicated product to lubricate the sensor gasket Insert the sensor so that tab 5 engages into slot 6 Fit the ring nut 7 and tighten it to a tor...

Page 788: ...Insert plug 8...

Page 789: ...Removing the fuel tank flange To remove flange 1 from tank 2 loosen the retaining nuts 3 Remove flange 1 from tank 2...

Page 790: ...e from all parts Note The flange is supplied as a spare part complete with the fuel pump and pressure regulator the entire flange assembly must be replaced in the event of malfunction Fuel level senso...

Page 791: ...Duly grease the new sealing washer 4 and its seat on tank Position the complete filler cap 2 paying attention to fit the two breather hoses 3 in the relevant seats Start and tighten the six securing s...

Page 792: ...Removing the tank filler plug Loosen and remove the six securing screws of the tank plug 1 Remove the complete plug 2 paying attention to recover the two breather pipes 3 Collect the seal 4...

Page 793: ...panels Removing the side body panels The figure shows the fuel supply circuit lay out A Fuel pump immersed in the fuel and provided with filter and pressure regulator B Fuel delivery pipes C Injector...

Page 794: ...Disconnect connector 4 from the fuel pump 5 Remove the fuel pipe 6 and the breather pipes 10 and 11...

Page 795: ......

Page 796: ...Remove the two retaining screws 7 of tank 8 Remove tank 8 from the vehicle by sliding it out of support 9 To do this first push it forwards and after removing the support 9 lift it vertically...

Page 797: ......

Page 798: ...roduct strictly necessary to carry out the following assembly operations Insert injector 23 onto fuel pipe unit union 28 Important To avoid damaging the O rings drive the injector fully home on the th...

Page 799: ...e funnel 32 on the throttle body 33 Fix the intake funnel 32 with the two screws 33 Check that the throttle body bearing surface is clean Check that the two O rings 34 on the sleeve are not worn out o...

Page 800: ...Fit the throttle body on the airbox and fix the latter with screws 24 Reconnect the connectors of injectors 12 and of the ETV motor 10 and 11 Reconnect the fuel pipe 23...

Page 801: ...Position the upper airbox 22 Start screws 21 retaining the upper airbox 22 Pay attention to the two washers 35 of the fuel pipe and cable passages Tighten screws 21 to the specified torque...

Page 802: ...REFITTING THE AIR FILTER Position filter 20 as shown in the figure...

Page 803: ...Position cover 18 and tighten the screws 19 REFITTING THE AIRBOX If previously removed fix the connector bracket 36 and tighten screw 37...

Page 804: ...AP sensor 38 and fix it using the screw 39 with the relevant spacer If previously removed position the vertical MAP sensor 40 and fix it using the screw 41 with the relevant spacer Fit the breather ho...

Page 805: ...Use the indicated product to lubricate the O ring and fit it fully home in the airbox Insert the union hose 44 for the secondary air system actuator Fix it with clamp 45...

Page 806: ...Position the airbox on the heads Tighten clamp 14 that keeps the airbox against the horizontal cylinder head 15 Tighten clamp 16 that keeps the airbox against the vertical cylinder head 17...

Page 807: ...Connect the two ETV connectors 10 and 11 the injection connector 12 and the vertical map sensor 13...

Page 808: ......

Page 809: ...Engage the control unit in the pins Connect the control unit 9 Position the main wiring on the airbox Position wiring cover 7 and fix it by tightening the two screws 8 Connect the air sensor 6...

Page 810: ......

Page 811: ...Fit the secondary system valve 4 and fix it with the two pins 5 Connect connector 3 of the secondary air valve 4 Tighten the retaining clamp...

Page 812: ......

Page 813: ...Fit the Blow by tank union in the airbox having care not to damage the O ring Tighten the two retaining screws 1 of the Blow by tank 2...

Page 814: ...Refit the tank Refitting the tank...

Page 815: ...Removing the airbox and throttle body Remove the fuel tank Removing the tank Loosen the two retaining screws 1 of the Blow by tank 2 Remove the secondary air system union tie...

Page 816: ...Remove the secondary system valve 4 by sliding it out of the two pins 5 Disconnect the air sensor 6 Remove the wiring cover 7 by loosening the two retaining screws 8 Release the wiring from the airbox...

Page 817: ......

Page 818: ...Disconnect the control unit 9 and remove it by sliding it upwards Disconnect the two ETV connectors 10 and 11 the injection connector 12 and the vertical and horizontal map sensor 13...

Page 819: ...Loosen clamp 14 that keeps the airbox against the horizontal cylinder head 15...

Page 820: ...Loosen clamp 16 that keeps the airbox against the vertical cylinder head 17...

Page 821: ...Remove the airbox REMOVING THE AIR FILTER Loosen screws 19 and remove cover 18 Remove the airbox 20...

Page 822: ...REMOVING THE THROTTLE BODY Loosen screws 21 retaining the upper airbox 22...

Page 823: ...Remove the upper part of the airbox 22 Disconnect the connectors of injectors 12 and of the ETV motor 10 and 11 Loosen the retaining screw to remove the injectors 23...

Page 824: ...Working on the opposite side loosen the eight retaining screws 24 and remove the two throttle bodies 25...

Page 825: ......

Page 826: ...positions of the covers and components of the two valves of the secondary air system Refer to the reference notches present on the secondary air system valve cover and on head cover If disassembled re...

Page 827: ...cover 12 on head cover aiming it as shown by aligning the references A with those on head cover and references B with those on valve cover 12 Start the two screws 11 Tighten the two screws 11 to a tor...

Page 828: ...Fit the secondary air actuator 2 with the two pipes 6 and 9 Working on the vertical head fit the retaining clamp 8 of the secondary air system pipe 9 Tighten the retaining clamp 8...

Page 829: ...Working on the horizontal head fit the retaining clamp 5 of the secondary air system pipe 6 Tighten the retaining clamp 5 Insert the secondary air actuator 2 Fix it with clamp 4...

Page 830: ...Reconnect connector 1 of the secondary air actuator 2 Refit the fuel tank Refitting the fuel tank...

Page 831: ...Removing the secondary air system Remove the fuel tank Removing the tank Disconnect connector 1 of the secondary air actuator 2 Remove it from its support 3...

Page 832: ...clamp 4 and secondary air system actuator 2 Working on the horizontal head remove the retaining clamp 5 of the secondary air system pipe 6 Slide the secondary air system pipe 6 out of the horizontal...

Page 833: ...cal head remove the retaining clamp 8 of the secondary air system pipe 9 Slide the secondary air system pipe 9 out of the vertical head 10 Slide out of the vehicle the secondary air actuator 2 with th...

Page 834: ...plying the same procedure for both heads Loosen the two screws 11 and slide out cover 12 reed valve 13 and spark arrestor 14 in this order Note block off the secondary air system duct on head cover wi...

Page 835: ...Refitting the air filter Position filter 20 as shown in the figure Position cover 18 and tighten the screws 19...

Page 836: ...Removing the air filter Remove the fuel tank Removing the fuel tank Loosen screws 19 and remove cover 18 Remove the airbox 20...

Page 837: ...haust pipe 1 on the horizontal cylinder with the gasket 15 Note The gasket convex side must be facing outwards Tighten retaining nuts 13 to a torque of 10 Nm 10 If previously removed tighten the horiz...

Page 838: ...Fit the vertical exhaust pipe 2 on the horizontal cylinder with the gasket 15 Note The gasket convex side must be facing outwards Tighten retaining nuts 14 to a torque of 10 Nm 10...

Page 839: ...If previously removed tighten the vertical lambda sensor 17 to the torque of 24 5 Nm 10 Fit catalytic converter 3 and fix it to the frame with screw 12 Tighten the screw 12 to a torque of 10 Nm 10...

Page 840: ...Position the retaining spring 10 Tighten clip 11 to a torque of 18 Nm 10...

Page 841: ...Reconnect the two lambda sensors 9 and 8...

Page 842: ...Position control cable 5 in plate 7...

Page 843: ...facilitate the control cable insertion 5 Tighten retaining nut 6 to a torque of 2 5 Nm 10 If previously removed insert plugs 18 copper washers 19 start plugs in the vertical and horizontal head exhau...

Page 844: ...Refit the lateral plates Refit the exhaust silencer Refitting the exhaust silencer Refit the sump guard Refitting the sump guard...

Page 845: ...guard Removing the sump guard The exhaust system consists of the following parts 1 Horizontal primary pipe 2 Vertical primary pipe 3 Catalytic converter Turn the pulley 4 of the exhaust valve to facil...

Page 846: ......

Page 847: ...Disconnect the horizontal exhaust lambda sensor 8 Disconnect the vertical exhaust lambda sensor 9...

Page 848: ...Remove retaining spring 10 of the horizontal exhaust pipe 1...

Page 849: ...ining vertical exhaust pipe 2 Note For clarity reasons the figure shows the engine removed from the frame Working on the vehicle left side loosen and remove screw 12 Slide out the catalytic converter...

Page 850: ...and remove the three retaining nuts 13 Remove the horizontal exhaust pipe 1 by recovering the gasket Working on the vertical cylinder loosen and remove the three retaining nuts 14 Remove the vertical...

Page 851: ......

Page 852: ...ncer REASSEMBLING THE SILENCER Check that on the upper pipe cover 5 there is clip 11 Fit on silencer 7 the upper pipe cover 5 and the lower pipe cover 6 Fix the two covers by tightening screws 10 to a...

Page 853: ...Fit the central cover 4 and fix it with the screws 9 and 8 Tighten screws 8 to a torque of 5 Nm 10 REFITTING THE SILENCER Insert silencer 1 in the exhaust...

Page 854: ...Tighten the screw 3 to a torque of 5 Nm 10 Tighten clip 2 to a torque of 22 Nm 10...

Page 855: ...the silencer Remove silencer 1 by loosening clamp 2 and screw 3 DISASSEMBLING THE SILENCER The exhaust silencer consists of the following parts 4 Central cover 5 Upper pipe cover 6 Lower pipe cover 7...

Page 856: ...Loosen the screws 8 and 9 and remove the central cover Loosen the screws 10 and remove the upper 5 and lower 6 pipe covers...

Page 857: ......

Page 858: ...Refitting the Canister filter Position pipe 11 on the vertical head and fix it with clip 10 Position pipe 9 on the horizontal head and fix it with clip 8...

Page 859: ...Fit canister filter 5 from the top It must be fitted into plate 7 guides 6...

Page 860: ...Reconnect pipes 1 and 2 and fix them with clamps 3 and 4 POSITIONING THE CANISTER FILTER PIPES...

Page 861: ......

Page 862: ......

Page 863: ...REFITTING THE CANISTER FILTER SUPPORT Position the canister support 13 and fix it with the three retaining screws 12...

Page 864: ......

Page 865: ...he canister filter Disconnect pipes 1 and 2 by removing clamps 3 and 4 Remove canister filter 5 by sliding it upwards on the plate 7 guides 6 Work on the horizontal head and remove clip 8 and disconne...

Page 866: ...Work on the vertical head and remove clip 10 and disconnect pipe 11...

Page 867: ...REMOVING THE CANISTER FILTER SUPPORT Remove the three retaining screws 12 and remove the canister support 13...

Page 868: ......

Page 869: ...valve that is opened and closed according to the riding conditions PARKED MOTORCYCLE AND PURGE VALVE CLOSED In this condition the vapours released by the tank by means of pipe 1 are conveyed in the ca...

Page 870: ...ng the clutch slave cylinder Refit the cooling system hoses and unions on the engine block Refitting the cooling system hoses and unions Refit the water radiator lower retainer on the engine block Ref...

Page 871: ...Refit the fuel tank Refitting the fuel tank Refit the sump guard unit Refitting the belly pan Refit the seats Refitting the seat...

Page 872: ...ugs Remove the exhaust system Removing the exhaust system Drain the lubrication system Changing the engine oil and filter cartridge Drain the coolant Changing the coolant Remove the cooling system hos...

Page 873: ...If removed apply specific threadlocker on the bush 7 and screw it in the crankcase half observing the value A of 1 mm 0 2 Position the reference bushes 6 and the O rings 4 and 5 according to the casin...

Page 874: ...Position the complete oil pump 3 on the casing fit the relevant washers A and B and tighten screws 1 to 26 Nm Min 23 Nm Max 29 Nm and screw 2 to a torque of 10 Nm Min 9 Nm Max 11 Nm...

Page 875: ...tooth of oil pump gear and set the gauge to zero in this position Move the gear slightly to measure the backlash take four readings in diametrically opposed positions of the gear The clearance should...

Page 876: ...resent on the pump Fit the pump drive gear 7 on to the oil pump and secure it by installing the circlip 6 in its groove Insert by pass valve 5 spring 4 in the pump and tighten plug 3 to a torque of 17...

Page 877: ......

Page 878: ...ing care not to damage the drive gear 2 Warning Make sure that vice jaws are faced with soft material Remove the plug 3 and extract the spring 4 and by pass valve 5 Check the condition of the above co...

Page 879: ......

Page 880: ...pan Removing the belly pan Remove the clutch cover Removing the clutch cover Loosen and remove screws 1 and 2 that retain the complete pump and collect the relevant washers A and B Remove the oil pump...

Page 881: ......

Page 882: ...es 8 have been removed from the cooler fit a washer 9 on each nipple 8 and apply specified threadlocker on the cooler side threads Important The gasket must be positioned with the sharp edge facing th...

Page 883: ...5 to the cooler nipples 8 and finger tighten the nuts 11 fully home Tighten the nuts 11 to a torque of 18 Nm 5 while holding the nipple hex nuts Check the presence of vibration damping pads 12 on bot...

Page 884: ...Fit the oil cooler by inserting it first in the headlight support pin B Fit spacer 7 and screw 6 and tighten it to a torque of 6 Nm 10...

Page 885: ...Position pipes 5 as shown in the figure C delivery D return...

Page 886: ......

Page 887: ...Insert the pipes in the crankcase half Position plate 4 Apply the specified threadlocker and tighten screw 3 to a torque of 10 Nm 10...

Page 888: ...cooler and tighten sensor 1 to a torque of 19 Nm 10 Connect the oil pressure switch 1 to main wiring Fill the system Changing the engine oil and filter cartridge Refit the front half fairings Refittin...

Page 889: ...Inspecting the oil cooler Visually inspect the cooler Replace it at any sign of damage or leaks...

Page 890: ...fairings Removing the front half fairing Drain the system Changing the engine oil and filter cartridge Disconnect the oil pressure switch 1 from the main wiring and remove washer 2 Undo screw 3 of pl...

Page 891: ...Upon disassembly make sure not to lose the O rings A that guarantee the coupling sealing...

Page 892: ...Loosen and remove screw 6 with spacer 7 that retains the radiator to the headlight support Remove the radiator from the headlight support by sliding it out of pin B...

Page 893: ......

Page 894: ...her reservoir Insert pipe 4 in tank 2 by matching tooth A inside the pipe with recess B of union C Position reservoir 2 with hose 4 in the frame Connect the hose 4 to the blow by and tighten clamp 3 t...

Page 895: ...Refit the airbox Refitting the airbox Tighten the two screws 1 to a torque of 3 Nm 10 Refit the fuel tank Refitting the fuel tank Refit the seats Refitting the seat...

Page 896: ...ather reservoir Remove the seats Removing the seat Remove the fuel tank Removing the fuel tank Loosen screws 1 of the blow by tank 2 Remove the airbox Removing the airbox Loosen clamp 3 to slide hose...

Page 897: ...Slide the blow by tank 2 out of the frame To disassemble reservoir 2 from hose 4 loosen clamp 5 Separate the two parts...

Page 898: ......

Page 899: ...1 in tank 4 Note If it proves hard to fit the tubes in the relevant unions it is recommended to use RUBBER LUBRICANT and apply some on the unions Tighten clips 5 to a torque of 1 Nm 10 Position tank 4...

Page 900: ...Position hose 2 on the radiator with clip 1 and tighten clip 1 to a torque of 1 Nm 10...

Page 901: ...it the front half fairings Refitting the front half fairing Refit the half fairings Refitting the tank fairings Fill the cooling system Changing the coolant Positioning the water tank pipe water radia...

Page 902: ......

Page 903: ...Changing the coolant Remove the front half fairings Removing the front half fairing Remove the half fairings Removing the tank fairings Loosen clamp 1 and slide hose 2 out of the radiator Loosen the...

Page 904: ...Loosen the clamps 1 to remove the hoses 2 and 5 from the tank 4...

Page 905: ......

Page 906: ...e figure by tightening the clamps to a torque of 2 5 Nm 10 Install an O ring 17 in the seat of the vertical head union 16 and one in horizontal head union seat 13 Fix union 13 on the horizontal head w...

Page 907: ...Fix union 16 on the vertical head with screws 15 with specified threadlocker and tighten them to a torque of 6 Nm Min 5 Nm Max 7 Nm...

Page 908: ...ed fit water temperature sensor 18 on union 13 and tighten it to a torque of 23 Nm Min 20 Max 26 Working on the horizontal head fit the canister horn support bracket 10 and fix it with screws 11 Fit t...

Page 909: ...al cylinder and tighten the two clips 6 to a torque of 3 Nm 10 Position the pump pipe 1 to the horizontal cylinder and tighten the two clips 6 to a torque of 3 Nm 10 Repeat the operation with the pump...

Page 910: ...l head to the radiator and tighten clip 6 to a torque of 3 Nm 10 Tighten clip 6 with horizontal head bleed screw to a torque of 1 Nm 10 Position vertical head to water radiator pipe 3 and pump to wate...

Page 911: ...ng the coolant Refit the half fairings Refitting the tank fairings Refit the front half fairings Refitting the front half fairing Positioning hoses and clamps Position the vertical and horizontal head...

Page 912: ......

Page 913: ......

Page 914: ...water pump to vertical cylinder pipe 3 vertical head to radiator pipe 4 horizontal head to radiator pipe 5 water radiator to water pump pipe Loosen clamps 6 retaining the water radiator 7 hose 1 to th...

Page 915: ...amps 6 that retain the pipe 5 that goes from the radiator to the pump and clamps 6 and pipe 1 that goes from the pump to the vertical cylinder Loosen clamps 6 retaining pipe 2 and the vertical cylinde...

Page 916: ...Loosen the clamps 6 to remove the valve 8 from the pipes 3 and 4 Working on the horizontal head remove the spark plug cylinder head 9 Undo the screws 11 and remove the horn canister support bracket 10...

Page 917: ...Undo the screws 12 and remove the water union 13 and recover clip 14...

Page 918: ...cal head undo the screws 15 and remove the water union 16 and recover clip 17 Important Periodically check the connection unions for leaks Hoses that are cracked swollen or hardened due to dry sleeves...

Page 919: ...Fitting the radiator Check for the presence of vibration damping pads 10 and support 11 on the radiator brackets 4 Insert the radiator support 4 in pin E...

Page 920: ...Start screw 5 with spacer 6 on the left and right sides Tighten the screws 5 to a torque of 10 Nm 10...

Page 921: ......

Page 922: ...Reconnect the fan wiring to the main wiring C and D...

Page 923: ...nd 3 in the relevant unions on the radiator and tighten clamps 1 to a torque of 2 5 Nm 10 Insert pipe B between water tank and water radiator on the inlet of the radiator plug with clamp A and tighten...

Page 924: ...Fill the cooling system Changing the coolant Refit the half fairings Refitting the tank fairings Refit the front half fairings Refitting the front half fairing...

Page 925: ...acing the electric fan Undo the electric fan three retaining screws 7 and remove the electric fan 8 from the radiator Repeat the operation for the second solenoid valve 9 Upon reassembly tighten screw...

Page 926: ...ng the front half fairing Drain the coolant Changing the coolant Loosen clamps 1 of water pipes 2 and 3 and slide them out of the radiator unions 4 Loosen clamp A that connects the water tank and the...

Page 927: ...Loosen the screws 5 with spacer 6 securing the radiator to the frame LH side Disconnect the main wiring connections the RH solenoid valve C and the LH solenoid valve D...

Page 928: ...Remove water radiator 4 from the vehicle by disengaging it from pin E...

Page 929: ...sign of damage or leaks Check also that the air flow through the radiator fins are not obstructed by leaves insects mud etc Important Excessive coolant temperature can be caused by a partial obstruct...

Page 930: ......

Page 931: ...bricate the seat of the crankcase A Fit spacer 15 so that the chamfered edge is facing downwards Position bearings 13 and 12 fully home Fit the impeller shaft 6 by lubricating washer 9 and positioning...

Page 932: ...y attention not to pinch the rubber seal on the impeller edge Fit counter washer 14 fully home in the generator cover The counter washer must be positioned with the white side facing outwards Fit the...

Page 933: ...Check that the two centring bushes 5 are correctly fitted on the generator cover Working on the opposite side tighten the impeller 6 by means of the snap ring 7...

Page 934: ...ed threadlocker on the screws 10 Fit the two screws 10 with the washers 11 and tighten to a torque of 10 Nm Min 9 Nm Max 11 Nm Apply an even bead of sealing compound on the generator cover by respecti...

Page 935: ...Tighten the screws 1 and 2 to a torque of 13 5 Nm Min 12 5 Nm Max 14 5 Nm respecting the sequence shown in the figure...

Page 936: ...Pay attention to the screws as they are not all the same screws 1 M6x32 mm screws 2 M6x30 mm If previously removed fit plug 16 with the washer 17 and tighten it to a torque of 15 Nm Min 13 5 Max 16 5...

Page 937: ...ont sprocket cover Removing the front sprocket cover Drain the engine oil Changing the engine oil and filter cartridge Remove the clutch slave cylinder Removing the clutch slave cylinder Remove the ge...

Page 938: ...turning the impeller shaft 6 in case of excessive clearance it is necessary to replace them as follows Remove the snap ring 7 from the impeller shaft 9 Slide off the impeller 6 with the sealing ring 9...

Page 939: ...the washer 11 Working from the impeller side use a suitable drift to press on the inner ring of end bearing 12 until it can be extracted from the cover Use the same technique to remove the other bear...

Page 940: ...heck the condition of the mechanical seal components 9 and of the counter washer 14 there should be no signs of deformation cracking or excessive wear In case of damage both components must be replace...

Page 941: ...ng the radiator connected to the cooling system Removing the water radiator Disconnect the spark plug caps Disconnect the secondary air unit of the head covers Removing the secondary air system Remove...

Page 942: ...tinue to rotate until you obtain an intake valve lift of 1 mm on the gauge 2 during closure of the valve for the compression stroke Check the angular displacement value with the specified one Repeat t...

Page 943: ...clearance indicated before Place tool 1 part no 88765 1723 on the cylinder head the part marked A should be on the intake side and the part marked S should be on the exhaust side Seat the tool 1 and...

Page 944: ...hafts Connect the caps to the coils Connect the secondary air system pipe on the cylinder head Removing the secondary air system Fix the water radiator to the frame Refitting the water radiator Fix th...

Page 945: ...ws by leaving the radiator connected to the cooling system Removing the water radiator Disconnect the coil caps Disconnect the secondary air units of the head covers Removing the secondary air system...

Page 946: ...paragraph Removing the valves and replace it with one of suitable height to obtain the prescribed clearance Note Opening rocker arm shims measuring 1 80 to 3 45 are available as spare parts the size...

Page 947: ...camshaft lobe B...

Page 948: ...cribed in paragraph Removing the valves and replace it with one of suitable height to obtain the prescribed clearance Note Opening rocker arm shims measuring 1 80 to 3 45 are available as spare parts...

Page 949: ...tuator covers A on the heads Apply the specified threadlocker to screws 4 and 5 Position the external cover 6 by starting screws 4 and 5 Tighten the screws 4 and 5 to a torque of 10 Nm Min 9 Nm Max 11...

Page 950: ...en the screws 1 to a torque of 10 Nm Min 9 Nm Max 11 Nm following the sequence indicated in the figure Apply the recommended threadlocker to the screws 1 Position upper cover 2 by starting screws 1 Ti...

Page 951: ...Note If the above operations have been carried out with the engine installed in the frame refit the previously removed parts...

Page 952: ...w the engine removed from the frame Use tool no 88765 1523 to rotate the crankshaft in the vehicle direction of travel by looking the tool from the front side counter clockwise to bring the horizontal...

Page 953: ...the timing is correct fit tool B no 88713 2011 to block the crankshaft On the vertical head install tool C part no 88765 1737 Check the variators alignment i e they must be flush with the head flat su...

Page 954: ...Fit the belt 7 as shown in the figure using a screwdriver to tension it...

Page 955: ...If previously removed fit the chain tensioner 8 washer 9 and tighten it by means of nut 10 Do not tighten to torque...

Page 956: ...Remove tool C part no 88765 1737 and fit it on the horizontal head...

Page 957: ...Check on the variators 11 that the references are aligned with the head flat surface Fit the belt 12 in the horizontal head as shown in the figure using a screwdriver to tension it...

Page 958: ...If previously removed fit the chain tensioner 13 washer 14 and tighten it by means of nut 15 Do not tighten to torque...

Page 959: ...point D Tension the belt according to the values indicated in the table Reference Assembly Value new belt Assembly Value used belt Cold belt tension adjustment DDS 2 90 5 Hz horizontal 90 5 Hz vertic...

Page 960: ...icated point E Tension the belt according to the values indicated in the table Reference Assembly Value new belt Assembly Value used belt Cold belt tension adjustment DDS 2 90 5 Hz horizontal 90 5 Hz...

Page 961: ...Remove all the previously installed tools Refit the cylinder head covers Refitting the camshafts Refit the external timing belt covers Refitting the timing belt external covers...

Page 962: ...r heads pulleys idler pulleys Check the pulleys of the intake side IN and of the exhaust side EX Check that pins 8 are present on the camshafts 7 Take special care when positioning the pins 8 They mus...

Page 963: ...Insert the pulley fully home on the camshaft by centring pin 8 in hole C...

Page 964: ...ated product and tighten them by respecting the following sequence pre tightening to 20 Nm Min 18 Max 22 check clearance between pulley and camshaft final tightening to 90 Nm Min 85 Max 95 check clear...

Page 965: ...wo plugs 4 Start plugs 4 and tighten them to a torque of 20 Nm Min 18 Max 22 Fitting the variable timing actuators If previously removed fit the variable timing variators D Use the indicated product t...

Page 966: ...overcome the O ring force F Apply the recommended threadlocker on the thread of screws G and tighten them to 10 Nm Min 9 Max 11 Fixed tensioner Apply the indicated product and insert the fixed tension...

Page 967: ......

Page 968: ...sioner pins Apply the recommended threadlocker to the pin thread Insert the tensioner pins 1 on the heads and tighten them with tool A no 88713 1821 Tighten the tensioner pins to a torque of 50 Nm Min...

Page 969: ...Refitting the timing layshaft pulley To fit the snap ring 7 in the timing layshaft seat use the tool no 88713 2834 Install the inner spacer 6 on the timing layshaft taking care to match the key notch...

Page 970: ...Fit the first key 4 on the timing layshaft Locate the inner pulley 3...

Page 971: ...Refit the second key 4 and the washer 5 Locate the outer pulley 3 and the spacer 2 Apply the recommended grease to the threads of the shaft...

Page 972: ...serious engine damage always use new self locking ring nuts on all the timing belt rollers Block with tool A no 88713 1805 the rotation of the belt rollers and tighten to 71 Nm Min 64 Nm Max 78 Nm the...

Page 973: ...e rotation of the driving belt rollers on the crankcase If this operation is carried out with the engine installed in the frame hold the driving pulleys against rotation using tool no 88713 2011 mount...

Page 974: ...Remove the first key 4 from the timing layshaft Remove the spacer 5 and the inner pulley 3...

Page 975: ...Remove the inner spacer 6 and second key 4 on the timing layshaft...

Page 976: ...It is now possible to remove the snap ring 7 on the timing layshaft...

Page 977: ......

Page 978: ...Removing the tensioner pins Use tool part no 88713 1821 to remove tensioner pins 1 from the heads...

Page 979: ...he cylinder head pulley fixed tensioner Note The procedure below refers to one head but it applies to both coils Loosen the nut 1 recover washer 2 and slide out tensioner pulley 3 Loosen the two closi...

Page 980: ...Loosen the two retaining screws 5 and remove the two pulleys...

Page 981: ...tensioner 3 from the pin 4 on the cylinder head Remove the timing belt 5 from the piston cylinder assy Important If the belts are to be re used mark the direction of rotation with an arrow and also ma...

Page 982: ...s For clarity the figures show the engine removed from the frame Undo the fixing screws 1 of the upper external cover 2 and remove it from the vertical piston cylinder assy Undo screws 1 of the interm...

Page 983: ...Using suitable tools lift up plug 3 to remove it...

Page 984: ...Loosen the fastening screws 4 and 5 on the main cover 6...

Page 985: ...nder head Tighten stud bolts 13 to a torque of 10 Nm Min 9 Nm Max 11 Nm Check that the camshafts marked VA and VS for the vertical head and OS and OA for the horizontal head are clean and in good cond...

Page 986: ...Use the specified lubricant to lubricate the head the supports 10 and 11 and the camshaft seats Fill tanks A with specified lubricant...

Page 987: ......

Page 988: ...ad and rotate them to distribute the lubricant evenly Bed down the supports Apply sealant at the four points of the support 10 as shown in the figure Clean off any excess of sealant Check that plugs 1...

Page 989: ...rque of 10 Nm Min 9 Nm Max 11 Nm Pre tighten one support at a time working in the sequence 1 2 3 4 5 6 7 8 Then tighten screws to a torque of 22 5 Nm Min 21 Nm Max 25 Nm Tighten one support at a time...

Page 990: ...ng rings Lubricate the sealing rings 17 with denatured alcohol Install driving tool B no 88713 4648 on the camshaft and start the seal ring on the cylinder head with the side featuring a spring 18 fac...

Page 991: ...Using the drift no 88713 4965 provided with the tool and a mallet drive the sealing rings into their seats...

Page 992: ...led the sealing ring 17 should be flush with the bevel of the cylinder head Check that the head features the centring bushing 19 Fit the variators as described in chapter Refitting the cylinder head p...

Page 993: ...If previously removed install the oil flow pin 20 using suitable tools...

Page 994: ...Cylinder head cover Apply the indicated sealant on the four highlighted points...

Page 995: ......

Page 996: ...the gaskets 7 and 8 on the cylinder head cover as shown in the figure Cylinder head cover identification To distinguish the two heads check that the secondary air valve is outwards as shown in the fig...

Page 997: ...Locate cover 6 on the cylinder head aligning it with the four fixing holes Start screws 3 and 4 with O rings 5...

Page 998: ...screws 3 and 4 to a torque of 10 Nm Min 9 Nm Max 11 Nm respecting the indicated sequence Repeat the same procedure for the other cylinder head Install and tighten spark plug 1 with a suitable wrench n...

Page 999: ...er radiator Fix the timing belt covers Refitting the timing belt external covers Refit the airbox Refitting the airbox and throttle body Refit the fuel tank Refitting the fuel tank Refit the front hal...

Page 1000: ...engine power Place the camshaft between two opposite centres and check the run out on the areas indicated using two dial gauges Service limit 0 1 mm Visually inspect the camshaft tracks for scoring a...

Page 1001: ......

Page 1002: ...le body Loosen the timing belt covers Removing the timing belt external covers Loosen the water radiator retaining screws by leaving the radiator connected to the cooling system Removing the water rad...

Page 1003: ...Remove the gaskets 7 and 8...

Page 1004: ...do the screws 9 securing the camshaft supports Withdraw the camshaft supports 10 and 11 straight out from the cylinder head by prying in the indicated points taking care not to damage the machined fac...

Page 1005: ......

Page 1006: ......

Page 1007: ...the head check that the gasket E is fitted on the mating surface between head and cylinder Lower the cylinder head carefully over the stud bolts Take care not to damage the threads Fit the special wa...

Page 1008: ...the cooling system hoses Refitting cooling system hoses and unions Refit the timing belts and covers Refitting the cylinder head pulleys fixed tensioners Refit the engine in the frame Refitting the e...

Page 1009: ...g and inspect the sealing surfaces for scoring steps or other damage Check that the cylinder mating surfaces of the cylinder head are free of carbon deposits and scale If this is not the case spread d...

Page 1010: ...alve seat Visually check the contact surface between the valve and its seat on the head There must be no pitting or cracks Check that the outer diameter of the valve seat contact surface Standard exha...

Page 1011: ...no leaks by filling the intake and exhaust pipes with a suitable product In case of leaks check the repair quality with Prussian blue Replacing the valve seat Important When you change the valve seats...

Page 1012: ...chill the new valve seats in dry ice 5 Drive the seats perfectly square into the head housings using the appropriate installers 88713 2846 and 88713 2847 6 Allow the cylinder head to cool down and gri...

Page 1013: ...t be maximum detected value minimum detected value 0 028 0 013 mm Change the valve guides when the ovality exceeds permissible limit or the valve stem clearance is outside the tolerance range When you...

Page 1014: ...des in dry ice lubricate the seats in the cylinder head and install the valve guides using the appropriate service tools and with reference to the dimensions given in the figure INTAKE A 26 2 mm EXHAU...

Page 1015: ...heck the valve stem for buckling Place the valve on a V reference block set a dial gauge perpendicular to head and measure concentricity of valve face at 45 nominal concentricity 0 01 mm service level...

Page 1016: ...ing the valve seal After grinding the seats it is important to check the seal between valve face and seat if the seat contact area S on the valve is wider than the 45 band W this could lead to poor se...

Page 1017: ...Checking the rocker arms Check for signs of wear grooves or chrome flaking off Check the condition of rocker arm bore and shaft Clearance upon fitting 0 025 0 049 mm Wear limit 0 08 mm...

Page 1018: ...Check the conditions of the return springs of the closing rocker arms no cracks deformations or failure must be present...

Page 1019: ...cker arm conditions they must feature no scratches or breakage Note The closing rocker arms are longer than the opening ones OPENING ROCKER ARMS Fit the opening rocker arm shafts 7 using suitable tool...

Page 1020: ...Using the pawl of the rocker arm spring tensioning kit no 88713 2069 fit springs 6 in the closing rocker arms 5...

Page 1021: ...s install the closing rocker arms on the exhaust side before those on the intake side Warning Take care not to damage the shoe of the closing rocker arm with the intake spring during assembly CLOSING...

Page 1022: ...Locate the closing rocker arm 4 and drive the shaft 3 home...

Page 1023: ...adjusting the valve clearance Insert the gaskets 2 on the plugs 1 orienting them preferably with the square edge side T facing the cylinder head Apply the recommended threadlocker on the plug 1 thread...

Page 1024: ...ming pulleys Refitting the cylinder head pulleys fixed tensioners Connect the caps to the coils Connect the secondary air pipe Refitting the secondary air system Refit the complete head Fitting the co...

Page 1025: ...the engine heads Remove the camshafts Removing the camshafts The procedure below refers to one head but it applies to both coils Loosen blanket plugs 1 and collect seals 2 Use suitable tools to slide...

Page 1026: ...w the same procedure to remove the opening rocker arms 4 on the intake and exhaust side Using the pawl of the rocker arm spring tensioning kit no 88713 2069 slide springs 6 out of the closing rocker a...

Page 1027: ......

Page 1028: ...Withdraw the shafts 7 of the closing rocker arms on the exhaust and intake sides...

Page 1029: ...Remove the closing rocker arms 5 the springs 6 with the spacers 8...

Page 1030: ...lly clean the two intake valve seats A and the two exhaust valve seats B Lubricate the stems of the two intake valves 5 and the two exhaust valve stems 4 with engine oil Fit the valves in their seats...

Page 1031: ...ng the valves Lubricate the rings with indicated product then use tool no 88713 2442 to drive the four seal rings 6 in the relevant valve guide seats Important Pay attention not to lubricate the ring...

Page 1032: ...Fit the closing rocker arms as described in chapter Refitting the rocker arms Insert closing shims 2 in the valve stem...

Page 1033: ...Insert the two split rings 3 in the valve seat Using suitable tools quickly push the closing rocker arm to bring the shim 2 into seat...

Page 1034: ...Fit the opening shims 1...

Page 1035: ...Repeat the same procedure for the other valves...

Page 1036: ...ng the valves Remove the rocker arms Removing the rocker arms Remove the opening shim 1 from the valve using a pair of pliers Lower the closing shim 2 and remove the split rings 3 using a magnet screw...

Page 1037: ...Withdraw the exhaust and intake valves 4 and 5 from underhead of the cylinder head Repeat the same procedure for the other cylinder head...

Page 1038: ...emove the cooling system hoses Removing cooling system hoses and unions Remove the belts and their external covers Removing the timing belt external covers Use tool part no 88713 2676 undo the nuts 1...

Page 1039: ...Remove the cylinder head assembly by lifting it off the engine stud bolts Repeat the same procedure for the other cylinder head...

Page 1040: ...der piston components Note If the pistons have been separated from their cylinders before reassembling these components position the piston ring gaps at 120 from one another the markings must always f...

Page 1041: ...osits and degrease the contact surfaces of the crankcase half and the cylinders Check that on the engine block there is the cylinder centring dowel B O ring C Apply the indicated sealant on both sides...

Page 1042: ...Using cap no 88713 1920 fit the O rings A on each stud bolt and guide them into their seats in the crankcase Bring the con rod small end to the TDC and insert cylinder 4 on the stud bolts...

Page 1043: ...gudgeon pin 9 must slide smoothly in the connecting rod small end bush and in the piston Close the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the snap...

Page 1044: ...Push the cylinder 4 down until it seats against the crankcase Refit bushings 7 and O ring 11...

Page 1045: ...et prevents incorrect fitting provided that the fluid flow holes are aligned with those on the cylinder Repeat the procedure for the other cylinder and refit the cylinder heads Refitting the cylinder...

Page 1046: ...a torque of 2 5 Nm Min 2 Nm Max 3 Nm Refit the belts and their external covers Refitting the timing belt external covers Refit the cooling system hoses Refitting cooling system hoses and unions Refit...

Page 1047: ...urface and in two directions at 90 between them check that the measurements of taper and ovality fall within the range specified in Sect Cylinder piston In order for the liner to be conforming the fol...

Page 1048: ...iameter must be measured at 7 5 mm up from the bottom of the skirt and in perpendicular direction to the gudgeon pin axis The pistons must always be replaced as a pair Checking the piston cylinder cle...

Page 1049: ...blueing due to overheating The well lubricated gudgeon pin must slide smoothly inside the piston without stiffness For the coupling clearance values with the piston and the connecting rod see chapter...

Page 1050: ...Overhauling the piston rings The piston rings must not show any signs of scuffing or scoring Spare pistons are supplied complete with piston rings and gudgeon pin...

Page 1051: ...grooves clearance The maximum permissible wear limit is 0 15 mm for the top ring 1st ring S and 0 10 mm for the others 2nd ring T and oil scraper ring R The piston rings must always be fitted with ma...

Page 1052: ...First ring S...

Page 1053: ...Second ring T Oil scraper ring R...

Page 1054: ...ositioned perfectly square to the cylinder axis by checking with a gauge at several points around the ring that the top surface of the ring is 50 mm from the cylinder top face Measure the piston ring...

Page 1055: ...and unions Remove the belts and their external covers Removing the timing belt external covers Remove the heads from the engine block Removing the engine heads Loosen the clips 1 and remove the hoses...

Page 1056: ...Remove the bushes 7 Use tool B part no 88765 1657 to bring the piston of the horizontal cylinder near the TDC...

Page 1057: ...erform at the time of reassembly remove the piston together with the barrel as described below Stuff the crankcase opening with a rag or soft paper to prevent foreign material from falling inside Remo...

Page 1058: ...Remove from the cylinder head stud bolts the four O rings A located on the crankcase between the cylinder and the gasket 10...

Page 1059: ...Proceed in the same way for the other cylinder Important Mark the pistons to show from which cylinder they were removed V Vertical O Horizontal...

Page 1060: ...Refitting the clutch Insert guide 14 Locate the clutch housing 13 and the spacer 12...

Page 1061: ...Position the clutch drum 8 Fit the clutch plates on the hub When removing new plates the driving ones 7 must be lubricated on both sides with the indicated product...

Page 1062: ...The plate pack consists of 11 driving plates A with 2 8 mm thickness 1 driven plate B 2 0 mm thickness...

Page 1063: ...9 driven plates C 2 0 mm thickness 1 judder spring D thickness 1 0 mm 1 anti juddering spacer E 1 2 mm thickness...

Page 1064: ...pply the indicated grease to the thread of the gearbox primary shaft and the mating surface of nut 9 and fit it over Belleville washer 10 Block the clutch drum using tool F part no 88713 3408 and tigh...

Page 1065: ...Insert the control pin 6 in the bearing 7 and the latter in the gearbox primary shaft...

Page 1066: ...lace the pusher plate 4 on the centring tool G part no 88713 3352 Fit the pressure plate 4 Insert a spring 3 in each recess Position ring 2 Lubricate the thread of the screws 1 with oil Start screws 1...

Page 1067: ...ews 1 to a torque of 10 Nm Min 9 Nm Max 11 Nm Refit the clutch cover Refitting the clutch cover Fill the engine with oil Changing the engine oil and filter cartridge Refit the sump guard unit Refittin...

Page 1068: ...replace the plates and if necessary the clutch housing Overhauling the clutch plates The clutch plates must not show any signs of blackening grooves or deformation Measure the thickness of the fricti...

Page 1069: ...h it in the same manner as described previously for the cylinder head surface Overhauling the cylinder head components Check the condition of the spring guide seats G of pusher plate 4 and of snap rin...

Page 1070: ......

Page 1071: ...engine oil and filter cartridge Remove the clutch cover Removing the clutch cover Note For clarity the figures show the engine removed from the frame Undo the fixing screws 1 and remove the ring 2 and...

Page 1072: ...Remove the clutch control pin 6 and bearing 7 Block clutch drum 8 using the tool part no 88713 3408 and loosen retaining nut 9...

Page 1073: ...Remove Belleville washer 10 and remove clutch plates 11 from the clutch housing Slide out the clutch drum 8...

Page 1074: ......

Page 1075: ...Slide out the spacer 12 Slide out the clutch housing 13...

Page 1076: ...Slide off the guide 14...

Page 1077: ...earbox primary shaft from the crankshaft Working on clutch lever 1 the master cylinder 2 is pressurized and pushes on the control rod 3 Therefore the pusher plate 4 is moved and detaches the driven pl...

Page 1078: ...ven plates 8 The driving clutch plates move together with housing 5 and crankshaft 10 by means of gear 9 While the driven plates move together with the clutch hub 11 that is fixed to the gearbox shaft...

Page 1079: ...clutch lever thanks to the pusher plate mechanism the clutch will be detached and the plates will rotate freely with no connection to housing and hub This will allow the detachment of crankshaft and...

Page 1080: ...ousing A clutch which slips may be caused by no backlash of the control lever worn out clutch plates weakened springs faulty clutch release mechanism excessive wear of the hub or clutch housing A nois...

Page 1081: ...over using a suitable drift and a press Lubricate the sealing ring 10 with indicated product refit the new part 10 in the clutch cover positioning it so that the side without a spring is facing the ci...

Page 1082: ...rance that allows the circlip 8 to rotate Position the soundproofing panel 7 inside the clutch cover as shown in the figure Position the internal cover 6 on panel 7 Apply the recommended threadlocker...

Page 1083: ......

Page 1084: ...ng 2 from the cover the plug 3 and its seal 4 Undo screws 5 of the inner cover 6 Remove the inner cover 6 and the soundproofing panel 7 Remove the circlip 8 and withdraw the shim 9 and the sealing rin...

Page 1085: ...emoving the belly pan Loosen the fastening screws 2 3 and 4 on the clutch cover 1 Tap around the edge of the cover with a plastic mallet to detach it from the crankcase half Remove the clutch cover 1...

Page 1086: ...he corresponding spline on the primary drive gear Position spacer D on the crankshaft Fit the driving gear B onto the crankshaft with the oil pump drive sprocket facing the crankcase Temporarily secur...

Page 1087: ...ween 0 05 and 0 07 mm Repeat the check at 16 different points of the driven gear If the measured values are outside the tolerance limits try changing the position of driven gear A on the primary shaft...

Page 1088: ...Position washer 4 and ring nut 3 Using the suitable tool U tighten ring nut 3 to a torque of 190 Nm Min 171 Nm Max 209 Nm...

Page 1089: ...tween the oil pump gear and primary drive gear on the crankshaft Refitting the oil pump Thoroughly degrease the mating surfaces of the clutch housing 1 Fit the spacer 2 onto the primary shaft Fit the...

Page 1090: ...the clutch unit Refitting the clutch Refit the clutch cover Refitting the clutch cover Refit the belly pan unit Refitting the belly pan Fill the engine with oil Changing the engine oil and filter cart...

Page 1091: ...ving the clutch cover Remove the clutch unit Removing the clutch Withdraw the clutch housing 1 complete with driven gear of the primary drive gear A Remove the inner spacer 2 Remove the oil pump C Rem...

Page 1092: ...Remove the ring nut 3 and the lock washer 4...

Page 1093: ...Remove the complete primary drive driving gear B using a commercial puller and placing a brass or aluminium pad between crankshaft and puller screw Remove spacer D...

Page 1094: ......

Page 1095: ...ctor drum If it proves necessary to change components disassemble the gearchange mechanism Reassemble the gearchange mechanism orienting the pins 6 suitably lubricated in such a way that the lever 7 i...

Page 1096: ...Note There are two types of springs therefore pay attention to the installation seats...

Page 1097: ...rollers Position the gearchange mechanism 3 together with control shaft spring and plate into the chain side crankcase half Insert the screws 1 and 2 with the spacer 4 Temporarily fit gearchange lever...

Page 1098: ...A part no 88713 3334 inserting the clutch rod E into the tool hole block the pin F of the tool in the gear pawl pressing with the hand in the point G pawl stroke stop plate towards the right as shown...

Page 1099: ...a torque of 36 Nm Min 34 Nm Max 38 Nm and the screw 2 to a torque of 16 Nm Min 15 Nm Max 17 Nm Remove service tool Check that the pin H placed on the gearbox selector drum is aligned with the notch L...

Page 1100: ...l generator assembly and the generator cover Refitting the flywheel generator assembly Refit the pump water radiator hose Refitting cooling system hoses and unions Refit the pump cylinder hoses Refitt...

Page 1101: ...spring on the gear ratchet as shown in the figure Apply threadlocker to the screw thread Start the screw in the crankcase half Position end B of the spring so that it rests against rib C of the crank...

Page 1102: ...clutch unit Refitting the clutch Refit the clutch cover Refitting the clutch cover Fill the system with engine oil Changing the engine oil and filter cartridge Refit the sump guard unit Refitting the...

Page 1103: ...ter cartridge Remove the clutch cover Removing the clutch cover Remove the clutch unit Removing the clutch Remove the primary drive gear Removing the primary drive gear Undo the interlock plunger scre...

Page 1104: ......

Page 1105: ...ch slave cylinder Drain the coolant Changing the coolant Remove the pump cylinder hoses Removing the cylinder piston assembly Remove the pump water radiator hose Removing cooling system hoses and unio...

Page 1106: ......

Page 1107: ...ng gear B when engaging the gears Refit the clutch cover Refitting the clutch cover Refit the cover the drum and the clutch housing Refitting the clutch Refit the starter motor Refitting the starter m...

Page 1108: ...particular care when installing the idler gears The assembly of the 3rd 12 and 4th 9 speed gears and the relative fixing components on the secondary shaft is given as an example Fit the snap ring 7 c...

Page 1109: ...Fit the 3th speed gear 12...

Page 1110: ...he gear Fit another roller bearing cage 10 using the method already described Fit the 4th speed gear 9 Fit another three pointed washer 8 and another snap ring 7 into the shaft Push it inside its seat...

Page 1111: ......

Page 1112: ...een exceeded determine which part must be replaced by comparing these dimensions with those of new components Gearbox Also check the wear on the drum support pins these must not show any signs of scor...

Page 1113: ...ad to difficulties in gear changing or may suddenly disengage when under load Use a feeler gauge to check the clearance of each fork in its gear groove If the service limit has been exceeded check whe...

Page 1114: ......

Page 1115: ...wear The threads and splines of the shafts must be in perfect condition Also check that the component parts of the gear selector mechanism are in good condition Engage the gears and check that the ge...

Page 1116: ...e shim position upon reassembly this would potentially lead to jamming when using the gear selector control making it necessary to reopen the crankcase Disassembling the gearbox secondary shaft Remove...

Page 1117: ...vers to remove the snap ring 7 from its seat taking care not to damage the shaft surface Slide off the splined washer 8 Remove the fourth speed driven gear 9 with its roller bearing cage 10 Remove the...

Page 1118: ...he snap ring 7 Remove the sixth speed driven gear 13 Remove the snap ring 7 and withdraw the splined washer 8 and the second speed driven gear 14 Withdraw the roller cage 10 and the shim 15 All the co...

Page 1119: ...Disassembling the gearbox primary shaft Remove washer 18 from the primary shaft 17...

Page 1120: ...ring 7 and the splined washer 8 Important Take care to avoid damaging the surface of the shaft while removing the snap ring Remove the snap ring 7 and the splined washer 8 Remove the sixth speed drivi...

Page 1121: ...driving gear 21 Remove the snap ring 7 and the splined washer 8 Slide out the fifth speed driving gear 22 with the relevant roller bearing cage 10 and the shim 15 All the components have thus been re...

Page 1122: ......

Page 1123: ...r piston assembly Remove the generator side cover and the generator assembly Removing the generator cover Remove the oil pump Removing the oil pump Remove the starter motor Removing the starter motor...

Page 1124: ...Once removed it is possible to replace the special rollers 7 Remove gear selector forks 8 and 9...

Page 1125: ...plete with gears taking care to recover the shim washers on the ends of the shafts If the bearing inner rings A are left on the shafts slide them off the ends of the gearbox primary 10 and secondary 1...

Page 1126: ......

Page 1127: ...e reference point is centred on the references of the timing gear 10 Note Check that in this position the horizontal cylinder piston is at top dead centre Fit the roller bearing cage 7 in bushing 8 by...

Page 1128: ...Thoroughly clean the shaft and nut threads and ensure they move freely Heat up the flywheel to 100 5 Install the flywheel assembly 6 with the gear 7 aligning the notches as shown in the photo...

Page 1129: ...Block the flywheel rotation with the suitable tool no 88713 3367 Fit washer 5...

Page 1130: ...it to 150 Nm Wait for the flywheel to cool down Completely loosen the nut that was tightened before and apply the product on the first 4 5 threads Tighten nut 4 to 300 Nm Thoroughly clean any residues...

Page 1131: ...ck that the starter clutch is working properly and that the roller races do not show signs of wear or damage of any kind Disassemble the unit if you find faulty operation Disassembling the generator f...

Page 1132: ...from flywheel 4 Reassembling the flywheel generator assembly Fit starter clutch 5 on flange 6 taking starter clutch edge A fully home on flange Important The edge of the starter clutch must be on the...

Page 1133: ...Insert the flange with starter clutch in the flywheel 4 so that the holes are concentric Insert rotor 3 on flywheel 4 and apply the indicated threadlocker...

Page 1134: ...r clutch ensuring it is properly seated Note To help insertion turn the driven gear in the direction indicated by the green arrow Hold the flywheel 1 with one hand and check that the driven gear can r...

Page 1135: ......

Page 1136: ......

Page 1137: ...enerator assembly Fix tool A part no 88713 3367 Block the tool on the flywheel by inserting screw 1 into hole 2 and on the casing by means of screws 3 Unscrew the generator flywheel retaining nut 4 Re...

Page 1138: ...Remove the flywheel unit 6 and the driven gear 7...

Page 1139: ...Remove the roller bearing 7 and bushing 8 Remove gear 9...

Page 1140: ......

Page 1141: ...g compound on the cover mating surface and around the holes for the screws and bushes Grease the crankshaft and the gearchange lever shaft ends to facilitate installation of the cover and to prevent t...

Page 1142: ...riving shaft Lubricate with the indicated product the oil seal 4 and orient the spring inwards Fit the oil seal fully home with tool B 88713 3394 Remove the tools Start the generator cover retaining s...

Page 1143: ...ince they are different Screws 3 6x35 mm Screws 5 6x20 mm Screws 4 6x30 mm Fit cover 2 with the relevant gasket Fix it with the two screws 1 Tighten them to a torque of 5 Nm Min 4 5 Max 5 5 Connect co...

Page 1144: ...r piston assembly Fit the clutch slave cylinder Refitting the clutch slave cylinder Refit the front sprocket cover Refitting the front sprocket cover Fill with engine oil Changing the engine oil and f...

Page 1145: ...hreadlocker on screws 1 and tighten them to 10 Nm Min 9 Max 11 Fit bearing 4 and fix it with circlip 5 Check that the cable ring 3 is correctly fitted Insert plate 6 as shown in the figure Push it dow...

Page 1146: ...If previously removed fit the Pick Up plug 7 with threadlocker and the relevant seal 8 Tighten plug to a torque of 15 Nm Min 13 Max 17...

Page 1147: ...If necessary fit the water pump assembly Refitting the water pump...

Page 1148: ...n stator 2 remove the cable ring 3 and stator 2 The generator cover is fitted with a bearing 4 held in place by the circlip 5 which is located on the end of the crankshaft Remove the circlip 5 with su...

Page 1149: ...utch slave cylinder Remove the pump cylinder hoses Removing the cylinder piston assembly Remove the water pump radiator hose Removing the water pump Remove the gear shift Removing the gear shift Note...

Page 1150: ...ing screws 3 4 and 5 on the generator cover 6 Fix service tool no 88713 1749 to the holes left vacant by the screws 1 you have just removed Turn the tool shaft slowly to separate the cover 6 from the...

Page 1151: ...a sealing ring 10 on the cover in correspondence with the gearchange lever shaft that may be damaged when removing the generator cover Always check the condition of this sealing ring and replace it if...

Page 1152: ...retaining screws 3 with specified threadlocker Tighten the screws 3 to a torque of 10 Nm min 9 Nm max 11 Nm Start the retaining screw 2 and tighten it to a torque of 10 Nm 10 Place starter motor sole...

Page 1153: ......

Page 1154: ...tor Loosen nut and remove starter motor cable 1 Undo the retaining screw 2 Remove the flywheel assembly Removing the flywheel generator assembly Working on the other side loosen the retaining screw 3...

Page 1155: ...lave cylinder Drain the coolant Changing the coolant Remove the pump water radiator hose Removing cooling system hoses and unions Remove the generator cover and flywheel generator assembly Removing ge...

Page 1156: ...se of removal Check that tab 5 is present and correctly fitted on the shaft When fitting the timing gear 4 align reference A to the cover hole B The timing gear 4 should be aligned with the driving ge...

Page 1157: ...ly and the generator cover Refitting the flywheel generator assembly Refit the pump water radiator hose Refitting cooling system hoses and unions Refit the pump cylinder hoses Refitting the cylinder p...

Page 1158: ...slave cylinder Removing the clutch slave cylinder Drain the coolant Changing the coolant Remove the pump water radiator hose Removing cooling system hoses and unions Remove the generator cover and fl...

Page 1159: ...omponents Position the knock sensor 14 on the head as shown in the figure and fix it by starting screw 15 Tighten the screw 15 to a torque of 25 Nm Min 22 5 Max 27 5 Make sure that the O rings 13 are...

Page 1160: ...eat in the crankcase half Start the screw 11 with the washer 12 and tighten to a torque of 10 Nm Min 9 Nm Max 11 Nm If the oil breather valve 2 has been disassembled reassemble it tightening the three...

Page 1161: ...to a torque of 10 Nm Min 9 Nm Max 11 Nm Position the by pass spring 5 on the nipple 4 and apply the recommended threadlocker to the end of the nipple to be screwed in the crankcase half Screw oil filt...

Page 1162: ...half Clean the plug thread apply a bead of Ducati sealing compound along the plug thread spreading it by the entire circumference 360 Screw the drain plug 16 with seal 15 to a torque of 6 Nm Min 5 Nm...

Page 1163: ...Changing the engine oil and filter cartridge Check the condition of the O rings 17 of the stud bolts 9 and replace them if necessary Use tool C part no 88713 1920 to fit the O rings 17 in the suitable...

Page 1164: ...on If previously removed apply recommended threadlocker on dowel 18 tighten to a torque of 15 Nm Min 13 5 Nm Max 16 5 Nm fit the seal 19 on the service plug 20 the seal must be positioned so that the...

Page 1165: ...tor Refit the generator assembly and the generator side cover Refitting the flywheel generator assembly Refit the complete cylinder piston assembly Refitting the cylinder piston assembly Refit the com...

Page 1166: ...ve the starter motor Removing the starter motor Remove the clutch cover Removing the clutch cover Remove the clutch unit Removing the clutch Remove the oil pump Removing the oil pump Remove the mesh f...

Page 1167: ...Remove the mesh filter A from the clutch side crankcase half Remove the drain plug 6 with its seal 7...

Page 1168: ...Remove the gearbox position sensor 8 with tool part no 88713 3407 Remove the cylinder head stud bolts 9 with the aid of the appropriate tool...

Page 1169: ...To remove the engine sensor 10 undo the screw 11 and collect the washer 12...

Page 1170: ...Check the condition of O rings 13 and replace them if necessary Remove the knock sensors 14 by loosening screws 15...

Page 1171: ......

Page 1172: ...er on the screw thread 12 Start the screw 12 with gasket 13 and tighten it to a torque of 5 Nm Min 4 Max 6 If previously removed apply threadlocker on dowel 14 tighten to a torque of 20 Nm Min 18 Nm M...

Page 1173: ...If previously removed apply recommended threadlocker to the plug 15 and tighten to a torque of 24 Nm Min 21 Nm Max 27 Nm...

Page 1174: ...ring 13 in its seat in the crankcase half Apply the indicated threadlocker on screw 11 Tighten screw 11 to a torque of 8 Nm Min 7 Nm Max 9 Nm Repeat the operations described above with the other valv...

Page 1175: ...Make sure that the two centring bushes A are correctly fitted on the crankcase...

Page 1176: ...ed below Shim the gearbox shafts 7 as described in Shimming the shafts and fit them Drive the two shafts into seat using a mallet Check the shaft movement Fit the gearbox forks 16 in the secondary sha...

Page 1177: ...8 in the area shown in the figure Shim the gearbox drum as described in Shimming the shafts and insert it in the crankcase half Insert pins of the gearbox forks in the gearbox drum seats Apply specif...

Page 1178: ...Insert the timing shaft 10 Lubricate the crankshaft 9 with the indicated product in the areas shown in the figure...

Page 1179: ...Fit the two spacers B with the chamfered side facing the crankshaft...

Page 1180: ...ng rods matching the corresponding seats of the cylinders Important Make sure that the connecting rods are correctly positioned in the relevant cylinder seats Incorrect positioning of the connecting r...

Page 1181: ...9 after having lubricated it with the indicated product Apply a uniform and continuous bead of DUCATI sealing compound to the mating surfaces of the crankcase halves going around all the holes as show...

Page 1182: ...the snap ring 1 in the groove on the shaft and remove the protective cap Bring the two crankcase halves together tapping if necessary with a rubber mallet on the shafts if necessary Fix the two crank...

Page 1183: ...osition and start the screws 3 by pre tightening them to 19 Nm min 17 Max 21 respecting the indicated sequence Tighten the screws 3 to a torque of 25 Nm Min 22 Max 28 respecting the indicated sequence...

Page 1184: ...Tighten the screws 3 and 4 to a torque of 25 Nm Min 22 Max 28 respecting the indicated sequence Tighten screws 5 and 6 to a torque of 10 Nm Min 9 Max 11 respecting the indicated sequence...

Page 1185: ...guide of tool C part no 88700 5685 on the gearbox secondary shaft bearing 7 Fit the O ring 20 on the guide with spacer 21 duly lubricated with the indicated product and push the O ring into seat Remo...

Page 1186: ...tarter motor Refitting the starter motor Refit the generator assembly and the generator side cover Refitting the flywheel generator assembly Refit the complete cylinder piston assembly Refitting the c...

Page 1187: ...e shafts The following shims are supplied as spare parts Gearbox shaft shims Position Clutch side mm Chain side mm Gearbox primary shaft 1 1 6 Position Clutch side mm Chain side mm Gearbox secondary s...

Page 1188: ...Gearbox selector drum shims The following shims are supplied as spare parts Position Clutch side mm Chain side mm Gear shift drum 3 1 0 0 9...

Page 1189: ...ankcase halves must be in good condition and perfectly clean The mating surfaces must be perfectly flat and free from burrs To fit the bearings we recommend heating up the casings to a temperature bet...

Page 1190: ...Insert bearing 1 with the marks facing up Fit the two spacers 3 and the two screws 2 with the indicated threadlocker Tighten the screws 2 to a torque of 10 Nm Min 9 Max 11 PRIMARY SHAFT BEARING 4...

Page 1191: ...Fit the oil seal 6 by respecting the values indicated in the figure...

Page 1192: ...tant While heating the casing if the seal ring is heated to a temperature above 120 C looses its properties Apply indicated grease on the bearing needles 4 Fit ring 5 in bearing 4 with the marks facin...

Page 1193: ...TIMING LAYSHAFT BEARING 7 Fit bearing 7 and fix it with snap ring 8...

Page 1194: ...Note The closed side of the plastic cage must be facing towards the crankcase half Generator side external part Side A SECONDARY SHAFT OIL SEAL 9...

Page 1195: ...Lubricate the oil seal with the recommended product Fit the oil seal 9 by respecting value X 88 0 2 mm as shown in the figure...

Page 1196: ...NEEDLE ROLLER BEARINGS 10 FOR SWINGARM SHAFT...

Page 1197: ...ing 13 in the crankcase half Apply indicated grease in the hole Fit seal ring 12 and the two needle roller bearings 10 respecting the indicated value The bearing marks must be facing up Fit the sealin...

Page 1198: ...ARY SHAFT BEARING 14 Insert bearing 14 with the marks facing up Fit tab 17 in the groove on the crankcase Fit the two spacers 16 and the two screws 14 with the indicated threadlocker Tighten the screw...

Page 1199: ...SECONDARY SHAFT BEARING 18 Apply indicated grease on the bearing needles 18 Fit ring 19 in bearing 18 with the marks facing up...

Page 1200: ...TIMING LAYSHAFT BEARING 20...

Page 1201: ...Fit bearing 20 and fix it with snap ring 21...

Page 1202: ...g 25 in the crankcase half Apply indicated grease in the hole Fit seal ring 24 and the two needle roller bearings 22 respecting the indicated value The bearing marks must be facing up Note The picture...

Page 1203: ...Fit the sealing ring 23 TIMING SHAFT SEAL RING 26...

Page 1204: ...Lubricate seal 26 using the specified product...

Page 1205: ...ring 26 by respecting the indicated values X 69 2 0 2 mm Check the presence of the oil intake pipe plug 27 If previously removed apply threadlocker to the plug 27 and tighten to a torque of 24 Nm Min...

Page 1206: ......

Page 1207: ...nsuring that the side with marks faces upwards and is fully home on the bush REFITTING PROCEDURE CLUTCH SIDE MAIN BEARING To refit the bearing A insert the roller bearing 1 so that the side with marks...

Page 1208: ...Make sure that opening C is in a diagonally opposed position of machining D of bush 2...

Page 1209: ...ole F of the locking dowel Apply recommended threadlocker to the special dowel thread 4 Tighten the special dowel 4 on the crankcase half 5 fitting the tapered side G inside the slot E of the previous...

Page 1210: ...GENERATOR SIDE MAIN BEARING...

Page 1211: ...To refit the bearing l insert bearing 7 so that the side with marks faces outwards and is fully home on the bush 8 Groove H must be visible Fit snap ring 9 in groove N...

Page 1212: ...ing 7 by means of snap ring 11 in groove M Heat up the crankcase half to a temperature between 95 C and 110 C Once the desired temperature is reached drive the bearing assembly l fully inside the cran...

Page 1213: ......

Page 1214: ...condition of centring bushes If apparently distorted or loose in their seats change them using proper tools To better identify the position of each component the casing has been divided into four area...

Page 1215: ...Undo the two retaining screws 2 and recover spacers 3 Remove the bearing 1...

Page 1216: ...PRIMARY SHAFT BEARING 4 Remove the internal ring 5 Remove the bearing 4...

Page 1217: ...Remove the sealing ring 6...

Page 1218: ...TIMING LAYSHAFT BEARING 7 Remove the snap ring 8 Remove the bearing 7...

Page 1219: ...Generator side external part Side A SECONDARY SHAFT OIL SEAL 9...

Page 1220: ...Remove oil seal 9 NEEDLE ROLLER BEARINGS 10 FOR SWINGARM SHAFT Remove the following components in the following sequence sealing ring 11 needle roller bearings 10 sealing ring 12 snap ring 13...

Page 1221: ...Clutch side internal part Side C PRIMARY SHAFT BEARING 14 Undo the two retaining screws 15 and recover spacers 16 Remove bearing 14 and tab 17...

Page 1222: ...SECONDARY SHAFT BEARING 18...

Page 1223: ...Remove the internal ring 19 Remove the bearing 18...

Page 1224: ...TIMING LAYSHAFT BEARING 20 Remove the snap ring 21 Remove the bearing 20...

Page 1225: ...Clutch side external part Side D NEEDLE ROLLER BEARINGS 22 FOR SWINGARM SHAFT...

Page 1226: ...Remove the following components in the following sequence sealing ring 23 needle roller bearings 22 sealing ring 24 snap ring 25 TIMING SHAFT SEAL RING 26...

Page 1227: ...Remove the sealing ring 26...

Page 1228: ...er Changing the engine oil and filter cartridge Remove the gearchange mechanism Removing the gearchange mechanism To better identify the position of each component the casing has been divided into fou...

Page 1229: ...Working on the generator side of the casing Side A and the clutch side Side D loosen the screws 3 4 5 and 6...

Page 1230: ...ft with a plastic mallet to separate the crankcase halves Note Take care not to lose the shim washers on the shafts and on the selector drum Working on the crankcase half internal side Side B remove t...

Page 1231: ...Loosen screw 11 remove the lubrication valve 12 and collect the O ring 13...

Page 1232: ...halves Closing the crankcase Refit the mesh filter Changing the engine oil and filter cartridge Refit the oil pump Refitting the oil pump Refit the clutch unit Refitting the clutch Refit the clutch co...

Page 1233: ...7 and lubricate it with the indicated product Check the crankshaft con rod coupling Checking the crankshaft con rod clearance Replacing connecting rod big end bearings Before installing the bearing i...

Page 1234: ...Crankshaft Bearings Each class corresponds to a certain colour on the bearings highlighted on the edge as shown in the figure...

Page 1235: ...rings colour A A YELLOW BLUE A B YELLOW YELLOW B A BLUE BLUE B B YELLOW BLUE Con rod weight class Crankshaft weight class Weight After checking and choosing the bearing type 2 lubricate it with the in...

Page 1236: ...While inserting it pay attention that shell tooth C matches with seat D of the con rod shank and the other shell with seat F of the con rod cap Check that the centring dowels E are present...

Page 1237: ......

Page 1238: ...ed Insert the connecting rods in the crankshaft so that the centring pins E face the internal side of the crankshaft Join the connecting rod cap with the corresponding connecting rod shank ensuring th...

Page 1239: ...sed is irritant in contact with the skin wear protective gloves Important Lubrication of con rod bolts is essential to obtain the correct coupling and to prevent breakage of the parts The con rod scre...

Page 1240: ...n rods and take up residual axial clearance with the fork feeler gauge H of tool no 88713 2878 which has shims of the following sizes 0 1 mm 0 2 mm 0 3 mm Temporarily fit the gudgeon pin 5 to align th...

Page 1241: ...recommended grease to the thread tighten the screw to a torque of 35 Nm 10 wait for 2 seconds then loosen by 360 tighten to a snug torque of 20 Nm 10 tighten to a snug torque of 35 Nm 10 tighten with...

Page 1242: ...llelism 3 checking and replacing the con rod big end bearings 4 checking the crankshaft 5 checking the crankshaft con rod clearance 1 checking and replacing the con rod small end bush The clearance be...

Page 1243: ...g the new bushing 3 align its concentric holes with the holes of the con rod 2 2 Checking the con rod parallelism Check for parallelism error measured at 100 mm from the connecting rod longitudinal ax...

Page 1244: ...ident signs of machining The connecting rod is supplied in two size classes A and B relative to the big end diameter as punch marked on the side of the cap and two weight classes 1 and 2 Connecting ro...

Page 1245: ...illet between journal and shoulder Fillet radius 3mm Use a micrometer to measure oval and taper of the crank pin Measure oval and taper in several different directions Use a dial gauge to measure the...

Page 1246: ...Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues that have accumulated and are restricting the oil flow...

Page 1247: ...Apply recommended threadlocker to the threads of plugs 4 and 5 and refit them Tighten all plugs to a torque of 13 Nm Min 11 Nm Max 15 Nm 5 Checking the crankshaft con rod clearance...

Page 1248: ...In order to correctly couple big end bearings 6 and crank pin 7 proceed as follows...

Page 1249: ...e applied tightening torque Min 70Nm Max 103Nm Continue the coupling procedure as described below loosen the screws and remove the connecting rod check the width of the strip of GREEN Plastigauge PG 1...

Page 1250: ...if the clearance value complies with the established limits carefully remove the strip of GREEN Plastigauge PG 1 A from the crankshaft and repeat the tightening procedure as described above...

Page 1251: ...the connecting rod assembly Loosen the screws 1 and separate the connecting rods from the crankshaft Important Take care not to mix up components of different connecting rods and maintain the origina...

Page 1252: ...emove the generator side cover and the generator assembly Removing the generator cover Remove the starter motor Refitting the starter motor Remove the clutch cover Removing the clutch cover Remove the...

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Ducati MULTISTRADA 1200S ABS 2015, Workshop Manual

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