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MV Agusta Rivale 800, Workshop Manual

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MV Agusta Rivale 800 Workshop Manual Download Page 447

Diagnostic

- 5 -

O

ABS SYSTEM (Perform testing using TEXA diagnostic software)

ABS system warning light on

Faulty front/rear speed sensor connection

Deoxidize/Repair

Front/rear speed sensor damaged

Replace

Broken or damaged phonic wheel

Repair/Replace

Gap between sensor and phonic wheel not as specified

Replace

Fuse 25A connection faulty

Deoxidize/Repair

Blown 25A fuse

Replace

Fuse 15A connection faulty

Deoxidize/Repair

Blown 15A fuse

Replace

Fuse 10A connection faulty

Deoxidize/Repair

Blown 10A fuse

Replace

DIAGNOSTICS

DASHBOARD INSTRUCTIONS

PRESSURE SENSOR

Faulty pressure sensor connection

Deoxidize/Repair

Rubber fitting pipe damaged or not connected

Repair/Replace

Pressure sensor damaged 

Replace

Faulty ECU connection

Deoxidize/Repair

ECU failure

Replace

Problem with the electrical system

Repair/Replace

PHASE ERROR

See above

AIR TEMP

Faulty air temperature sensor connection

Deoxidize/Repair

Air temperature sensor failure

Replace

Faulty ECU connection

Deoxidize/Repair

ECU failure

Replace

Problem with the electrical system

Repair/Replace

H2O SENSOR

Using a diagnostic instrument check which if the two sensors is faulty

Faulty engine water temperature sensor connection

Deoxidize/Repair

Engine coolant temperature sensor broken

Replace

Faulty engine coolant temperature sensor connection

Deoxidize/Repair

Radiator coolant temperature sensor broken 

Replace

Faulty ECU connection

Deoxidize/Repair

ECU failure

Replace

Problem with the electrical system

Repair/Replace

THROTTLE POSITION

Faulty throttle body connection

Deoxidize/Repair

Throttle body position sensor failure

Change throttle body

Faulty ECU connection

Deoxidize/Repair

ECU failure

Replace

Problem with the electrical system

Repair/Replace

LAMBDA SENSOR

Faulty lambda probe connection

Deoxidize/Repair

Lambda probe failure

Replace

Faulty ECU connection

Deoxidize/Repair

ECU failure

Replace

Problem with the electrical system

Repair/Replace

INJECTOR N (N=1, 2, 3)

Injector N connection faulty

Deoxidize/Repair

Injector N broken

Replace

ECU failure

Replace

Faulty ECU connection

Deoxidize/Repair

Problem with the electrical system

Repair/Replace

GAS POSITION

Faulty gas control connection

Deoxidize/Repair

Gas control failure

Replace

ECU failure

Replace

Faulty ECU connection

Deoxidize/Repair

Problem with the electrical system

Repair/Replace

FUEL PUMP RELAY

Injection relay broken

Replace

Injection relay connection faulty

Deoxidize/Repair

ECU failure

Replace

Faulty ECU connection

Deoxidize/Repair

Fuel pump connection faulty

Deoxidize/Repair

Problem with the electrical system

Repair/Replace

RPM SENSOR

Faulty engine rev sensor connection

Deoxidize/Repair

engine rev sensor failure

Replace

ECU failure

Replace

Faulty ECU connection

Deoxidize/Repair

Problem with the electrical system

Repair/Replace

Summary of Contents for Rivale 800

Page 1: ......

Page 2: ...2014 The reproduction even partial of this document is forbidden without prior written agreement of MV Agusta Motor S p A Part no 8A00B8457 Edition no 1 Printed April 2014...

Page 3: ...Motorcycle workshop manual MV AGUSTA RIVALE 800...

Page 4: ...e collection of spare parts the preparation of tools and equipment etc To reach the part to be repaired limiting the work to the essential operations With regards to this a valid help would be to cons...

Page 5: ...IR INTAKE INJECTION SYSTEM ELECTRICAL SYSTEM SUSPENSION AND WHEELS FRAME BRAKES COOLING SYSTEM SPECIAL TOOLS TORQUE PRESSURES DIAGNOSTICS ANALYTICAL INDEX Rev 0 B Rev 0 C Rev 0 D Rev 0 E Rev 0 F Rev 0...

Page 6: ......

Page 7: ...1 General description A SECTION A Revision 0...

Page 8: ...ARY HOW TO CONSULT THIS MANUAL PAGE 3 THE PURPOSE OF THIS MANUAL PAGE 3 GLOSSARY AND SYMBOLS PAGE 4 RIGHT HAND AND LEFT HAND STANDARD PAGE 5 SAFETY PAGE 6 OBSERVATIONS PAGE 8 INDEX PAGE 8 OPERATIVE TE...

Page 9: ...ols and other information See the symbols lists for their significance The procedures are described step after step PURPOSE OF THE MANUAL Principally this manual has been written for MV Agusta dealers...

Page 10: ...t of the operation NOTE Utilise a specific tool or equipment for the correct carrying out of the operation described Tighten to the specified torque Tolerance or limit of use Utilise the tester Use th...

Page 11: ...er 2 Cylinder 3 Left side Right side RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual herewith below is a diagram of the motorcycle and th...

Page 12: ...the environment Keep used oil out of the reach of children Engine coolant Under certain situations the ethylene glycol contained in the engine coolant is inflammable and its flame is invisible Ethylen...

Page 13: ...urise the shock absorber The use of unstable gases can cause explosions that could cause burns Do not place the shock absorber near to flames or sources of heat as this could cause explosions with con...

Page 14: ...hem in con tainers respecting exactly the order of disassembly Always use the special utensils where necessary and each time where prescribed Always use adhesives sealants and lubricants where pre scr...

Page 15: ...ide of the steering head The engine registration number is stamped on the upper engine casing near the swingarm ZCG S3 10 AA E V 000011 Manufacturer identification Vehicle model Progressive frame numb...

Page 16: ...10 General description A...

Page 17: ...B 1 Maintenance SECTION B Revision 0...

Page 18: ...E FITTINGS PAGE 26 CHECKING ENGINE DURING IDLE PAGE 29 BRAKES PAGE 31 BRAKE CLUTCH GEARCHANGE COMMANDS CHECK PAGE 36 BRAKE PADS PAGE 39 ACCELERATOR CONTROL PAGE 39 LOCKS PAGE 40 STEERING PAGE 43 TRANS...

Page 19: ...on RIVALE 800 CHARACTERISTICS Wheelbase mm 1410 Total length mm 2070 Maximum width mm 885 Seat height mm 881 Ground clearance mm 142 Trail mm 104 5 Dry weight kg 178 Fuel tank capacity lt 12 88 Fuel r...

Page 20: ...nt mesh gears Gear ratios total ratios 1st 2 846 13 819 2nd 2 125 10 317 3rd 1 778 8 632 4th 1 579 7 666 5th 1 429 6 936 6th 1 318 6 400 FRAME Type ALS steel tubular trellis MAG welded Fork fulcrum pl...

Page 21: ...dicator LED Tail light bulb LED Brake rear light LED Battery 12V 8 6Ah Alternator 350 W at 5000 r p m BODYWORK Side fairings Thermoplastic material Front fairing Thermoplastic material Front upper fai...

Page 22: ...00 24000 30000 36000 600 3800 7500 11200 14900 18600 22400 Pre delivery Description Operation Engine oil Substitution At least once a year Engine oil filter At every substitution of engine oil Engine...

Page 23: ...tution Substitution Side stand Check functioning Side Check functioning stand switch Rear wheel hub Check Substitution Swingarm bearings Check lubricate Drive chain pads on swingarm Check substitution...

Page 24: ...crew it anticlockwise 8 Maintenance B NOTE Description Recommended product Specifications Engine oil eni i Ride moto2 5W 40 SAE 5W 40 API SL Ethylene glycol Engine coolant AGIP ECO PERMANENT diluted w...

Page 25: ...e to collect the used oil Remove the oil discharge plug 2 Recover the oil in an appropriate container Do not scatter the drainage oil into the envi ronment Allow the lubrication system to drain comple...

Page 26: ...re replacing the cap make sure it is completely clean Replace the sealing washer with a new one Screw in the oil discharge plug and tighten it to the specified torque Torque pressure oil discharge plu...

Page 27: ...eference notch correct it by empty ing a little oil out of the engine Oil pipes During ordinary maintenance operations ensure that the different components are properly fitted and that no oil is leaki...

Page 28: ...expansion vessel side cap 8 N m 2 Should the motorcycle have been disassembled for other interventions it can also be restored by removing the top cap Open the expansion tank only when the engine is c...

Page 29: ...2 once again at the specific tightening torque using a newly supplied gas ket Coolant drain plug tightening torque 35 N m Fill the cooling system with a suitable liquid described in the table see pag...

Page 30: ...ain keeping the expansion vessel pipe closed with relevant pincers for rubber pipes MIN level Should the level be too low open the connection tube to the expansion vessel and let liquid flow out until...

Page 31: ...ALVE MECHANISM ADJUSTMENT Check and adjust Every 12000 kilometres Tappet play must be adjusted with the engine cold Remove in order the following components to carry out the measuring of the play betw...

Page 32: ...above and clean on a workstation as indicated in the figure Apply adhesive paper tape to the frame tubes This operation will protect the paintwork from knocks scratches and abrasions that could occur...

Page 33: ...Maintenance 17 B Disconnect the coil connector in three phases a move the Secondary Lock back b press the retainer clip c disconnect the connection...

Page 34: ...head cover To carry out this operation use only the work surfaces indicated Take care to not ruin or deteriorate the motorcycle parts in the proximity of the work area Remove the engine head cover Co...

Page 35: ...Maintenance 19 B Remove the head cover gasket Now remove the cover of the phonic wheel by acting on the eight screws For further operations see the Engine Workshop Manual Part Code 8000B6231...

Page 36: ...o proceed as described in the overhaul section of the Rivale 800 workshop engine manual Part Code 8000B6231 SPARK PLUGS Check substitute Every 12000 kilometres Substitute Every 12000 kilometres The fo...

Page 37: ...re extremely used or burnt substitute the spark plugs Also substitute the spark plugs in the case of breakage of the ceramic isolation or damage to threading When the spark plugs are renewed check the...

Page 38: ...y to remove in sequence the following parts Saddle Saddle side panels Fuel tank side panels Side number holder Fuel tank NOTE Consult chapter C Bodywork Removing the fuel pump unit Lift the tank and p...

Page 39: ...nd lubri cate it by applying silicone grease If it is damaged change it for a new one Using a worn gasket can cause petrol to leak from the tank and therefore pose the risk of the vehicle taking fire...

Page 40: ...he removal operations in reverse order 3 Replacement the fuel filter Open the two metal band fasteners one upper 1 and one lower 2 using the specific tool Hand pliers Oetiker 1098i Disconnect the two...

Page 41: ...Maintenance 25 B FUEL PUMP ASSEMBLY...

Page 42: ...roceed with the re assembly of the parts that have been removed following the operations in reverse order to disassembly as described in chapter C Bodywork Fuel tank Side number holder Fuel tank side...

Page 43: ...t every three years The procedure to follow in the case of substitution of the feed tubing is as follows Remove in this order Saddle Saddle side panels Fuel tank side panels Side number holder Fuel ta...

Page 44: ...ottle body until you hear it lock UTILISE ONLY NEW PARTS 28 Maintenance B To re mount the tank pipe press the two lateral green buttons at the same time and insert the pipe Replacing fuel pipe from th...

Page 45: ...making sure the exhaust is working correctly correct installation holes leaks the state of the catalyst etc checking engine phase CHECKING ENGINE DURING IDLE The engine control unit is designed to adj...

Page 46: ...as shown in the figure Remove the air filter 3 by sliding it out from the left air box intake hole Check the condition of the air filter If it is necessary to substitute it proceed as follows Prepare...

Page 47: ...ake fluid level The procedure described below must be followed for the front brake fluid tank Place the motorcycle in a vertical position with the han dlebars straight Check the level of fluid in the...

Page 48: ...akage or seepage of brake fluid from the fittings and pipes If any breakages are seen substitute the damaged parts as described in chapter H Brakes Brake fluid leakages are dangerous and immediately d...

Page 49: ...le to check the level of the rear brake fluid If the fluid is below the low level mark follow these steps to top up with brake fluid complying with the specifications remove the oil tank 1 from the fr...

Page 50: ...void drip ping on painted areas fill the braking system by acting on the lever of the rear brake fill the rear brake fluid tank until it reaches the max level Recommended brake fluid AGIP Brake 4 Do n...

Page 51: ...screw and the tightening torque indicated Torque pressure 8 10 N m Apply Loctite 243 8 10 N m Substitution and bleeding of the brake fluid The substitution of the brake fluid and the successive bleed...

Page 52: ...arry out adjustments whilst riding the motorcycle Pull the lever to neutralise the push of the spring and at the same time adjust the position by rotating the ring in a clockwise or anti clockwise dir...

Page 53: ...ister located on the handlebar control For greater differences set the register on the handle bar at the indicated measurement of 22 mm Adjust the main register sheltered by the clutch cover by acting...

Page 54: ...guard 1 by removing the three screws 2 2 Slacken the two counter nuts 3 rh thread and 4 lh thread 2 1 3 4 3 Screw unscrew by hand the gearbox transmission rod 5 until the lever reaches the desired pos...

Page 55: ...place the pads as described in chapter H Brakes Wear limit 1 mm If the brake pads are substituted it is nec essary to effectuate a proper running in period before reaching an optimal braking efficienc...

Page 56: ...sactivates the elec trical system and the steering lock The three control positions are as follows OFF position ON position ON position All electrical circuits are activated the instruments and warnin...

Page 57: ...i dust cover LOCK position Turn the handlebar left or right Press the key down and rotate it to the LOCK position All electrical circuits are disactivated and the steering is blocked The key can be pu...

Page 58: ...d part is correctly placed and that it is firmly secured to the motorcycle framework Personal compartment lock Insert the key Push the seat downwards at the back and at the same time turn the key in a...

Page 59: ...tion must be 116 mm from the lower chain guard Manually turn the rear wheel and perform the check at different points along the chain As the wheel is turned the play should remain virtual ly the same...

Page 60: ...adjuster nut backwards or forwards respectively slackening or tightening the chain until the correct play is reached as described previously Successively tighten the screws of the rear wheel hub to t...

Page 61: ...5 B Chain lubrication Lubricate At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres The chain is of the O ring type Clean the chain with a clean cloth and or a jet o...

Page 62: ...f excessive play of the front wheel bearings is found during checks then substitute them as indicated in chapter F Suspension and wheels 1 5 mm TYRES Check pressures At the pre delivery at the first 1...

Page 63: ...carry out certain preliminary operations by consulting the relative chapters Remove the rear wheel see chapter F Suspension and wheels Lift up the motorcycle by utilising a mechanic s lift Remove the...

Page 64: ...00 kilometres and then every 6000 kilometres Make sure the bike cannot be started when the stand is down and the bike is in gear Also check that with the engine switched on when the side stand is lowe...

Page 65: ...ew 4 3 To refit the stand follow the same steps in reverse order taking care to tighten the screws to the pre scribed torque Tightening torque for stand plate screws 40 44 N m Apply Loctite 243 40 44...

Page 66: ...with no friction or sticking remove the hinge plate 2 1 2 remove the nut 3 and free the stand from the plate but pulling off the pin 4 Proceed in the opposite order for reassembly following the instr...

Page 67: ...d then every 6000 kilometres Carry out a general check on all tube band fasteners for their condition and tightness Substitute damaged band fasteners by following the relative procedure delineated in...

Page 68: ...l on the relative pole of the battery as shown in figure Turn the screw of the positive terminal and perform the prescribed tightening torque using a torque wrench Tightening torque 7 8 N m When it ha...

Page 69: ...screw of the negative terminal and perform the prescribed tightening torque using a torque wrench Tightening torque 7 8 N m Before tightening make sure the cables face the right way When mounting is f...

Page 70: ...while riding stop the motorcycle immediately and check that the ABS system is activated 3 Low beam green It turns on when the low beam is on 4 Reserve fuel indicator orange Comes on when approximatel...

Page 71: ...variable number of segments on a graduated scale When the temperature falls outside the nor mal operating range it may display one of the fol lowing information the display shows just one blinking se...

Page 72: ...electing the display functions The following settings may be changed on the display RUN Odometer SPEED LIMITER TC Traction control CHRONO Chronometer ABS Antilock braking system QUICK SHIFT CLOCK Cloc...

Page 73: ...Total odometer TOTAL Trip counter 1 TRIP 1 As an alternative Total odometer TOTAL Trip counter 2 TRIP 2 TC Mode This mode adjusts the engine traction control level to your driving requirements SPEED...

Page 74: ...lap CURRENT LAP Chronometer Fastest lap BEST LAP Chronometer Last lap LAST LAP Rev counter Total laps covered N LAP QUICK SHIFT mode This mode allows to turn off or on the quick shift func tion of th...

Page 75: ...G The display modes may be changed or set when the engine is off the gear in neutral the motorbike stationary with your feet on the ground The display may not be changed while driving Access the RUN m...

Page 76: ...nce B Press the OK key for less than three seconds until the partial speedometer 2 function TRIP 2 appears on the display By pressing the OK key for more than three sec onds the TRIP 2 value will be r...

Page 77: ...s SET for less than three seconds the maxi mum speed value is decreased of 2 km h with refer ence to the one shown on the display On the other hand if you press OK for less than three seconds the maxi...

Page 78: ...f the SPEED LIMITER function has been enabled when riding the vehicle the speed value shown on the odometer starts blinking when it reaches the set value of the maximum speed Press OK for less than th...

Page 79: ...i vated the first pressing of the headlight but ton automatically enables the TC function From this moment on it is possible to immediately change the traction control level by properly operate the SE...

Page 80: ...than the time measured during the previous lap Data display Once all times have been recorded they may be dis played Access the CHRONO mode the time of the fastest lap BEST LAP and the time of the la...

Page 81: ...the flashing high beam headlight all the times previously acquired starting from the last lap memorised can be displayed in sequence Once all the data have been displayed press the SET key to return t...

Page 82: ...e the display while driving Resetting of individual time recordings Access the CHRONO mode and press the SET key for less than three seconds until the words SINGLE LAP RESET appear on the display Pres...

Page 83: ...ll the data have been cancelled press the SET key to return to the SINGLE LAP RESET mode and then to the following mode Resetting of best lap time Access the CHRONO mode and press the SET key for less...

Page 84: ...elled press the SET key to exit the BEST LAP RESET mode and then pass to the following mode Resetting of all lap times recorded Access the CHRONO mode and press the SET key for less than three seconds...

Page 85: ...functions Press SET in order to access to ABS mode SET TING ABS appears on the display WARNING The display modes may be changed or set when the engine is off the gear in neutral the motorbike station...

Page 86: ...g the OK button for less than three sec onds the caption toggles from OFF to ON and inversely Press SET to confirm the selected quick shift acti vation state Otherwise by pressing OK while the caption...

Page 87: ...g numeric value Press the OK button for over three seconds the selected hour digit is confirmed If instead one press es the SET button for less than three seconds the setting procedure is interrupted...

Page 88: ...sing the start button when the engine is switched on this way the mapping switches to the following set ting value The corresponding mapping characteristics are listed in the following table Mapping M...

Page 89: ...itivity Press OK for less than three seconds until GAS SENSITIVITY appears Press SET for less than three seconds The display shows the current setting for throttle control sensitivi ty Press OK for le...

Page 90: ...after a few seconds the display returns to GAS SENSITIVITY mode It is now possible to pro ceed with the setting of the following parameter Maximum engine torque Press OK for less than three seconds un...

Page 91: ...three sec onds the following settings can be displayed in sequence RAIN SPORT Press OK for more than three seconds the new set ting will be confirmed The displayed caption stops flashing and after a...

Page 92: ...conds the displayed setting will start flashing By repeatedly pressing OK for less than three sec onds the following settings can be displayed in sequence NORMAL SPORT Press OK for more than three sec...

Page 93: ...s SET for less than three seconds The display shows the current setting for engine response Press OK for less than three seconds the displayed setting will start flashing By repeatedly pressing OK for...

Page 94: ...d The displayed caption stops flashing and after a few seconds the display returns to ENGINE RESPONSE mode Engine RPM limiter Press OK for less than three seconds until RPM LIMITER appears Press SET f...

Page 95: ...lowing settings can be displayed in sequence NORMAL SPORT Press OK for more than three seconds the new set ting will be confirmed The displayed caption stops flashing and after a few seconds the displ...

Page 96: ...s the warning alert shown in the picture In particular this message highlights the vehicle part or device on which the fault has been detected Press OK button to access to RUN mode The direction indic...

Page 97: ...to be filled up If the warning alert appears even if the level is adequate stop driving Dealer Menu The instrumentation provides the opportunity to oper ate on an additional set of parameters The aux...

Page 98: ...f the motorcycle UNIT CHANGE Mode This function allows for simultaneous editing of the fol lowing units of measure Speed Distance covered SERVICE Mode Press the SET and OK buttons at the same time for...

Page 99: ...d maintenance the mileage range must be reset using the following procedure Access SERVICE mode and press the OK button for less than three seconds until the message RESET KM appears and the mileage r...

Page 100: ...ERVICE mode as described in the pre ceding pages and press the SET button for less than four seconds to until the message UNIT CHANGE appears Press the OK button for less than three seconds and the un...

Page 101: ...splay returns to the RUN mode LIGHTS Check At the pre delivery at the first 1000 kilometres and then every 6000 kilo metres If any of the warning lights or the main lights are burnt out replace them a...

Page 102: ...86 Maintenance B Remove the screws on the left side Open the left clamp and rotate the headlight assem bly as shown in the picture Remove the protection cover...

Page 103: ...Maintenance 87 B Slide out the bulb CAUTION Do not touch the bulb glass with bare hands If you do clean the bulb with an oil free solvent Release the retaining clips Unhook the connector...

Page 104: ...dlight assembly upwards until it is in abutment as shown in the picture FUSES The battery recharge fuse is located on the solenoid starter of the motorcycle To expose it remove the saddle of the motor...

Page 105: ...ctrical equipment of the motorcycle which could lead to a fire The services fuses are located under the saddle near the battery Release the two clamps and lift the fuse box cover CAUTION Turn the igni...

Page 106: ...nclosed electrical diagram The reference letters in the figure corre spond to those shown in the diagram Remember that the fuse box contains three spare fuses WARNING Never replace a fuse with a ratin...

Page 107: ...r The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the frame Headlight adjustment Place the vehicle at a distance of 10 m from a vertical wall Make sure...

Page 108: ...92 Maintenance B...

Page 109: ...1 Superstructures C SECTION C Revision 0...

Page 110: ...PAGE 16 RADIATOR SIDE PANELS PAGE 20 INTAKE AIR SYSTEM AIRBOX PAGE 23 REMOVING AIRBOX PAGE 24 AIRBOX REMOVAL PAGE 25 REAR TAIL PAGE 28 LOWER BULKHEAD AND TAIL LIGHT PAGE 29 TAIL TIDY DISASSEMBLY PAGE...

Page 111: ...Superstructures 3 C FAIRINGS...

Page 112: ...shown in figure the screws are mounted with a socket key Remove the front brake hoses from the clamps mount ed on the mudguard Pull off the mudguard towards the front FRONT HEADLIGHT COVER DISASSEMBLY...

Page 113: ...Slide the headlight cover out Remove the four fixing screws 1 of the headlight to the support C Superstructures 5 Remove the headlight connector 2 using a screwdriv er 2 1...

Page 114: ...6 Superstructures C HEADLIGHT SUPPORT DISASSEMBLY Remove the four fixing screws from the support two per part Open the light support hatches Extract the headlight support 1...

Page 115: ...ASHBOARD DISASSEMBLY Loosen the central fixing screw with relative washer Slide out the rubber hood 1 and release the connec tor 2 using a screwdriver Release the dashboard from the relevant rubber pa...

Page 116: ...ard and the low beam sup port optional as described in the previous pages Disconnect the six seven for vehicles with ABS main connectors n 4 situated in the front area of the vehicle on vehicles with...

Page 117: ...C disconnect the 2 manifolds situated on the right and left sides under the handlebar direction indicators Loosen the clutch on the handlebar side and engine side Slide out the clutch transmission cab...

Page 118: ...10 Superstructures C Remove the front brake pump by operating on the screw 1 and open the hatch 2 1 2 Slide the pump unit from the handlebar Disconnect the front brake stop light switch connectors 3 3...

Page 119: ...rt and remove the stand Remove the handlebar 5 When reassembling the handlebar pay attention to the correct positioning of the U bolts respect to the handlebar Refer to the timing signs on the sides o...

Page 120: ...O L W A R N IN G W E RE CO M M EN D O N LY AL CO H O L FR EE FU EL A TT EN TI O N NO US CO NS EI LL ON S SE UL ES SE NC E SA NS AL CO OL A C H TU N G W IR EM PF EH LE N NU R AL CO HO LF RE I KR AF TS...

Page 121: ...ank the driver s seat must be removed beforehand DISASSEMBLY OF NUMBER CARRIER SIDE PAN ELS AND SEAT RAIL SIDE PANELS Remove the two upper screws 1 of the number carri er side panel 2 and one lower sc...

Page 122: ...14 Superstructures C Release the side panel from the pin and extract it Remove the five screws of the seat rail side panel n 4 lateral 1 n 1 lower 2 1 2...

Page 123: ...Superstructures Release the tank side panel by loosening the five screws Remove the side panel as shown in the figure 15 C...

Page 124: ...en and remove the four fixing screws from the tank upper plate and remove the plate Unscrew and remove the two front screws 1 fasten ing the fuel tank to the frame Two persons are required for the fol...

Page 125: ...nect the overflow pipe on the bottom rear part To make disengaging fittings from the fuel pump flange easier two operators are rec ommended one to support the tank and the other to disconnect the quic...

Page 126: ...with the motorcycle in the fuel cap lock turn it clockwise and open the cap 1 1 1 Remove the safety screw 2 When putting the fuel tank cap back on perform the same operations in the opposite order as...

Page 127: ...C Superstructures 19 Remove the cap 3 Fuel tank cap fixing screws tightening torque n 3 external screws 4 5 N m Internal safety screw 4 5 N m Apply Loctite 243 and take it into position 1...

Page 128: ...20 Superstructures C RADIATOR SIDE PANELS...

Page 129: ...tures 21 C Remove the three fixing screws 1 from the aluminium bulkhead 1 Remove the bulkhead 2 2 Remove the three fixing screws 3 of the plastic sup port to the frame and the radiator and remove the...

Page 130: ...22 Superstructures C For USA version vehicles insert the two spac ers 4 shown in the photo one per side 4 NOTE...

Page 131: ...Superstructures 23 C INTAKE AIR SYSTEM AIRBOX...

Page 132: ...C REMOVING AIRBOX Before removing the Airbox you must first remove the fuel tank as described in this chapter Disconnect the air temperature sensor connector Disconnect the air pressure sensor and eng...

Page 133: ...Superstructures 25 C Remove the right and left air inlet duct unscrewing three screws on the side Remove the air filter AIRBOX REMOVAL Remove the nine fixing screws on the Airbox cover...

Page 134: ...26 Superstructures C Remove the two front fixing screws Remove the rear fixing screw Disconnect the blow by pipe...

Page 135: ...res Lift the lower airbox Rear fixing screw tightening torque 8 N m 27 C When reassembling it perform the same operations carried out during disassembly 2 front fixing screws tightening torque 10 N m...

Page 136: ...28 Superstructures C REAR TAIL...

Page 137: ...Superstructures 29 C LOWER BULKHEAD AND TAIL LIGHT...

Page 138: ...seat the fuel tank side panels the side number holder and the underseat panels refer to the paragraph Fuel tank in this chapter TAIL TIDY DISASSEMBLY Remove the four upper screws and the lower screw 1...

Page 139: ...SASSEMBLY Remove the two screws 1 and slide the foot peg sup port out DISASSEMBLY OF THE FRAME LOWER BULK HEAD Remove the six fixing screws of the frame bulkhead three per side Slide the bulkhead from...

Page 140: ...F THE GLOVE COMPARTMENT BULKHEAD Remove the fixing screw 1 and remove the bulkhead 2 REMOVING NUMBER PLATE SUPPORT Loosen the left screw 1 of the hub Turn the wheel manually and insert the spanner in...

Page 141: ...he right screw manually without removing it Remove the left screw To facilitate sliding out the right screw it is good prac tice to remove the rear wheel as described in Chapter F Suspensions and whee...

Page 142: ...tures C Loosen and remove the screw 3 of the rear third point attachment 3 3 Remove the switch cover 4 by loosening the two M5 screws 5 5 4 Slide the right screw of the hub out 2 supporting it with th...

Page 143: ...res Rest the support on the surface Disconnect the three connectors 6 to for the indica tors and one for the number plate light with the aid of a small screwdriver The support is disassembled at this...

Page 144: ...ove the arm by taking out the five screws four at the bottom 5 and one at the top 6 DISASSEMBLY OF THE COMPLETE MUDGUARD NUMBER PLATE CARRIER UNIT Remove the two small plates that contain the electric...

Page 145: ...y removing the four screws 7 with wrench and 2 5 screwdriver as shown in the figure 37 C 7 Loosen the two screws on the slide 8 Push the slide upwards in a way to release the four M6 fixing screws 9 o...

Page 146: ...four fixing screws 10 attaching the mud guard to the internal support and tilt the mudguard without internal support Remove the internal support 11 from the mudguard Remove the two small plates 12 hol...

Page 147: ...shrinking material 13 on the electric cables Release the number plate carrier unit from the mud guard Loosen the two screws 14 and remove the number plate light 39 C 13 14 Loosen the two nuts 15 and r...

Page 148: ...oining the electric cables At this point the indicators will be as in the figure com plete with spacers and rubber pads To re assemble the unit proceed in reverse order fol lowing the layout given bel...

Page 149: ...Superstructures 41 C...

Page 150: ...C TAIL LIGHT DISASSEMBLY Disassemble the number carrier side panel from the rear frame To remove the tail light operate on the three screws 1 loosening them and releasing the tail light 1 DISASSEMBLY...

Page 151: ...Superstructures 43 C Remove the eight screws 1 4 per part as shown in the photo and slide the two bulkheads downwards 1 1...

Page 152: ...44 Superstructures C...

Page 153: ...Air intake injection system 1 D SECTION D Revision 0...

Page 154: ...TROL UNIT PAGE 8 SENSORS PAGE 8 ATMOSPHERIC AIR TEMPERATURE SENSOR PAGE 8 THROTTLE BODY POSITION SENSOR PAGE 10 INJECTOR CONTROL PAGE 11 FUEL PUMP CONTROL PAGE 11 ACTUATORS PAGE 13 DIAGNOSTICS SYSTEM...

Page 155: ...request the r p m the pressure of the intake duct and various compensations that are determined according to signals coming from various sensors that reveal the condition of the engine and the riding...

Page 156: ...the temperature of the intake air is low the injection time volume is increased BATTERY VOLTAGE SIGNAL The voltage of the battery is supplied to the ECU for the functioning of the ECU and this voltage...

Page 157: ...the feed tubing at a controlled pressure by the rel ative regulator and maintained at a certain constant value higher than the suction generated by the motor The fuel is injected into the air intake c...

Page 158: ...he fuel injects the fuel in a conical dispersion Given that the opening of the needle valve is constant the volume of fuel injected at any one time is dependent on the time that the solenoid is agitat...

Page 159: ...the pump motor func tion continuously When the ignition switch is switched to the OFF position the control of the pump relay is interrupted and con temporaneously also the control of the injectors an...

Page 160: ...es the value of the air temperature Check Connect the connector and measure the resistance value between the two contacts on the sensor which must be 2 5 kOhm 10 at 20 C 1 INTAKE AIR PRESSURE SENSOR T...

Page 161: ...t to the ECU The volume of the injection increases when the air temperature is low The resistance of the Thermistor increases when the air temperature is low and diminishes when the tem perature is hi...

Page 162: ...alues it deter mines the throttle opening angle If the two values are not coherent it will provide a fault alert The sensor is checked by diagnostic software 10 Air intake injection system D 1 T O W 1...

Page 163: ...hm 10 at 20 C Otherwise proceed with changing the faulty injector FUEL PUMP CHECK Check the condition of the fuel pump fuse To check the condition of the fuel pump proceed as fol lows After having rem...

Page 164: ...o function correctly after the above described tests proceed with relative relay control 1 located behind the right fairing of the motorcycle identified by a ring marked with I located on the cable ha...

Page 165: ...e injection system 13 D Ignition coils The ignition coils are of the top plug type they are assembled directly on the spark plugs This avoids the use of the HT leads and enhance the overall system rel...

Page 166: ...identifying and recording the faults present or that were present previously on the motorcycle This soft ware is equipped with a guide book for the use of the software itself to carry out checks on e...

Page 167: ...ent is DELTA MAPPHASE Ck Er Vr Hole in manifold diagnosis P0101 0101 hex Plausibility 1000 Signal is not plausible or not coherent CONDITION FOR DETECTION The detection starts if there isn t an electr...

Page 168: ...s recognized a fault if the sensor voltage VangThrottle2 VANGTHRMIN PO Ck Er Vr Plausibility 1000 Signal is not plausible or not coherent CONDITION FOR DETECTION Rpm 0 DETECTION It is recognized a fau...

Page 169: ...agnosis P0221 0221 hex Over maximum Threshold 0001 Short circuit to Supply volta ge or Vehicle supply CONDITION FOR DETECTION Always DETECTION It is recognized a fault if the sensor voltage VgasPos2 T...

Page 170: ...nized a fault through the hardware component signal feedback check Ck Er Vr Engine speed sensor diagnosis P0335 0335 hex Plausibility 1000 Signal is not plausible or not coherent CONDITION FOR DETECTI...

Page 171: ...ibility 1000 Signal is not plausible or not coherent CONDITION FOR DETECTION Always DETECTION It is recognized a fault if Rpm THRPMVS CmeDriver THTORQUEVS for a time equal to NSAMPOBSVS with VehicleSp...

Page 172: ...geFSSTatusA 0 PO Ck Er Vr Sensor supply 1 P0641 0641 hex Over maximum Threshold 0001 Short circuit to Supply volta ge or Vehicle supply CONDITION FOR DETECTION Always DETECTION It is recognized a faul...

Page 173: ...22 hex Plausibility 1000 Short circuit to Supply voltage or Vehicle sup ply Open Circuit or Short Circuit to Ground CONDITION FOR DETECTION Always DETECTION It is recognized a fault if VGasPos1 VGasPo...

Page 174: ...ch the computation performed by Main Microcontroller PO Ck Er Vr Safety 2 diagnosis P1612 1612 hex Low Beam relay command P1655 1655 hex Plausibility 1000 System Error CONDITION FOR DETECTION Always D...

Page 175: ...if there are no messages from the DASHBOARD PO Ck Er Vr CAN Communication NCM YRS U1706 No Signal 0100 Electrical pro blems on CAN wires or XXX Fault CONDITION FOR DETECTION Always DETECTION It is rec...

Page 176: ...tion in the air intake system The frontal pressure of the air during normal rid ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there by im...

Page 177: ...ils D Camshaft position sensor E Air temperature sensor in the suction line F Fuel injectors G Throttle body position sensor H Fuel injectors I Fuses relays L Engine control unit M Solenoid starter N...

Page 178: ...TORS RELAY CLUTCH SWITCH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEEL FUEL PUMP INJECTOR FUSE COIL FUSE PRESSURE SENSOR UNDER THROTTLE THROTTLE BODY LOWER INJECTORS FUEL PUMP Ignition ke...

Page 179: ...ONTROL 1 INJECTORS Low side G1 OUT_INJECTOR_2B OUTPUT INJECTOR CONTROL 2 INJECTORS Low side G2 OUT_INJECTOR_3B OUTPUT INJECTOR CONTROL 3 INJECTORS Low side G3 OUT_INJECTOR_4B Low side G4 OUT_H_LAMBDA_...

Page 180: ...Sensor Ground E1 GND Analog ANALOGIC MASS 7 Sensor Ground E2 VREF_1 OUTPUT VREF1 5V FOR GRIP POSITION SENSOR 1 5V Sensor Supply E3 VREF_2 OUTPUT VREF1 5V FOR GRIP POSITION SENSOR 2 5V Sensor Supply E4...

Page 181: ...Electrical system 1 E SECTION E Revision 0...

Page 182: ...26 ENGINE PICK UP PAGE 27 E A S PAGE 27 TIMING WHEEL GAP PAGE 28 RUN OFF SAFETY SWITCH PAGE 28 INSTRUMENTATION PAGE 29 OIL PRESSURE SENSOR PAGE 30 FUEL LEVEL WARNING LIGHT SWITCH CHECK PAGE 30 WATER...

Page 183: ...connecting a coupling ensure that the body of the coupling is gripped and do not pull it apart by the leads Check that the terminals of the couplings are not slack or bent Check that the terminals are...

Page 184: ...drop semiconductor parts such as those incorporated in the ECU When checking these parts carry out the instruc tions to the letter The lack of using the correct pro cedure can cause grave damage 4 Ele...

Page 185: ...Gr O W Bk R Gr Bk Gr P Gy R V R W Br Y V Gr R V O Bk O Y R Gr B Bk W R B B Bk B W Y Bk B B Bk B W Y Gr B B W Bk W O Y Bk B O Br Y Br Bk R Bk V Bk R W Y B Br P Y B Gr O B Gr Y B Br B Y V W R Bk Br Gy...

Page 186: ...nt turn indicator right hand 37 Front light 38 Dashboard 39 Air pressure sensor 40 Front turn indicator left hand 41 Horn 42 Air temperature sensor 43 Light switch 44 Light relay 45 Water temperature...

Page 187: ...Br Y V Gr R V O Bk O Y R Gr B Bk W R B B Bk B W Y Bk B B Bk B W Y Gr B B W Bk W O B Y B O Br Y Br Bk R Bk V Bk R W Y Br Br P Y B Gr O B Gr Y B Br B Y V W R Bk Br Gy O B Sb O V Br Gr B Bk R B Y Y B Gr...

Page 188: ...17 Alternator 18 Rear speed sensor 19 Solenoid starter 20 Main relay 21 SET OK button 22 23 24 Injectors 25 Quick shift 26 Throttle potentiometer 27 Water temperature sensor for power unit 28 Oil swit...

Page 189: ...d battery with breather valve No elec trolyte level checking is required Never remove the battery seal caps nor block the breather opening 9 E During vehicle downtime e g the winter season it is not n...

Page 190: ...er the level of the electrolyte thus making the bat tery unusable Voltages lower than 11 8V shorten the life and impair the operation of the battery Checking stored batteries once a month pro longs th...

Page 191: ...Remove the battery by lifting it from its housing To install the battery carry out the disassembly opera tions in reverse order beginning by connecting the pos itive terminal on the relative pole of t...

Page 192: ...NG SYSTEM Warning function Conditions of abnormal operation of the battery charg ing function voltage 10V is indicated by the warning lamp and the voltage value displayed on the dash board As shown in...

Page 193: ...ENSIONE SU TERMINALI DEL REGOLATORE DI TENSIONE SI SI SI SI SI SI SI SI SI SI SI NO NO NO NO NO NO SI Electrical system 13 E A list of possible problems that could occur when the warning light is swit...

Page 194: ...an 1mA First of all when using an ampmeter utilise a high range of the multi tester because the current losses in the case of malfunctioning could be elevated Do not turn the ignition switch to the ON...

Page 195: ...6V or more than 14 5V the cause will be found in the generator When carrying out this check ensure that the battery is fully charged Feed charge Standard 13 5 14 5V at 2000 r p m NOTE STARTER SYSTEM T...

Page 196: ...gaged Clutch not pulled in Engine is starting SOLENOID STARTER BATTERY KEY SWITCH SAFETY SWITCH MAIN RELAY FUEL PUMP COILS INJECTORS RELAY CLUTCH SWITCH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PI...

Page 197: ...CH SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEEL FUEL PUMP INJECTOR FUSE COIL FUSE PRESSURE SENSOR UNDER THROTTLE THROTTLE BODY LOWER INJECTORS FUEL PUMP PLUG TOP COILS Ignition key in th...

Page 198: ...SIDE STAND SWITCH NEUTRAL SWITCH TILT SENSOR PICK UP WHEEL FUEL PUMP INJECTOR FUSE COIL FUSE PRESSURE SENSOR UNDER THROTTLE THROTTLE BODY LOWER INJECTORS FUEL PUMP PLUG TOP COILS Ignition key in the...

Page 199: ...TOR Disconnect the generator connector Make sure that there is a resistance of 0 3 Ohm 10 at 20 C between each of the contacts of the 3 pins generator line Make sure that there is NO continuity betwee...

Page 200: ...r C Superstructures Remove the seat lock plate 1 Remove the blow by tube Disconnect the cable of the starter motor 1 Remove the two fixing screws 2 of the starter motor Remove the motor by sliding it...

Page 201: ...y of MOLYKOTE to the rotor shaft Apply a small quantity of LOCTITE 243 to the bolts of the starter motor STARTER MOTOR CHECK If a fault has been diagnosed in the starter motor it is necessary to proce...

Page 202: ...k that the winding is on open circuit or if a resistance is present The wind ing is in good condition if the value of the resistance revealed is as indicated Multi tester dial indication ohm Starter r...

Page 203: ...owered After the tests described above whenever it is neces sary to replace the switch proceed as indicated in chapter B Maintenance GEARCHANGE POSITION SWITCH The connector 1 of the gear position sen...

Page 204: ...ck up To identify the position and function of the fuses refer to the table IMPORTANT Be careful to restore the correct fuse amperage Using an amperage that dif fers from the required one could damage...

Page 205: ...F4 15 High Beam Low Beam Fuse Box F5 15 Solenoid Starter Dashboard Front speed sensor Rear speed sensor Lean angle sensor Fuse Box F6 15 Intermittence Stop light Horn Diagnostics Fuse Box F7 15 Elect...

Page 206: ...ed by a label with the let ter M Take the general relay out M from the connector and check that there is a resistance of 82 Ohm 10 at 20 C between pins 1 and 3 M Check the resistance between the elect...

Page 207: ...e connector Pick up resistance value 680 700 E A S electronically assisted gear shift E A S mode which can be selected from the menu is used to change gear without using the clutch and with out closin...

Page 208: ...indicated in the figure 1 TIMING WHEEL GAP To guarantee the correct functioning of the pick up it is necessary to measure the gap between the pick up and the timing wheel by utilising a feeler gauge...

Page 209: ...etween the Y yellow and W R white red wires INSTRUMENTATION If faults are found in the instrumentation it is necessary to check the main wiring and the various components assisted by the same instrume...

Page 210: ...e contact must be inter rupted FUEL LEVEL WARNING LIGHT CHECK SWITCH After having checked the breakdown of the fuel reserve warning light check that there is continuity between terminal 4 of the tank...

Page 211: ...that the light bulb switches off after having poured more fuel into the tank than the maximum required for the reserve WATER SENSOR Verify sensor operation by measuring resistance between the pin by...

Page 212: ...a CAN line therefore if this information is not displayed and the message CAN ERROR appears on the dashboard the problem can be attributed to the dashboard KEY SWITCH Whenever the dashboard with the s...

Page 213: ...ure that when the sensor is placed in front of a tooth of the phonic wheel between terminal 3 and terminal 2 of the connector that the voltage is close to zero whilst when it is not placed in front of...

Page 214: ...fuse 4 If the fuse is ok check the continuity of the left handle bar control connector between positions between the Y B yellow blue and the Y yellow wires with the dri ving beam function selected If...

Page 215: ...vices and slide the number plate carrier out from the supports LICENCE PLATE LIGHT If the number plate light does not work check the integrity of fuse 3 in the fuse box if these are ok replace the bul...

Page 216: ...lock is put in the ON position Any anomaly is indicated on the instrument with the wording TAIL LIGHTS In the event that tail lights and brake lights do not work check the conditions of fuse 3 If the...

Page 217: ...cator command check the continuity between pins 6 and 3 operate in the same way on pins 6 and 2 with the right indicator command If the condition is also met the problem originates from the indicators...

Page 218: ...d are identical to those of the front indicators If an indicator must be replaced remove the licence plate carrier as indicated in page 35 for removal of the number plate light and release the indicat...

Page 219: ...condition check the cooling fan relay mounted on the right side of the battery com partment marked with the letter F If the relay is in good condition but is not energised aboard the vehicle check the...

Page 220: ...necessary to disconnect the battery cables Take the ECU out of its housing and remove the engine connector first red right side pressing the hook and turning the safety bracket Repeat this operation o...

Page 221: ...in order to preserve the surrounding components from brake fluid leaks during the following disassembling operations Brake fluid has a strong corrosive power Be careful not to spill the fluid on surr...

Page 222: ...ver the rear frame and extract the ABS unit with its support by pulling it towards the rear side of the motorcycle 2 3 3 Before removing the ABS unit from the motorcycle detach the connector by perfor...

Page 223: ...m Insert the connector to the ABS unit and rotate the blocking lever Place the ABS unit with its support on the motorcy cle Insert the three fixing screws of the ABS unit support and tighten them by h...

Page 224: ...the new ABS unit by using the TEXA diagnosis software as described below Start from the Self diagnosis display then press the button shown in the picture to enter the Adjustments mode Press the Codif...

Page 225: ...lower portion of the display In this case press the CONFIRM button in order to exit the Adjustment mode If you selected the wrong vehicle model when the activation procedure has been completed a war n...

Page 226: ...46 Electrical system E SWITCHES Check the continuity of each switch with a tester If there is any anomaly substitute the respective switch unit with a new one R H switch L H switch...

Page 227: ...mm Plastic clamp for cables Add q ty 1 clamp Cod 800092247 L 62 for wire harness up to Rev B To correctly position the electric wiring on the motorcycle first position the initial node of the wiring i...

Page 228: ...ace the connector vertically Code Code Code Code Code Code Note Pass the clutch cable over the electric wiring Sheath band fasteners Position sheath at 100 mm from the node O Note Place the wiring beh...

Page 229: ...rect passage of the On Off cable Code Code Code Note attention to the correct passage of the vent pipe Note attention to the cor rect passage of the air temp sensor cable Note Pay attention to the co...

Page 230: ...correspondence with the pint nearest to the dashboard Note Pay attention to the correct passage of the dashboard cable outside the headlight support Note Pay attention to the correct pas sage of the...

Page 231: ...e with the point nearest to the dashboard Note Avoid contact between the clutch pipe and dashboard Position the band fastener in corre spondence with the point nearest to the dashboard L 62 contains c...

Page 232: ...tion hidden behind the frame tube Sheath band fasteners Code See Fig 05 Code Code See Fig 05 Code Code L 25 contains standing cable and temperature sensor cable Code contains the generator connector h...

Page 233: ...ctor hidden behind frame tube only for wiring up to Rev B Code L 62 only for wiring up to Rev B Note Position fuel pump connector for wiring from Rev C Code L 25 for EAS ver sion only Code Code Note E...

Page 234: ...system E Code Code Code Note Pay attention to the correct pas sage of the cables Side stand cable con nector Lambda probe connector Pay attention to the correct direction of assembly of the starter m...

Page 235: ...Electrical system 55 E Code contains number plate carrier lights wiring speed sensor cable rear brake pipe Code Code Note Pay attention to the correct positioning of the connectors on the cover...

Page 236: ...56 Electrical system E Code Code Code Code Code Code...

Page 237: ...sage of the of the battery pole contactor cable Code updated version Code current version Code L 25 contains N 2 earth cables Note Pay attention to the correct passage of the motor earth cable Note Pa...

Page 238: ...lock cable Indicator inter mittence Dashboard diagnostics Code Code Position band fastener in correspondence of the clip nut Buffer Code Note Pay attention to the correct passage of the fall sensor c...

Page 239: ...stem 59 E Code on saddle transmission cable Code contains the voltage regulator cable only Battery connector Diagnosis connector Code Code Position sheaths at 50 mm from the connectors Sheaths band fa...

Page 240: ...536 1 Frame tube protection Before performing the installa tion of the brake hoses on the motorcycle apply the adhesive protection code 8000B4536 on the connection hose between front brake calipers AB...

Page 241: ...1 E Code Code Code Note Recovery of exceed ing cabling as shown Code Note Position of the bifurcation of the sensor ABS hose cable Keep the clutch cable over the ABS hoses Pay atten tion not to twist...

Page 242: ...teners Code Orient the head of the clamp as much as possible toward the front of the bike Sheaths band fasteners Code Pass the ABS hoses on the right side of the tank vent pipes Nr 1 screw cap Code 80...

Page 243: ...Keep the rear brake hose behind the other hoses Code already fitted on motorcycles without ABS see page 51 already fitted on motorcycles without ABS see page 51 Note Pay attention to the correct posit...

Page 244: ...ake caliper hose Front brake caliper hose Rear brake pump hose Front brake pump hose MC1 marked hose On completion of the positioning and clamping of pipes fix the terminals to the ABS module mounted...

Page 245: ...1 F Suspension and wheels SECTION F Revision 0...

Page 246: ...SUMMARY FRONT WHEEL PAGE 3 FRONT FORKS PAGE 10 STEERING ASSEMBLY PAGE 25 REAR SUSPENSION AND SWINGARM PAGE 31 CHAIN REMOVAL PAGE 40 REAR WHEEL HUB PAGE 49 MOTORCYCLE SET UP ADJUSTMENT PAGE 66 WHEELS C...

Page 247: ...60 Kg m ft lb Torque pressure Operation A B C D B E A F G Description Rivale 800 FRONT WHEEL Material Aluminium alloy Dimensions 3 50 x 17 FRONT TYRE Dimensions 120 70 ZR 17 M C 58 W TL Brand and type...

Page 248: ...and No 8000B7340 To facilitate the removal of the wheel it is advisable to tape the brake tubing to the special tool FRONT WHEEL REMOVAL Unscrew the two fixing screws of both front calipers and remove...

Page 249: ...front wheel fork attach ments Unscrew the nut from the left side Holding the wheel up with your left hand use your right hand to push the pin towards the right part of the motorcycle 1 Take the wheel...

Page 250: ...acement Utilise the special tool to extract the bearings To assemble the tool it is necessary to remove the screw 1 and extract the wheel spindle 2 Remove the nut 3 and then the flange 4 Before substi...

Page 251: ...eats of the bearings on the wheels are not scored or marked Reassembly front wheel bearings Before proceeding with the reassembly accurately clean the bearing seats in the wheel hub Lubricate the oute...

Page 252: ...ings Proceed as illustrated in the figure Attention the wheel bearings should be mounted with little interference but should the action of the press be blocked in any way release the press Having comp...

Page 253: ...ollowing the indications in page 68 After having carried out the check on the parts of the front wheel accurately clean the wheel spindle and assemble it from right to left Once the wheel has been put...

Page 254: ...Kg m ft lb Torque pressure Operation B A D B A I C E F G D H H Description Rivale 800 FRONT SUSPENSION Type Upside down telescopic hydraulic fork with external and separated adjustment of rebound and...

Page 255: ...Special tool No 8000B9312 Stem removal Loosen the 2 screws 2 from the steering base and the screw 3 from the steering head During this phase support the stem Slide out the stem supporting it with bot...

Page 256: ...a vertical position taking care to protect its surface against possible damage Completely unscrew the plug and lower the sheath as shown in the figure Perform this operation while hold ing the leg in...

Page 257: ...Suspension and wheels F 13 Remove the plug 1 Unscrew the plug Using the spanner adjust the spring preload while locking the nut on the damping piston rod 1 Remove the spring...

Page 258: ...a suitable container Recover the oil in an appropriate container Do not dispose of the used oil in the environ ment During this phase also take the spring pre load spacer out 1 1 35 N m Pull out the...

Page 259: ...F 15 Remove the retaining ring 2 with a screwdriver tak ing care to not scratch the stem Lower dust cap 1 taking care not to damage the seat on the sheath 1 2 Extract the sleeve from the stem by repe...

Page 260: ...described in the diagram Special tool No 8000B6785 Suspension and wheels F 16 Assembly oil seal and anti dust seal After having carefully checked all components substi tute those damaged and or deter...

Page 261: ...the lining taking the bushing into the seat with the respective washer use the specific tool Mount the oil retainer using the same technique Special tool No 8000B6785 Insert the clamping ring 1 in pl...

Page 262: ...atedly move the damping piston rod up and down until the it slides smoothly Oil type used SAE 7 5 Recommended oil Marzocchi EBH16 SAE 7 5 Check that the oil is at level X with reference to the upper s...

Page 263: ...t 1 in to the end of the threaded portion 1 Put the spring in by holding the pump rod in an extend ed position outside of the sleeve Insert the 13 mm wrench under the pump nut 1 to stop the rod from f...

Page 264: ...by hand and screw it on until it hits the rod and not the nut 2 Tighten the plug with the prescribed torque Fork leg plug tightening torque 20 N m 20 N m 1 Insert and screw in the complete cap 1 on th...

Page 265: ...nsure proper positioning of the rods refer to the figure at right taking care to observe fitting dimension X Rivale 800 X 239 mm Bring the two screws 1 into contact at the base of the steering Carry o...

Page 266: ...rect positioning of the stems even if the steering head has not been removed This check guarantees the standard set up of the motorcycle Mount the front wheel and brake callipers according to procedur...

Page 267: ...by fully turning the adjusting nut counterclockwise from this position turn the screw clockwise until you reach the standard position see table Rotate clockwise to increase the spring preload or coun...

Page 268: ...is obtained from the reference posi tion which is found by fully turning the screw clockwise and then counterclockwise until you reach the standard position see table Rotate clockwise to increase the...

Page 269: ...Suspension and wheels F 25 STEERING ASSEMBLY A B C D E F G H I N m 18 16 18 Into contact 22 24 10 Kg m ft lb Torque pressure Operation A C B A C B D E...

Page 270: ...EMBLY OVERHAUL In order to operate on the steering unit the first han dlebar unit must be removed by loosening the two screws 1 and sliding them out 1 Fold the handlebar over the headlight protecting...

Page 271: ...on the steering assembly it is necessary to remove the fork stems as described in this chapter in the paragraph Front fork overhaul or lift the front wheel using the specific kickstand Special tool N...

Page 272: ...teering pin Support the motorcycle sufficiently enough so that the front stand can be removed Ensure that the brake calipers are securely placed Special tool No 800091645 Remove the screw ring 1 previ...

Page 273: ...bearing the anti dust seal and the screw ring of the steering pin Remove the steering base from the lower part Assembly steering base Accurately clean all the parts and check the general condition Bef...

Page 274: ...of the fork stems Steering pin tightening Screw down without tightening the screw ring of the steering pin This operation must be done manually Ensure that the steering base is at the end of stroke co...

Page 275: ...l tank as described in chapter C Bodywork and the silencer as described in chapter H A B C D E N m 40 44 55 60 40 44 55 60 70 75 Kg m ft lb Torque pressure Operation E B C A D 243 Description Rivale 8...

Page 276: ...rrier side panels with the headlights and the under saddle bulkhead as described in Chapter C Fairing Lift up the rear part of the motorcycle with the specific lifter Slacken the upper nut 1 of the sh...

Page 277: ...d slide the screw out discharging the weight of the shock absorber Extract the complete shock absorber discharging the weight of the same Rear shock absorber test Make sure that the top connection of...

Page 278: ...he table must be made start ing from the relative initial reference positions These positions must be determined via the following proce dures Rebound damping turn clockwise until fully home and then...

Page 279: ...pensator assembly and lightly screw in the screw using the rela tive nut Lower the motorcycle to the ground remove the lift and safety straps This operation is necessary to recover the play between th...

Page 280: ...bber and the safety spring clip 1 and unscrew the screw ring of the wheel Attention The screw ring has a left handed thread 1 To remove the wheel in presence of the number plate carrier it is necessar...

Page 281: ...eg remove the clamping screw 1 from the gear extension 1 On the right foot peg also remove the silencer clamping screw 2 2 1 1 Operate on the two screws 1 of both the right and left foot peg supports...

Page 282: ...the two socket head screws 1 of the lower chain guard Remove the lower chain guard taking care to recover the internal bushes 1 Top chain guard removal Remove the two top chain guard screws 1 1 Silen...

Page 283: ...Suspension and wheels F 39 Remove the socket head screw on the right side Remove the silencers unit from the exhausts...

Page 284: ...has three functions As a chain cutter with a punch mounted aligned at A Press fitting of connecting link plate with a raised punch aligned at A As an anvil with a raised punch aligned at B Pre assemb...

Page 285: ...d the O Rings as shown in the figure by using the special grease supplied with the chain kit Utilise only new links Connect both ends of the chain with the connecting link and press the connecting pla...

Page 286: ...h in the position used in the previous operation Mount the tool onto one of the pins of the connecting link as shown in the figure and align the punch on B Turn the pin holder by hand until the punch...

Page 287: ...s F 43 Removing the rear brake caliper Loosen the two screws 1 and remove brake caliper 2 Speed sensor cable disassembly Remove the speed sensor cable holding clamp 3 3 1 2 Disconnect the speed sensor...

Page 288: ...re removing the swingarm pin loosen the suspen sion rocker pin 1 and the two engine pins 2 See chapter G Frame 1 2 Also loosen the pin for the pads Remove the screw 1 on the left side of the vehicle R...

Page 289: ...void it from falling on the ground and slide it towards the rear part of the motor cycle Upper chain guide removal Remove the 2 screws 1 and relative plates and the screw 2 on the front 1 2 Lift up th...

Page 290: ...screws 1 with their relative spacers 1 Bearings overhaul If it is necessary to substitute the bearings of the swingarm because of excessive play operate as fol lows Remove the right and left spacer R...

Page 291: ...the fork from the right side Fitting the bearings and the roller cases on the rear swingarm Take two new roller cases Part No 800084936 and two new ball bearings Part No 800084938 Preassemble the 2 r...

Page 292: ...8 Complete the assembly by fitting the two bushings relating to the tool Part No 800092866 on the right side of the swingarm Special tool No 800092866 Utilising a press fit the bearings and the roller...

Page 293: ...22 25 200 220 28 32 220 240 140 10 18 20 5 7 18 Kg m ft lb Torque pressure Operation 270 243 270 270 243 Description Rivale 800 REAR WHEEL Material Aluminium alloy Dimensions 5 50 x 17 REAR TYRE Dimen...

Page 294: ...d the rear wheel by remov ing the polygonal nut Utilise the following tools Torque wrench 55 mm polygonal spanner The polygonal fixing nut of the rear wheel has a left hand thread To effectuate the re...

Page 295: ...e figure Utilise the following tools Torque wrench 55 mm polygonal spanner Remove the nut 1 with the shim 2 underneath 1 2 With the special spanner mounted on the extension tube pull forward the eccen...

Page 296: ...nsion and wheels F 52 Remove the rear sprocket unit 3 and the spacer ring 5 underneath 5 3 Remove the rubber clamp 1 around the rear brake pipe 1 Slacken the two screws 6 and remove the brake caliper...

Page 297: ...ith the brake disc extracting it from the right side of the motorcycle as shown in the figure At the same time support the ring gear unit with one hand Brake caliper support flange removal Remove the...

Page 298: ...e caliper holder pin 1 only if it is damaged When reassembling apply the prescribed type of Loctite and tighten to the prescribed torque pressure Recommended thread locking fluid Loctite 243 Caliper h...

Page 299: ...ent splines If it is worn substitute as follows Remove the four clamping screws 1 of the brake disc holder flange as they are usually assembled with threadlocker fluid after having heated them with a...

Page 300: ...ssembling apply force on the crown of the peg not on the point see figure Assemble the brake disc carrier plate by tightening the screws to the prescribed torque pressure and the rec ommended type of...

Page 301: ...If the spring drives are worn replace with new ones Check that the coupling bushes of the gear flange sup port 1 and the driving flange 2 do not show any signs of excessive or uneven wear 3 2 1 Remov...

Page 302: ...coupling areas Bushes coupling area 1 Grease AGIP GR SM Bushes coupling area 2 Grease AGIP GREASE 30 Do not apply grease to the threads of the pins Reassembly wheel hub Lightly grease the wheel hub In...

Page 303: ...of the seat Grease the rollers bearings Introduce the first bush the spacer and then the sec ond bush and successively the gear rim spacer The grease used must have the following characteristics Lithi...

Page 304: ...1 and tighten the fixing screws 2 at the specified torque Special product Loctite 243 Torque pressure 18 N m Reinsert the rubber clamp 1 around the rear brake pipe Reposition the nut of the flange 1...

Page 305: ...flange nut coupling torque 200 220 N m Apply grease only on the threaded part Assemble the retaining ring 1 1 200 220 N m 220 240 N m Rear wheel assembly In the case of substitution of the rear tyre...

Page 306: ...embly Remove the gear shift fixing 1 Remove the covering on the pinion lid by loosening the three screws 1 and allow the gear shift rod to disen gage from the work area 2 1 Remount the number plate ca...

Page 307: ...F 63 1 Remove the 3 clamping screws 2 and remove the pinion cover 1 2 Straighten the metal tongue with a flat head drift and hammer Put it in first gear by moving the lever clockwise by hand Heat the...

Page 308: ...e pinion to end stroke Take a new washer assemble it with the nut and tight en to the prescribed torque pressure utilising Loctite thread locking fluid Torque pressure 140 N m Recommended thread locki...

Page 309: ...he pinion wheel cover after having cleaned the support base Proceed with the tightening screwing down respec tively on the three screws M6 1 Torque pressure M6 Screws 10 N m 10 N m Re position the gea...

Page 310: ...gure Special tool No 8000B6787 1 Raise the rear part of the motorcycle until the full extension of the rear shock absorber is reached Contemporaneously measure the distance X1 between the upper extrem...

Page 311: ...adjustment of the motorcy cle set up it is necessary to adjust the tension of the chain Check also the orientation of the front headlight and if necessary effectuate the necessary adjustments Both the...

Page 312: ...wing tolerances Ovalization and maximum eccentricity must not exceed 0 5 mm Flatness must not exceed 0 5 mm When effectuating balancing on certain makes of tyres it is necessary to refer to the yellow...

Page 313: ...auge and check the following tolerances Ovalization and maximum eccentricity must not exceed 0 5 mm Special tool No 8000A1953 Place the dial gauge as shown in the figure and check the flatness Flatnes...

Page 314: ...certain makes of tyres it is necessary to refer to the yellow mark 1 present on the side of the tyre as shown in the figure It indicates the lightest point of balancing and must be situated close to t...

Page 315: ...Frame 1 G SECTION G Revision 0...

Page 316: ...DISCONNECTING THE HORN PAGE 19 THROTTLE BODY REMOVAL PAGE 19 REMOVING THE SEAT LOCK PAGE 23 REMOVING THE MAIN CABLING PAGE 24 REMOVING CLUTCH CONTROL TRANSMISSION PAGE 27 FRAME REMOVAL FROM THE ENGIN...

Page 317: ...ure Disconnect the negative pole of the battery When removing the battery it is necessary to remove the negative pole cable first and then the positive pole cable When reassembling proceed in the reve...

Page 318: ...4 Frame G Remove the battery from its compartment Disconnect the positive pole of the battery...

Page 319: ...Frame 5 G FOOT PEG REMOVAL Act on the 2 screws 1 of both foot peg mountings and remove them On the right foot peg also remove the silencer clamping screw 2 1 2...

Page 320: ...XHAUST SILENCER DISASSEMBLY Remove the clamping screw 1 on the left side Remove the socket head screw 2 on the right side 1 Slide the silencer unit out from the exhausts towards the rear part of the m...

Page 321: ...Proceed as described below for exhaust manifold replacement Disassemble the water radiator and oil radiator before hand as described in chapter L Cooling system Slide off the Lambda probe connector 1...

Page 322: ...head Apply sufficiently adequate wadding to the exhaust ports to stop the entry of dirt and dust into the cylin ders If the engine has to be removed from the frame it will be necessary to remove the...

Page 323: ...g stands Code 8000B9312 Rear stand Code 800095807 Front stand Code 8000B7340 Front stand pin Code 8000B6789 Engine support Remove the following components in order Front mudguard Front brake callipers...

Page 324: ...as semble the frame Slide the control unit complete with rubber support from the battery holder seat Disconnect the two connections acting on the safety flaps with a flat screwdriver Turn the bayonet...

Page 325: ...Frame 11 G Remove the control unit from the motorcycle If the battery has not yet been removed do so as described in the Maintenance chapter...

Page 326: ...Remove the central screw 2 12 Frame G BATTERY BOX REMOVAL Remove the two lateral screws 1 1 2 Remove the four relays 3 3...

Page 327: ...Frame 13 G Remove the battery box GLOVE COMPARTMENT REMOVAL Remove the glove compartment fixing screw 1 Slide the glove compartment 2 from the upper part 1 2...

Page 328: ...14 Frame G REMOVAL OF IGNITION SWITCH Remove the two M6 screws fixed with Loctite 1 Remove the three rubber band fasteners 2 Disconnect the connector 3 1 1 2 3...

Page 329: ...Frame 15 G Cut the safety band fastener on the temperature sen sor 4 Remove the complete ignition switch 5 4 5...

Page 330: ...PANSION TANK REMOVAL Remove the three fixing screws 1 of the expansion tank Push the expansion tank out of the frame and remove it from the vehicle 1 Remove the four rubber band fasteners of the vent...

Page 331: ...Frame 17 G Pull the vent pipe from the upper part of the frame Remove the click band fastener 3 on the pipe from the radiator cap to the radiator 3 Remove the pipe from the radiator...

Page 332: ...18 Frame G Slide the pipe out from inside the frame Slide the pipe and the expansion vessel out from the upper part of the motorcycle Empty the liquid from the expansion vessel completely into a basin...

Page 333: ...ame 19 G DISCONNECTING THE HORN Disconnect the 2 connectors 1 from the horn 1 THROTTLE BODY REMOVAL Protect the frame by applying adhesive tape as shown in figure 1 Remove the 2 cable retaining clamps...

Page 334: ...20 Frame G Disconnect the pressure sensor 2 2 Disconnect the 3 injector connectors 4 4 Remove the safety band fastener 3 3...

Page 335: ...me 21 G Remove the throttle body first lifting it from the left as shown in figure Disconnect the 6 clamping screws 5 of the throttle body to the intake flange 5 Disconnect the DBW control connection...

Page 336: ...ws of the throttle body at a tightening torque of 10 Nm respecting the tightening sequence shown in the figure Loosen the 6 fixing screws in the opposite order Tighten the 6 fixing screws of the throt...

Page 337: ...uts 1 fixing the lock support to the frame Slide the lock complete with support from inside the motorcycle 23 G To remove the nut at the bottom the starter cable nut with screw must also be disassembl...

Page 338: ...cabling it is necessary to discon nect all of the connections and remove all the rubber clamps Disconnect the three plug top connectors Disengage the yellow tab 1 Lift the black tab 2 At the same time...

Page 339: ...Frame 25 G Remove the engine rpm pick up Remove the current generator connection Remove the gear position sensor...

Page 340: ...26 Frame G Remove the engine coolant temperature sensor Remove the rear wheel speed sensor operation not essential Position all of the wiring on the small frame...

Page 341: ...Frame 27 G REMOVING CLUTCH CONTROL TRANSMISSION Loosen the nut on the clutch cable Unhook the transmission from the lever Unscrew the counter nut to free up the transmission from the plate...

Page 342: ...move the front screw 1 fixing the engine to the frame from the left side recovering the nut and spacer 2 from the right side 2 1 Unscrew and remove the upper screws fixing the frame to the plate from...

Page 343: ...Frame 29 G Take the engine clamping pin out from the left side of the frame Supporting the front part of the frame shift it towards the front Remove the frame from the engine by lifting...

Page 344: ...an thoroughly and check the housings of the steer ing bearings Make sure that none of the surfaces of the housings have signs of impact or dents Using a bore meter check circularity of the housing of...

Page 345: ...sta recommends the immediate replace ment of the frame not advising and in all cases not authorising any type of interven tion except repainting which implies as an example the straightening and or we...

Page 346: ...8 3 1 3 1 1 4 6 7 9 1 1 2 9 7 1 8 5 0 0 3 2 3 2 0 2 2 4 0 5 5 7 9 9 1 4 0 4 0 1 A B 0 5 0 5 X 0 5 X 0 5 X 1 5 1 5 2 9 5 8 0 8 0 1 9 3 6 5 1 5 5 P 7 2 4 0 3 2 0 5 5 P 7 Y 0 5 X 1 8 6 0 8 0 2 1 6 0 8 0...

Page 347: ...G Measure ovalisation in different points as shown in the diagram STEERING BEARINGS HOUSING CHECK Check the diameter and for any ovalisation on the stearing beerings as shown in the drawing here to t...

Page 348: ...particular the fairing attachment plates and threaded caps These components can be assembled on the new frame after having carried out a careful inspection Contact MV AGUSTA spare parts service for a...

Page 349: ...Frame 35 G Once the frame has been re installed re install the electrical cabling See Chapt E Electrical System regarding the posi tioning and passage of cables clamps and wiring...

Page 350: ...0 5 5 6 0 5 8000B7165 Front frame engine fixing screw M12x1 25 55 60 5 5 6 0 6 8000B2750 Upper frame engine fixing screw M12x1 25 55 60 5 5 6 0 7 8A00B2755 Plates fixing screw M10x1 25 45 50 4 5 5 0 8...

Page 351: ...Frame 37 G...

Page 352: ...f all the neces sary components described in the previous paragraph perform the following operations Remove all rubber band fasteners holding the wiring until the frame appears as in the photo Disconn...

Page 353: ...ONTACTOR AND FUSE BOX Remove the fixing screw 1 of the contactor protection 2 Remove the contactor protection 2 towards the rear part 1 2 2 Slide the double control unit out on the right side 3 interm...

Page 354: ...the saddle lock cable 1 onto the rear frame Unscrew and remove on both sides the two lower screws fixing the rear sub frame to the union plates taking care to recuperate the nuts Unscrew and remove t...

Page 355: ...out the operation of reassembling the rear sub frame on the motorcycle in the reverse order of removal taking care to tighten the fixing screws to the prescribed torque pressure Rear sub frame fixing...

Page 356: ...the plate fix ing screw from the left side Remove the lower screw fixing the plates to the engine from the left side ENGINE REMOVAL Cut the chain as described in chapter F Suspension and Wheels Remove...

Page 357: ...the engine Operating as shown in the figure loosen the lower screw fixing the plates to the rocker arm to widen the plates respect the engine Using a rubber mallet slightly widen the plates as shown...

Page 358: ...en the plates and engine one on each side and remove them by hand Insert a support to bear the plates Disconnect the gear rod 2 removing the screw of the gearshift transmission 3 Disassemble the chain...

Page 359: ...Frame 45 G Disconnect the rear wheel speed sensor connector 1 1 Disconnect the hydrostop sensor connector 2 2 Disconnect the number plate carrier group 3 connec tor 3...

Page 360: ...To re assemble the vehicle in an easy fashion do the following position the engine on tool 8000B6789 assemble the following parts 1 engine earth cable 2 electrical system protection 3 engine oil vapo...

Page 361: ...H 1 Brakes SECTION H Revision 0...

Page 362: ...RAKE CALIPERS SUBSTITUTION PAGE 11 FRONT BRAKE PUMP REMOVAL PAGE 12 FRONT BRAKE LEVER REMOVAL PAGE 17 FRONT BRAKE DISCS PAGE 18 FRONT BRAKE DISC REMOVAL PAGE 18 REAR BRAKE SYSTEM PAGE 20 REAR BRAKE PA...

Page 363: ...and discs mm 320 Disc flanges Steel Calipers pistons mm Radial type with 4 pistons 32 Front disc thickness mm 5 Min pad thickness mm 1 Brakes 3 H FRONT BRAKE SYSTEM A B C D E F G N m 8 10 16 18 42 46...

Page 364: ...NG FRONT MUDGUARD To facilitate replacement of the front brake pads remove the front mudguard as described in Chapter C Superstructures FRONT BRAKE PADS SUBSTITUTION Remove the safety catch 1 Loosen t...

Page 365: ...Brakes 5 H Remove the pads pin 2 Slide the safety plate out 3 Remove the two pads 4 2 3 4...

Page 366: ...ke Pad Wear limit 1 mm Brake Disc SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID Place the motorcycle on a horizontal surface with the steering in a straight line Protect the zone with a cloth Rem...

Page 367: ...the brake caliper Put the other end of the rubber tube in a suitable con tainer Pull the brake lever without releasing it Slacken the bleed valve and empty the brake system Tighten again the bleeding...

Page 368: ...d brake fluid from sealed containers NEVER use old or used brake fluid 8 Brakes H Tighten the bleed screw remove the rubber tube care fully clean the screw with alcohol blow it dry and put the protect...

Page 369: ...bed brake fluid from sealed containers NEVER use old or used brake fluid Top up the level of the fluid until it reaches the maxi mum mark upper Carefully clean around the edge of the brake fluid chamb...

Page 370: ...lements of the brake fluid chamber cap with alcohol and dry with compressed air Position and screw on the top brake fluid tank cap and tighten the two lateral fixing screws Use a clean cloth to clean...

Page 371: ...of brake fluid during subsequent operations Remove the sealing washer and replace them in the assembly phase with new one Remove the two caliper fixing screws indicated in the figure Unscrew the fitti...

Page 372: ...the first threads of the brake caliper fixing screw Refit the caliper connection after replacing the sealing washers Torque pressure caliper union 23 26 N m Fill the system with brake fluid Bleed the...

Page 373: ...Brakes 13 H Remove the three fixing screws 1 of the cover Remove the hand guard front fixing 2 Remove the two hand guard lateral fixing screws 3 1 1 1 2 3...

Page 374: ...14 Brakes H 4 Leave the hand guard hanging as indicated 4 Remove the two hand guard plate fixing screws 5 Remove the two clips of the front brake stop 6 5 6...

Page 375: ...Brakes Remove the hand guard fixing plate 7 15 H 7 Remove the pump bar clamp fixing screws 8 Open the bar clamp 9 and extract the pump 10 from the handlebar 8 10 9...

Page 376: ...rations avoid con tact with painted surfaces When reassembling pay attention to the position of the brake hose fitting and use two newly supplied washers Brake hose fitting torque pressure 16 18 N m T...

Page 377: ...ove the brake lever When reassembling take care to insert the lever into its seat Grease the pin Recommended grease Agip Grease 30 Insert the pin into the seat and screw it in until the beat is reache...

Page 378: ...ake down the front wheel as described in chapter F Suspensions and Wheels Place the wheel in a horizontal position and remove the five screws of each disc proceeding in a star like mode for the remova...

Page 379: ...le the discs in the original posi tions it is advisable to mark them by applying an adhe sive label This operation is important so that a good contact between the brake discs and the rel ative pads Pr...

Page 380: ...iscs mm 220 Caliper pistons mm With 2 pistons 34 Rear disc thickness mm 5 Min pads thickness mm 1 REAR BRAKE SYSTEM 20 Brakes H A B C D E F G H I N m 220 240 23 26 8 10 18 18 20 16 18 8 10 3 Kg m ft l...

Page 381: ...lising circlip pincers as shown in the figure widen the pads so that the pistons are pushed back into their seats The outward movement of the brake pads provocates the retraction of the pistons in the...

Page 382: ...well 2 Carry out the check every 6000 kilometres Check the condition of the rear braking system and its components Proceed with re assembly following the operations for disassembly in reverse order R...

Page 383: ...the exhaust tubes that could cause grave burns To perform this operation the tank must be removed 1 complete with support bracket 2 from the frame plate 2 1 Remove the rubber band fastener Open the co...

Page 384: ...to the bleed valve empty the system in an appropriate container by slackening the bleed valve as shown in the figure Be careful not to let the liquid fall below the minimum level before topping it up...

Page 385: ...clamps the supporting bracket to the plate of the frame Torque pressure 8 10 N m 8 10 N m 1 REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation remove the brake pads as described previously Em...

Page 386: ...mbly tighten the two screws to the prescribed torque pressure Recommended threadlocking product Loctite 243 Torque pressure 18 N m 18 N m Assemble the union tightening to the prescribed torque Torque...

Page 387: ...ke pump removal Loosen the two fixing screws 1 of the front right foot peg support 2 Loosen the exhaust foot peg support fixing screw 3 3 1 2 Loosen the two M6 screws 4 that hold the foot peg support...

Page 388: ...ion 6 as shown in the figure so as to disengage the pump from the brake line 6 Disassemble the clips complete with pin 5 Loosen the retaining clamp 7 sliding it off the work zone upward and slip off t...

Page 389: ...s Tighten the fixings to the prescribed torque pressure Torque pressure pump union 16 18 N m Conclude the operations by filling the system with brake fluid and successively bleeding the system see pag...

Page 390: ...rity value must not exceed 0 3 mm Utilise a micrometer gauge with support to carry out this check Remove the four nuts fastening the disc to the flange REAR BRAKE DISC REMOVAL Before proceeding with t...

Page 391: ...Conclude the reassembly operations of the various components by following the procedures previously described in the chapter 18 20 N m Use the following tightening torque to reassemble the phonic whe...

Page 392: ...32 Brakes H...

Page 393: ...L 1 Cooling system SECTION L Revision 0...

Page 394: ...R RADIATOR DISASSEMBLY PAGE 9 WATER RADIATOR COMPONENT DISASSEMBLY PAGE 15 WATER RADIATOR GROUP ASSEMBLY PAGE 20 THERMOSTATIC VALVE REMOVAL PAGE 22 THERMOSTATIC VALVE ASSEMBLY PAGE 24 WATER RADIATOR V...

Page 395: ...the cooling system carry out cer tain preliminary operations 1 Let the engine cool down 2 Remove the side fairings the underfairing the fairings push rod the headlight fairing the suction duct covers...

Page 396: ...ure of approximately 120 kPa 1 2 kg cm2 and check that the system maintains the pres sure for at least 10 seconds If the pressure diminishes within ten seconds means that there is a leak in the system...

Page 397: ...wly cre ate a pressure by activating the tester Make sure that the increase in pressure is interrupted at 110 15 kPa 1 1 0 15 kg cm2 and check that with the tester held steady the pressure is maintain...

Page 398: ...e the radiator plug Cooling system L 6 Tilting the motorcycle 30 on its right side let the liq uid flow out paying attention to where it pours Using a funnel and tilting the motorcycle further have al...

Page 399: ...ING EXPANSION TANK After having emptied the cooling system as described in the previous paragraph in order to remove the expansion tank you must first remove the seat the tank panels the fuel tank the...

Page 400: ...ary Remove the expansion tank from the vehicle Cooling system Operating on the right side of the vehicle remove the CLIC R 66 100 clamp connecting the water radiator vent hose to the expansion tank us...

Page 401: ...After having emptied the cooling system proceed as follows to remove the radiator 1 Remove the right and left radiator side panels removing the three M4 screws 1 and the three M5 screws 2 with collar...

Page 402: ...ft side of the vehicle remove the sleeve clamp of the hose from the radiator to the pump using the special pliers CLIC R 205 Special CLIC R 205 pliers tool 5 Slip the hose from the sleeve leaving a co...

Page 403: ...ght side of the vehicle disconnect the sleeve clamp of the hose from the radiator to the head using the special pliers CLIC R 205 and pull the hose off Special CLIC R 205 pliers tool 7 Remove the thre...

Page 404: ...aced on the right side of the vehicle 8 Release the water radiator from the frame by remov ing the two special screws positioned on the left and right side of the vehicle 9 At this point the water rad...

Page 405: ...he water radiator 11 Disengage the water radiator from the oil radiator releasing it from the seat of the pin located on the oil radiator pushing the water radiator from right to left 12 Remove the wa...

Page 406: ...Cooling system L 14 13 The vehicle remains in the conditions shown in the figure to the side with the oil radiator suspended on the engine pipes...

Page 407: ...ADIATOR PARTS Disassembly of the electric fan Remove the 2 screws that clamp the conveyor to the radiator Lift the conveyor and slide it from the retaining pins Turn the conveyor by 180 and unscrew th...

Page 408: ...Cooling system L 16 Disassembly of the radiator clamping elements Slide off the 2 threaded circlips Remove the fan...

Page 409: ...Cooling system 17 L Pull the spacer from the lower support bracket Remove the silent block from the lower fixing bracket Remove the 2 silent blocks from the fan conveyor bracket...

Page 410: ...of the 2 top sup porting brackets Disassembly of the liquid temperature sensor Whenever it is necessary to check whether the liquid temperature sensor is operating efficiently proceed as described bel...

Page 411: ...he oil so as to slowly increase the temperature and observe the readings provided by the thermome ter and ohmmeter If the resistance of the coolant liquid temperature sensor does not change as indicte...

Page 412: ...tion of all components and all connec tions Radiator check and clean The dirt and extraneous material embedded in the radi ators must be removed It is recommended to use compressed air for the clean i...

Page 413: ...hten the 2 screws to the prescribed tightening torque Torque pressure 5 6 N m Replace the previously removed components following the disassembly procedures inversely 5 6 N m The assembly of the new r...

Page 414: ...Cooling system L 22 THERMOSTAT REMOVAL Remove the 2 fixing screws of the thermostat cover Remove the cover of the thermostat 1 Remove the thermostat 2 2 1...

Page 415: ...ease in temperature of the thermometer Observe the temperature at the moment of opening of the thermostat The temperature at which the thermo stat commences to open should be between the indi cated va...

Page 416: ...substi tute it with a new one Apply a thin layer of silicone grease Recommended grease Silicone Grease Apply grease on the outer flange of the thermostatic valve on the inlet side of the engine Insert...

Page 417: ...the thermostat cover on the engine Tighten the 2 fixing screws to the prescribed torque pressure Torque pressure 8 N m 8 N m WATER RADIATOR VEHICLE UNIT ASSEMBLY Reassemble the radiator unit in the op...

Page 418: ...sassembled as well To avoid oil leakage during disassembly lift the motor cycle with specific tools Specific tool front stand 800095807 Specific tool pin 8000B7340 Specific tool rear stand 8000B9312 P...

Page 419: ...ct the vent pipe band fastener radiator side Remove the three fixing screws TORX TX 27 of the hose support plate and pull it downwards Pull off the connection pipes from the engine block one at a time...

Page 420: ...Cooling system L 28 Remove the oil radiator Check the integrity of the component and if needed straighten the bent fins using a screwdriver or tweezer...

Page 421: ...e connecting pipes Take the retaining screw off of the plate Slide the pipe out making sure not to ruin the O Rings Do the same with the other one Removal of spacers and silent blocks Pull the two spa...

Page 422: ...bled Grease O rings with silicone grease Proceed to re assemble the previously removed parts following the disassembly instructions described below being careful not to put the pipes in backwards conf...

Page 423: ...of the supply and return radia tor hose retaining plate but do not tighten them Insert the supply and return pipes in their housing on the motor block Position the hose support plate and insert the t...

Page 424: ...wait for the oil radia tor to be mounted on the water radiator in order to pro vide the right orientation at the oil tubes If the hoses are not deformed in this position tighten the screws in the fol...

Page 425: ...em 33 L One screw is placed on the right side of the vehicle tighten the three fixing screws of the hose support plate tighten the two screws fixing the supply and return pipe retaining plate to the o...

Page 426: ...the quantity of items consult the parts catalogue When you have finished tightening the unit make sure the hoses respect the orientation shown in the figure ATTENTION The oil hoses must be the right d...

Page 427: ...e radiator cap into the highest position to facilitate the escape of the air Close the cap and bring the motorcycle back to a ver tical position on the central stand Fill the expansion tank up to the...

Page 428: ...m aged pipes etc in the cooling system If nec essary overhaul the system following the steps described in this chapter Check the coolant liquid level inside the expansion tank again It must be above t...

Page 429: ...the required quantity of oil Make sure that the oil level is between the MIN and MAX level markings on the fill cap control rod Before replacing the filler plug grease O ring 1 with silicone grease th...

Page 430: ...ground is flat and keep the motorcycle standing as much as possible The level must be near the MAX reference on the tim ing case as much as possible Do not exceed this limit Check any oil leakages Av...

Page 431: ...Special tools 1 M SECTION M Revision 0...

Page 432: ...2 MAINTENANCE TOOLS The special tools shown in the following chapter are indispensable for a correct carrying out of the described maintenance operations To order the special tools refer to the spare...

Page 433: ...bearings puller 7 8000B9312 1 Cavalletto posteriore Rear stand 8 8000A1953 1 Perno per albero Pin for centering di centraggio shaft 9 800092865 1 Attr bilanciamento Rear wheel ruota posteriore balanci...

Page 434: ...Special tools M 4...

Page 435: ...lletto anteriore Front stand 7 8000B7340 1 Perno cavalletto Front stand pin anteriore 8 8000B6779 1 Attrezzo cuscinetto Steering pin perno di sterzo bearing tool 9 8000B6780 1 Piastra di riscontro Ste...

Page 436: ...Special tools M 6...

Page 437: ...ubber caps gommini valvola removal tool 10 62N115538 1 Rosetta elastica Spring washer 11 8C0069056 3 Vite M8x30 Screw M8x30 12 8000B6789 1 Supporto Engine removal smontaggio installation montaggio mot...

Page 438: ...Special tools M 8...

Page 439: ...1 Tightening torques N SECTION N Revision 0...

Page 440: ...2 Tightening torques N...

Page 441: ...Tightening torques 3 N...

Page 442: ...4 Tightening torques N...

Page 443: ...Diagnostic 1 O SECTION O Revision 0...

Page 444: ...ch switch connection Deoxidize Repair Fall detection sensor failure Replace Faulty fall detection sensor connection Deoxidize Repair Side stand switch failure Replace Faulty side stand switch connecti...

Page 445: ...for faults relative to the speed sensor Replace indicated on the dashboard ECU failure Replace Faulty ECU connection Deoxidize Repair SPEED LIMITER Check whether it is enabled from the dedicated dashb...

Page 446: ...re Replace Faulty ECU connection Deoxidize Repair Error messages See diagnostic messages Page management not possible Handlebar controls left side broken Replace Faulty accident control connection Deo...

Page 447: ...sor connection Deoxidize Repair Radiator coolant temperature sensor broken Replace Faulty ECU connection Deoxidize Repair ECU failure Replace Problem with the electrical system Repair Replace THROTTLE...

Page 448: ...failure Replace DBW Faulty throttle body connection Deoxidize Repair Throttle body sensors failures Change throttle body Throttle body locked Repair Replace Problem with the electrical system Repair R...

Page 449: ...ing nut overtightened Use prescribed torque FRONT SUSPENSION Front suspension soft Fork oil deteriorated Renew Spring preload low Adjust Fork oil level low Top up Tyre pressure low Adjust Fork damaged...

Page 450: ...e Brake discs distorted Replace Caliper pistons do not slide freely Check Brake fluid level too high Adjust Brake pads worn down Replace EXHAUST SYSTEM Exhaust noise excessive Exhaust pipe damaged Rep...

Page 451: ...Analytical index 1 P SECTION P Revision 0...

Page 452: ...ion B 3 Transmission chain B 43 Tube fastening bands B 51 Tubes Fuel fittings B 26 Tyres B 46 Valve mechanism adjustment B 15 Wheels B 47 Warning lights and instrumentation B 54 Section C Bodywork Fai...

Page 453: ...Timing wheel gap E 28 Turn indicators E 33 Section F Suspension and wheels Chain removal F 40 Front forks F 10 Front wheel F 3 Motorcycle set up adjustment F 66 Rear suspension and swingarm F 31 Rear...

Page 454: ...il system filling L 37 Oil radiator assembly L 30 Oil radiator component disassembly L 29 Oil radiator disassembly L 26 Removing expansion tank L 7 System function verification L 30 Thermostatic valve...

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