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service station manual dorsoduro factory abs

1. Undo and remove the top bolt on the headstock Screw the fixing screws of the upper plate SUSP 302 DORSODURO FACTORY ABS Suspensions Undo and remove the two screws fixing the instrument panel support to the fork upper plate Slide off the fork upper plate by moving it towards the instrument panel Get the suitable tool for the tightening of the ring nut Carry out the following operations carry out a first tightening of the ring nut to the indicated tightening torque for the settlement of the steering package turn the steering completely from both sides for several times Loosen the ring nut completely carry out the final tightening of the ring nut to the indicated tightening torque Specific tooling 020884Y 46 mm wrench for steering ring nut STEERING RING NUT Description Type Torque Notes um Headstock ring nut pre tightening M25x1 30 Nm 22 13 Ib ft Steering package settlement Headstock ring nut tightening M25x1 12 Nm 8 85 Ib ft Fit the entire fork upper plate adjusting with short taps with a rubber hammer e Scatter the nut thread with the specific product and pre fit it to the indicated tightening torque Recommended products LOCTITE 243 Loctite adhesive to assemble cylindrical pieces Loctite adhesive to assemble cylindrical pieces SUSP 303 Suspensions DORSODURO FACTORY ABS Tighten the fixing screws of the
2. Lambda Speed sensor Bo Engine Ground a Pressure Switch e D y e ia cn S C Y CLE Engine Start 5 4 Stater Relay 2 Fuel X mj pump L2 s Dros Sensar Positive Battery i i Main Fuse 1T 7 m Rear Lamp P L ED Starter Relay 1 StaderRelsy 4 ii Diag Dashacard Diag CHAR 33 Characteristics DORSODURO FACTORY ABS ELECTRICAL SYSTEM 2 pos Description Type Quantity Torque Notes 1 Screw fastening ECU to filter box 4 2 5 Nm 1 47 Ibf ft base Starter relay fastener 2 3 4 2 Nm 2 21 3 1 Ibf ft LOCKS pos Description Type Quantity Torque Notes 1 TCEI screw M8x40 1 25 Nm 18 44 Ibf ft 2 Switch fastener shear head 1 Manual screw 3 TE screw fastening saddle lock bat M6x25 2 10 Nm 7 37 Ibf ft tery compartment to saddle mount ing CHAR 34 DORSODURO FACTORY ABS Characteristics A2 THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake union fastener screw M6 8 12 Nm 8 85 Ib ft Loctite 242 2 RBW control unit fastener screw M5 2 3 50 Nm 2 58 Ibf ft Loctite 242 3 Injector fastener screw M6 2 12 Nm 8 85 Ib ft Loctite 242 4 Injection Throttle Body fastener M6 8 12 Nm 8 85 Ib ft Loctite 242 screw Back side CHAR 35 Characteristics DORSODURO FACTORY ABS SADDLE MOUNTING
3. Lubricate the threads before tight ening 26 Nm 19 18 Ibf ft 3 50 Nm 2 58 Ibf ft Loctite 243 Loctite 243 CHAR 44 DORSODURO FACTORY ABS Characteristics pos Description Chain tensioner fastener screw Cylinder plate fastener screw Chain tensioner adjustment screw CYLINDER Type Quantity M6 4 M6 4 M6 2 Torque 13 Nm 9 59 Ib ft 7 84 9 81 Nm 5 78 7 23 lb ft 5 50 Nm 4 06 Ib ft Notes CHAR 45 Characteristics DORSODURO FACTORY ABS TIMING SYSTEM pos Description Type Quantity Torque Notes 1 Camshaft gear fastener nut pre M15x1 4 30 Nm 22 13 Ibf ft tightening 1 Camshaft gear fastener nut tighten M15x1 4 90 Nm 66 38 Ibf ft ing 2 Timing drive gear fastener screw M24x1 5 2 40 Nm 29 50 Ibf ft 3M SCOTCH GRIP 2353 3 Special screw for fastening mobile M8 4 19 Nm 14 01 Ibf ft Loctite 242 fixed shoes CHAR 46 DORSODURO FACTORY ABS pos Description 4 Cam tower head fastener screws pre tightening 4 Cam tower head fastener screws tightening 4 Viti fissaggio castelletto testa ser raggio 5 Camshaft retainer plate fastener screw Type M6 M6 Torx torx M3 Quantity 16 16 16 8 Torque 4 90 6 86 Nm 3 61 5 06 Ibf ft 9 81 12 75 Nm 7 24 9 40 Ibf ft 12 14 Nm 8 85 10 32 Ibf ft 3 Nm 2 21 Ibf ft Characteristics Notes Loctite 270
4. Insert the spring guide and lock it by the appropriate seeger Place the fork vertically e Insert the washer SUSP 295 Suspensions DORSODURO FACTORY ABS Refill the fork with oil according to the prescribed quantity Fit the spring CAUTION BE CAREFUL WHEN INSERTING THE SPRING SINCE THE COMPRESSED SPIRAL PART MUST BE PLACED DOWN WARDS See also Filling oil Insert the washer that will be supported on the spring Insert and hand tighten the nut on the pumping member pin Place the preload pipe Tighten the appropriate tool on the pumping member pin rod and keep it raised to allow inserting a wrench in the nut by compressing the spring Specific tooling 020890Y Pumping member stanchion support rod AP8140147 Spacer tool SUSP 296 DORSODURO FACTORY ABS Suspensions Tighten the nut as much as possible Insert the cover and tighten until it stops Remove the specific tools e Screw the cover in the sleeve to the prescribed torque Filling oil Place the sleeve upright in a vice fitted with protection shoes e Compress the sleeve in the stem Place a support under the stem in order to leave it com pressed Pour part of the fork oil into the sleeve Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the rim THE SLEEVE
5. DORSODURO FACTORY ABS Suspensions Replace the following components with new ones seal ring dust gaiter O Ring on the cap Reassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape e Lubricate the sliding edges with fork oil 5 or sealing grease Fit the dust gaiter the retainer ring and ra bd Tet ar 1 AM inset ua Er ir 675 AM the dust scraper on the stem fet SUSP 293 Suspensions DORSODURO FACTORY ABS Fit the ring the movable bushing and after removing the tape fit the fixed bushing e Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Oil seal fitting tool for 43 mm 1 69 in orifices AP8140146 Weight Insert the retainer ring in its position SUSP 294 DORSODURO FACTORY ABS Suspensions Fit the dust gaiter with the specific tool Specific tooling AP8140189 Oil seal fitting tool for 43 mm 1 69 in orifices AP8140146 Weight Insert the pumping member pin in the stem Using a hook spanner lock the pump ing member pin and tighten the fixing screw on the fork end to the prescribed torque Specific tooling 020889Y Pumping member ring nut locking spanner
6. M Separate the cylinder from the head M Collect the gasket See also Removing the cylinder Cylinder head to water cooler HEAD pos Description Type Quantity Torque Notes 1 Water Temperature Sensor M12x1 5 1 23 Nm 16 96 Ibf ft 2 Threaded plug for water sensor seat M12x1 5 1 10 Nm 7 38 Ibf ft Loctite Drise AL 506 3 Head stud bolt fastener nut pre M10x1 25 8 10 Nm 7 38 Ibf ft Lubricate the tightening threads before tight ening 3 Head stud bolt fastener nut tighten M10x1 25 8 13 Nm 9 59 Ibf ft 90 Lubricate the ing 90 threads before tight ening 4 Fastener for Head Cylinder Outer M6 2 13 Nm 9 59 Ibf ft side crankcase 5 Fastener for Head Cylinder Inner M6 4 12 Nm 8 85 Ibf ft side crankcase 6 Nut fastening Stud Bolts Head M6 4 12 Nm 8 85 Ibf ft ENG 217 Engine DORSODURO FACTORY ABS pos Description Type Quantity Torque Notes 7 Nut fastening Stud Bolts Head M8 2 26 Nm 19 18 Ibf ft 8 Bleed union fastener screw M5 4 6 5 Nm 4 79 Ibf ft 9 Water bleed union steel 1 3 50 Nm 2 58 Ibf ft Loctite 243 10 Water bleed union brass 2 2 Nm 1 48 Ibf ft Loctite 243 Removing the overhead camshaft Remove the clutch side crankcase half Rotate the crankshaft until the rear cyl inder reaches the TDC First remove the rear head cover in order to re move the rear head camshafts First remove the front head c
7. Quantity 1 TCElscrew fastening filler cap flange M5x16 n 3 Nm 2 21 Ibf ft SS Torque 10 Nm 7 37 lbf ft Notes CHAR 30 DORSODURO FACTORY ABS Characteristics FUEL PUMP pos Description Type Quantity Torque Notes 1 TEFL screw fastening fuel pump M5x16 6 6 Nm 4 42 Ibf ft AIR FILTER BOX pos Description Type Quantity Torque Notes 1 Cross head self tapping screw fas M5x20 10 3 Nm 2 21 Ibf ft tening separator filter box CHAR 31 Characteristics DORSODURO FACTORY ABS pos Description Type Quantity Torque Notes 2 SWP self tapping screw M2 9x12 TCCR 2 3 Nm 2 21 Ibf ft 3 Cross head self tapping screw fas M5x20 8 3 Nm 2 21 Ibf ft tening cover filter box 4 Cross head self tapping screw fas M5x20 3 3 Nm 2 21 Ibf ft tening lateral cap filter box Cross head self tapping screw M5x10 2 3 Nm 2 21 Ibf ft ENGINE pos Description Type Quantity Torque Notes 1 Flanged TE screw fastening pinion M10x1 25x25 1 50 Nm 36 88 Ibf ft Loctite 270 2 TCEI screw fastening Pin to gearbox M6x16 2 10 Nm 7 37 Ibf ft lever and Gearbox Lever to knurled shaft 3 LH lock nut for ball joint M6 1 10 Nm 7 37 Ibf ft 4 RH lock nut for ball joint M6 1 10 Nm 7 37 Ibf ft 5 Screw fastening engine bracket M6 2 12 Nm 8 85 Ibf ft clutch side crankcase half 6 Map sensor union brass 2 2 Nm 1 48 Ibf ft Loctite 243 6 Map sensor union ste
8. ln m a er x Pye Engine Start a starter Relay 2 Fuel pump Ns o Dros Sensar Postve Battery Main Fuse E RearLamp M RED P Starter Relay 1 StarerRelsy Diag Dashboard Diag DORSODURO FACTORY ABS pos Description Screw fastening ECU to filter box base Starter relay fastener Type ELECTRICAL SYSTEM 2 Quantity 4 2 Torque 2 5 Nm 1 47 Ibf ft 3 4 2 Nm 2 21 3 1 Ibf ft Electrical system Notes Components arrangement Key ELE SYS 93 Electrical system DORSODURO FACTORY ABS fall sensor Intake air pressure sensor Intake air temperature sensor Instrument panel Engine control unit Headlamp Start up relay Front ABS sensor CO N O oOo A W N Starter motor 10 Engine revolution sensor 11 Lambda probe 12 Rear ABS sensor 13 Coils 14 Main fuses 15 Hand grip position sensor 16 Main injection relay 17 Throttle control unit 18 Spark plugs 19 Taillight 20 Engine revolution sensor pick up 21 Gear in neutral sensor 22 ABS control unit modulator 23 Engine temperature sensor 24 Secondary fuses CAUTION A RELAY CANNOT BE IDENTIFIED BASED ONLY ON THE FOLLOWING INDICATIONS THIS SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE LIGHT LOGIC RELAY Location on the wiring diagram 7 Location on the vehicle under the
9. the under analysis or standby statuses may be displayed NAVIGATOR ACTIVATION NAVIGATOR ELECTRICAL ERRORS CAUTION IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT CIRCUITED OR NO ERROR IS DIS PLAYED CHECK THE ENGINE SPEED SENSOR CONNECTOR AND THE MARELLI CONTROL UNIT CONNECTOR IF NOT OK RESTORE IF OK CHECK THE SENSOR ELECTRIC CHARAC TERISTIC IS THE CORRECT ONE IF IT IS NOT REPLACE THE SENSOR IF IT IS THE CORRECT ONE CHECK THAT THERE IS CONTINUITY ON BOTH CABLES SUPPLY INSULATION AND GROUND CONNECTION INSULATION CARRY OUT THE TESTS FROM THE SENSOR CONNEC TOR TO THE SENSOR IF NOT OK RESTORE THE CABLE HARNESS REPLACE THE SENSOR IF OK PERFORM THE TEST FROM PINS 9 AND 23 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR NAVIGATOR LOGIC ERRORS Engine speed sensor P0336 Synchronism lost Error cause Displayed if the signal is not as the control unit expects for example due to voltage fluctu ations not correctly repeated Troubleshooting Check that the flywheel teeth are clean and the sensor is adequately placed in its fitting if not OK restore if OK replace the sensor ELE SYS 130 DORSODURO FACTORY ABS Electrical system Twistgrip position sensor THROTTLE GRIP POSITION SENSOR Function The throttle grip is the part to which the throttle control cables arrive its task is to translate the rider s power request Demand into an electrical signal to be sent to the electronic control unit Operatio
10. 205 Engine DORSODURO FACTORY ABS Removing the clutch cover CLUTCH COVER pos Description Type Quantity Torque Notes 1 Fastener screw for Clutch Cover M6 4 13 Nm 9 59 Ibf ft Clutch side cover 2 Clutch fastener nut M24x1 5 1 180 Nm 132 76 Ibf ft Chamfer 5 3 Fastening oil filler plug on Clutch cov 1 2 Nm 1 48 Ibf ft er 4 Screw fastening fixing Plate Clutch M5 3 5 50 Nm 4 06 Ibf ft control Mounting 5 Screw fastening clutch control M6 2 13 Nm 9 59 Ibf ft mounting on flywheel side crankcase half 6 Clutch Cover Clutch side Cover M6x55 2 10 Nm 7 38 Ibf ft TCEI fixing screw inox protection Undo and remove the perimeter fas tener screws Remove the protection plate and the clutch cover and collect the spacers ENG 206 DORSODURO FACTORY ABS Engine Removing the clutch cover alone is only recom mended when replacing the clutch plates When removing the entire clutch assembly removing the clutch side crankcase is recommended However removing the entire clutch assembly is possible by removing the clutch cover alone In this case proceed as follows measure the projection of the clutch housing from the crankcase before dis assembling when refitting check that the projection has not changed before tightening the clutch nut If the projection has changed rotate the crankshaft to cor rectly engage the engine oil pump drive gear on the
11. DORSODURO FACTORY ABS Pre delivery Response to throttle control Stability when accelerating and braking Front and rear brake efficiency Front and rear suspension efficiency Abnormal noise Static test Static check after test drive Restarting when warmed up Starter operation if present Minimum holding turning the handlebar Uniform turning of the steering Possible leaks Radiator electric fan operation if present Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE PRE DE 395 Pre delivery DORSODURO FACTORY ABS Specific operations for the vehicle LEFT Remove the left side chain protection e Fita left bracket and a left chain pro E WEE tection fasten then with a TEFL M8x35 gt he mm screw at the top and with a TCEI M8x35 mm screw at the bottom NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE THE SPECIFIC WRENCH WARNING OPERATION
12. Throttle control unit THROTTLE CONTROL UNIT Function lt receives the throttles target position from the Marelli control unit and it moves them so that they reach that target by reading their position through the potentiometers 2 per throttle body Level in wiring diagram throttle control unit Location on the vehicle inside the filter casing connector on the control unit Pin out see the CONNECTORS section See also Throttle control unit Connectors ECU ELE SYS 171 Electrical system CO CO CO CO GPO co CO CO Ni B GO S O 00 H OD B GO PO O CO 00 H OS AI BY GO PO 40 41 42 43 44 45 NOTE DORSODURO FACTORY ABS MARELLI CONTROL UNIT PIN OUT Specification Key switch Revolution sensor input Revolution sensor input Vehicle speed input Throttle grip input Track A Throttle grip input Track B Throttle grip input Track C Throttle grip input Track D Front cylinder intake pressure sensor input Rear cylinder intake pressure sensor input Water temperature sensor input Side stand input start engine input Clutch sensor input Fall sensor input Gear neutral input Start up control output Serial line K for diagnosis Auxiliary injection relay control output Front coil control output Hear coil control output Front injector control output Rear injector
13. aprilia SERVICE STATION MANUAL 898998 DORSODURO FACTORY ABS SERVICE STATION DORSODURO FACTORY ABS THE VALUE OF SERVICE As a result of continuous updates and specific technical training programmes for Aprilia products only Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out maintenance and repair operations correctly The reliability of the vehicle also depends on its mechanical conditions Checking the vehicle before riding it its regular maintenance and the use of original Aprilia spare parts only are essential factors For information on the nearest Official Dealer and or Service Centre consult our website www aprilia com Only by requesting aprilia original spare parts can you be sure of purchasing products that were developed and tested during the actual vehicle design stage All aprilia original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio amp C S p A reserves the right at any time and without being required to update this publication beforehand to make any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction re
14. lock nut Fit the special tool and fix it steadfastly to the crankcase by tightening the four fixing screws on the crankcase Tighten the crankshaft gear lock nut Specific tooling 020711Y Engine pinion locking Lubrication ENG 263 Engine DORSODURO FACTORY ABS Oil pump OiL PUMP pos Description Type Quantity Torque Notes 1 Oil drainage plug M16x1 5 1 19 Nm 14 01 Ibf ft 2 Fastening oil sensor on clutch side 1 13 Nm 9 59 Ibf ft crankcase half 3 Fastening oil filter union on clutch 1 20 Nm 14 75 Ibf ft side crankcase half 4 Oil filter 1 14 Nm 10 33 Ibf ft 5 Oil pressure regulator valve 3 4 Unf 16 1 43 Nm 31 72 Ibf ft 6 Oil pump fastener screw M6 2 5 50 Nm 4 06 Ibf ft Loctite 242 7 Hose pipe fastener screw 2 12 Nm 8 85 Ibf ft 8 Complete oil pump gear fastener 1 9 11 Nm 6 64 8 11 Ibf ft 9 Oil pump cover fastener screw M3 2 0 80 Nm 0 59 Ibf ft Removing OLD GENERATION PUMP REMOVAL Lock the pump gear with the commer cially available hook spanner and undo the screw then collect the washer ENG 264 DORSODURO FACTORY ABS Engine e Collect the shim washer Undo and remove the two screws fixing the oil pump Remove the entire pump NEW GENERATION PUMP REMOVAL ENG 265 Engine DORSODURO FACTORY ABS Press the raised side of the safety washer using a screwdriver Lock the pump gear with a commercial h
15. pos Description Type Quantity Torque Notes 1 Upper LH TCEI screw fastening sad M8x55 1 25 Nm 18 44 Ibf ft dle mounting to frame 2 Upper RH TCEI screw fastening sad M8x60 1 25 Nm 18 44 Ibf ft dle mounting to frame 3 Lower TCEI screw fastening Saddle M8x40 2 25 Nm 18 44 Ibf ft mounting to frame TCEI screw fastening passenger M8x80 4 30 Nm 22 13 Ibf ft grab handles to frame SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm Pin adjustment bushing 1 12 Nm 8 85 Ib ft 2 Swingarm pin ring nut 1 60 Nm 44 25 Ib ft 3 Swingarm pin nut 1 90 Nm 66 38 Ib ft 4 TPSI screw fastening rear stand M6x40 2 10 Nm 7 37 Ib ft bushing 5 TBEI screw fastening chain guard to M5x9 1 6 Nm 4 42 Ibf ft swingarm 6 TBEI screw fastening rear mudguard M5x9 2 6 Nm 4 42 Ibf ft Loctite 243 to swingarm 7 TBEI screw fastening chain guard to M5x9 1 4 Nm 2 95 Ibf ft rear mudguard 8 TBEI screw fastening chain guide to M5x9 2 6 Nm 4 42 Ibf ft swingarm Wheel axle nut M25x1 5 1 120 Nm 88 5 Ibf ft 10 Flanged TBEI screw fastening chain M5x9 2 4 Nm 2 95 Ibf ft Loctite 243 casing CHAR 36 DORSODURO FACTORY ABS Characteristics REAR SUSPENSION pos Description Type Quantity Torque Notes Upper TCE mounting screw M10x50 50 Nm 36 88 lbf f 2 Lower TCEI mounting screw M10x90 1 50 Nm 36 88 Ibf ft CHAR 37 Characteristics DORSODURO FACTORY ABS EXHAUST SYST
16. 237 Engine Specific tooling 020470Y Pin snap ring fitting tool Specific tooling 020470Y Pin snap ring fitting tool Fit a new retainer ring on the piston to fasten the gudgeon pin DORSODURO FACTORY ABS Fit the lower oil scraper ring on the pis m 4 ton with the gap turned towards the exhaust side Install the remaining piston rings on the piston offsetting the gaps in the rings by 90 relative to each other Fit a new retainer ring on the piston Fit the piston on the connecting rod and install the gudgeon pin Installing the cylinder Fit the stud bolts if previously removed CAUTION THE STUD BOLTS SHOULD BE FITTED SO THAT THEY PROTRUDE DISTRIBUTE Loctite 270 high strength ON THE THREAD AND SCREW THE STUD BOLT ON THE CRANKCASE UNTIL THEY PROTRUDE BY 137 mm 5 39 in THEN MAKE SURE THE Loctite HAS SET ENG 238 DORSODURO FACTORY ABS Engine Insert a new cylinder base gasket it should be as thick as the gasket previ ously removed 0 40 0 50 0 60 mm 0 0157 0 0197 0 0236 in The silicone side should be facing the crankcase CAUTION IF THE ORIGINAL GASKET THICKNESS CANNOT BE CHECKED OR SHOULD THE CYLINDER BE REPLACED REFER TO THE BASE GASKET SELECTION SECTION Before fitting the cylinder place the chain sliders and the timing chain on the crankshaft fit the timing chain on the crankshaft from the base side NOTE BEFORE FITTING THE CYLINDER
17. 9100896 Clutch housing locking tool Tighten the nut and proceed to caulk Insert the flat ring 1 Insert the cupped ring 2 CAUTION BE CAREFUL WITH THE CUPPED RING FITTING SIDE THE RING CONE SHALL BE DIRECTED TOWARDS THE ENGINE ENG 214 DORSODURO FACTORY ABS Engine Fit the lathed driven disc 3 Fit the nitrided steel disc 4 Fit the clutch plates Start with the fric tion material discs and alternate with steel discs Position all friction material discs with their teeth aligned in one of the long slots of the clutch housing e Place the control rod Place the thrust plate CAUTION ENSURE TO ALIGN THE ARROW ON THRUST PLATE WITH THE MACHINED REFERENCE ON HUB Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally Replace the gasket upon refitting Head and timing ENG 215 Engine DORSODURO FACTORY ABS Removing the head cover The operations described below are valid for both heads Unscrew and remove the four screws and collect the rubber rings Remove the head cover Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Remove the head cylinder unit Unscrew and remove the screw on the intake side Unscrew and remove the screws on the exhaust side ENG 216 DORSODURO FACTORY ABS Engine
18. Desc Quantity Gasket 0 4 mm 0 0157 in Gasket 0 5 mm 0 0197 in Gasket 0 6 mm 0 0236 in DORSODURO FACTORY ABS Engine Fit a new gasket between the cylinder and the head Couple the cylinder and the head M Screw without tightening the two screws on the outlet side Screw without tightening the screw on the intake side Tighten the cylinder head fixing screws to the prescribed torque Place the cylinder head unit on the crankcase stud bolts Installing the head cover CAUTION BEFORE REFITTING HEAD COVERS CLEAN HEAD AND COVER SURFACES CAREFULLY e Apply THREEBOND on the head cover 4 perimeter along the gasket housing ENG 243 Engine DORSODURO FACTORY ABS e Apply THREEBOND on the head in the areas indicated in the figure For the remaining operations follow the removal operations but in reverse order Crankcase crankshaft CRANKCASE 1 pos Description Type Quantity Torque Notes 1 Bearing retainer fastener screw M6 3 10 Nm 7 38 Ibf ft Loctite 270 2 Piston oil jet fastener screw M5 2 5 50 Nm 4 06 Ibf ft Loctite 242 3 Tapered plug for crankshaft main M8x1 4 15 Nm 11 06 Ibf ft bearing lubrication 4 Calibrated Brass dowel fixed to com M8 2 5 50 Nm 4 06 Ibf ft plete crankcase ENG 244 DORSODURO FACTORY ABS Engine CRANKCASE 2 pos Description Type Quantity Torque Notes 1 Engine speed sensor fixing screw M6 1 13 Nm
19. ENG 195 Engine DORSODURO FACTORY ABS GEAR SELECTOR pos Description Type Quantity Torque Notes 1 Gear retainer pawl fastener screw M6 1 12 Nm 8 85 Ibf ft 2 Selector plate fastener screw M5 3 5 50 Nm 4 06 Ibf ft 3 Screw fastening Desmodromic se M8 1 23 Nm 16 96 Ibf ft lector drum Selector sprocket 4 Gear sensor fastener screw M5 2 5 50 Nm 4 06 Ibf ft Loctite 243 5 Selector pin fastener onto clutch side M10x1 5 1 16 Nm 11 80 Ibf ft crankcase half 6 Tightening tone wheel on secondary M16x1 1 43 Nm 31 72 Ibf ft Loctite 270 gearbox Removing the gear selector To remove the gear selector refer to the operations described under Crankcase opening Checking the gear selector Selector spring Make sure that the spring ends on the two shifting positions forward downshifting and backward up shifting are always in contact with the selector plate Make sure that the clearance between the end of the spring on the selector plate and the stop pin is almost null when in home position see diagrams Pawl Make sure that both pawl tips run free without jamming Selector plate spring With a thickness gauge check that the spring is not deformed by over stretching ENG 196 DORSODURO FACTORY ABS Engine Gearbox Selector Shaft Removal Place the left hand crankcase in a press and extract the roller cage with the specific tool NOTE REPEAT THE SAME OPERATION FOR T
20. ENG 251 Engine DORSODURO FACTORY ABS Separate the crankcase halves by giv ing short taps with a rubber mallet Open the crankcase halves Retighten the two screws to the engine mounting ENG 252 DORSODURO FACTORY ABS Engine If necessary unscrew and remove the two screws fastening the rose pipe Remove the rose pipe See also Removing the cylinder Magneto flywheel removal Removing the crankshaft CRANKSHAFT pos Description Type Quantity Torque Notes 1 Crankshaft primary gear fastener nut M24x1 5 1 270 Nm 199 14 Ibf ft Anticlockwise nut 2 Connecting rod screw M10 4 15 30 Nm 11 06 Lubricate the 22 13 Ibf ft 50 2 threads before tight final control torque 65 ening 78 Nm 47 94 57 53 lbf ft ENG 253 Engine DORSODURO FACTORY ABS e Remove the crankshaft See also Splitting the crankcase halves Inspecting the crankcase halves BEARINGS AND OIL SEAL CHECK Thoroughly clean the two sections of the crankcase the ball bearings the threads of the crankcase fixing screws and the bearing seats with a non aggressive solvent Clean the seal surfaces and check that they are not damaged CAUTION TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE Check that both crankcase halves are not cracked or damaged Check that all threads are in proper conditions Check that all oil seals remaining in their po
21. N 0 75 30 R Bi 0 5 31 Az Gr 0 75 53 a s lj H ff EET 089 51001718 ELE SYS 173 Electrical system Throttle control unit 00 Ni GO PO co 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNEC TOR G Vi 1 4 Az Bi 1 1 G N 1 7 V BI 1 7 T TA R Gr 1 7 DORSODURO FACTORY ABS EFI THROTTLE CONTROL UNIT PIN OUT Specification 1A Front throttle motor control 2 CAN L 3A Voltage for front throttle potentiometers 5 V 4A Key input 5A Input for front throttle potentiometer 2 signal 6A Input for front throttle potentiometer 1 signal 7A Front throttle reset signal input 8A Rear throttle motor control 1B Battery power supply input 2B CAN H 3B Voltage for rear throttle potentiometers 5 V 4B Firmware reprogramming power supply 5B Input for rear throttle potentiometer 2 signal 6B Input for rear throttle potentiometer 1 signal 7B Rear throttle reset signal input 8B Battery power supply input 1C Front throttle motor control 2C Ground connection 3C Ground connection 4C Ground connection 5C Ground connection 6C Ground connection 7C Ground connection 8C Rear throttle motor control Bi N 0 5 1 Ro N 1 7 V R 1 1 ELE SY
22. RUSTY TERMINAL CONTACTS DEFECTIVE PROBE IF gt 1 1 THE PROBE READS RICH COMBUSTION CONDITIONS AND THE CONTROL UNIT RE DUCES INJECTION TIME CAUSES LITTLE AIR EXCESSIVE PETROL DEFECTIVE PROBE ELE SYS 147 Electrical system DORSODURO FACTORY ABS Injector INJECTOR Eunctian FRONT CYLINDER REAR CYLINDER To supply the correct amount of petrol at the right timing Operation Operating principle Injector coil is excited for the petrol passage to open Level in electrical circuit diagram Coils and in jectors Location e on the vehicle inside the filter box connector on injector Electrical characteristics e 14 8 Ohm 5 at 20 C 68 F Pin out 1 Supply 2 Ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Front cylinder injection time Rear cylinder injection time NAVIGATOR ACTIVATION Front injector The auxiliary injection relay No 40 in the wiring diagram placed under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the grey green cable of the injector is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be abl
23. Remove the fairing lug Release clamp 1 and disconnect con nector 2 By unscrewing the nuts remove and plug the brake oil pipes following this sequence 3 4 6 5 Slide off the rear system pipes from the hooks 7 Undo and remove the three screws collect the washers and remove the ABS modulator BRAK SYS 337 Braking system DORSODURO FACTORY ABS Rear brake calliper REAR BRAKE pos Description Type Quantity Torque Notes 1 Rear brake lever pin M6 1 25 Nm 18 44 Ibf ft 2 Flanged TE screw fastening pump to M6x20 2 10 Nm 7 37 Ibf ft footrest mounting 3 TBEI screw fastening oil pipe to M5x12 4 6 Nm 4 42 Ibf ft swingarm and rubber pipe to footrest mounting 4 Flanged self locking nut M6 1 10 Nm 7 37 Ibf ft 5 Screw nut fastening pedal to brake M6 1 1 10 Nm 7 37 Ibf ft lever 6 Brake pipe union M10x1 2 25 Nm 18 44 Ibf ft 1 Flanged TE screw fastening rear disc M8x20 5 30 Nm 22 13 Ibf ft Loctite 243 Flanged TE screw M6x16 1 10 Nm 7 37 Ibf ft BRAK SYS 338 DORSODURO FACTORY ABS Braking system Front brake calliper FRONT BRAKE pos Description Type Quantity Torque Notes 1 Union with breather fixing pipe to M10x1 2 25 Nm 18 44 Ibf ft callipers 2 TEFL screw Fixing calliper to fork M10x1 25 4 50 Nm 36 88 Ibf ft stems Fastener for brake pipe on steering M6x25 1 10 Nm 7 37 Ibf ft base
24. The throttle mechanical control may be damaged Troubleshooting Replace the throttle body RESET PROCEDURE If the Marelli control unit or the throttle body is replaced do not start the engine within the 3 seconds after the key is set to ON during this time the control unit carries out the throttle self learning process then make sure that the throttle self learning status reads carried out If the indication is Not carried out delete any possible errors present in the vehicle Carry out Throttle self learning process on the adjustable parameters screen page screwdriver and hammer and check again that the throttle self learning status reads carried out Engine oil pressure sensor ENGINE OIL PRESSURE SENSOR Function it indicates to the instrument panel if there is enough oil pressure 0 5 4 0 2 bar 7 25 2 9 PSI in the engine Operation Operating principle normally closed switch With oil pressure above 0 5 0 2 bar 7 25 2 9 PSI open circuit Location on the vehicle right side of the vehicle under the oil sump Pin out Voltage 5V ELE SYS 162 DORSODURO FACTORY ABS Instrument panel Error DSB 07 Error cause An oil sensor fault is signalled when with engine off it is detected that the sensor circuit is open The test is per formed only once when the key is set to ON There is an error when the gen eral warning light turns on Troubleshooting Check
25. WITH THE IGNITION OFF CHECK FOR VOLTAGE ON THE ORANGE RED WIRE OF THE MAIN INJECTION RELAY POLARISED 39 YES go to 6 NO go to 5 5 LOCATE THE INTERRUPTION IN THE ORANGE RED WIRE FROM THE MAIN IN JECTION RELAY POLARISED 39 TO BATTERY POSITIVE 6 WITH THE IGNITION ON CHECK FOR VOLTAGE ON THE GREEN BLACK WIRE OF THE MAIN INJECTION RELAY POLARISED 39 YES go to 8 NO go to 7 7 LOCATE THE GREEN BLACK WIRE FROM THE MAIN INJECTION RELAY POLAR ISED 39 TO THE IGNITION SWITCH END 8 15 THE BLUE CABLE GROUNDED YES go to 10 NO go to 9 9 RESTORE THE CABLE HARNESS 10 CHECK IF THERE IS VOLTAGE ON THE RED BLACK CABLE NOT OK go to 11 OK go to 12 TROUBL 85 Troubleshooting DORSODURO FACTORY ABS 11 REPLACE THE MAIN INJECTION RELAY POLARISED 39 END 12 CHECK FOR VOLTAGE ON THE ORANGE RED WIRE OF THE AUXILIARY INJEC TION RELAY 40 YES go to 13 NOT OK go to 14 13 CHECK IF THERE IS VOLTAGE ON THE YELLOW PURPLE CABLE OK go to 15 NOT OK go to 16 14 RESTORE THE CABLE HARNESS END 15 SET THE KEY TO OFF AND THEN ON DOES THE VOLTAGE ON THE YELLOW PURPLE CABLE REACH APPROX 1 2V FOR 2 SECONDS YES go to 17 NO go to 18 M 16 REPLACE THE AUXILIARY INJECTION RELAY 40 END 17 WITH THE IGNITION OFF CHECK THE RED BROWN WIRE FROM THE AUXILIARY INJECTION RELAY 40 TO THE FUEL PUMP CONNECTOR FOR CONTINUITY AND GROUND INSULATION YES go to 20 NO go
26. specific tool Specific tooling 020718Y Camshaft gear alignment pin ENG 228 DORSODURO FACTORY ABS Engine Using the specific jig check the correct position of the cams NOTE USE OF THE JIG THIS TOOL IS PLACED ON THE CAMS WITHOUT THE CAM TOWER USING THE PROFILE MARKED WITH THE NUMBER OF THE CYLINDER BEING USED WITH THE MARKINGS FACING THE FLYWHEEL SIDE NOTE THE JIG IS NOT A TOOL DESIGNED FOR TIMING BUT FOR IDENTIFYING THE CORRECT DIRECTION FOR CAM SHAFT FITTING THE SHAFTS MAY BE FITTED ROTATED BY 180 WITH REFERENCE TO THE CORRECT POSITION Specific tooling 020723Y Jig for timing overhead camshafts Place the cam tower Pre tighten the eight screws in the se quence indicated to the prescribed tor que Tighten the eight screws in the se quence indicated to the prescribed tor que Carry out camshaft timing with the ap propriate dowels Specific tooling 020719Y Timing pin Locking torques N m Cam tower head fixing screws M6 16 Pre tightening 4 90 6 86 Nm 3 61 5 06 Ib ft Tightening 9 81 12 75 Nm 7 24 9 40 Ib ft ENG 229 Engine DORSODURO FACTORY ABS CAUTION EN PAY ATTENTION TO THE SCREW FIXING TYPE OF THE VALVE CAM TOWER THREE DIFFERENT TYPES OF SCREWS CAN BE FOUND e HEXAGONAL HEAD WITH 8 MM 0 31 in SOCKET 1 e HEAD WITH TORX MARK 2 e FLANGED HEXAGONAL HEAD WITH 7 MM 0 27 in SOCKET 3 FOR THIS LA
27. this means that the alternator is defective and must be replaced ELE SYS 119 Electrical system DORSODURO FACTORY ABS RESISTANCE MEASUREMENT Winding stage Ambient temperature ohm Afterwards heat stabilisation ohm Stage 3 0 15 0 20 0 18 0 23 Empty voltage Disconnect the three way connector 1 For a correct detection of the alternator voltage a measurement must be carried out using alternatively the 3 engine side connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 Take the measurements If there is a significant difference between one stage and another other than 15 V this means that the alternator is defective and must be replaced CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4 5 V LESS THAN THOSE DETECTED WITH THE ENGINE COLD EMPTY VOLTAGE rpm 2000 6000 8000 Vm linked voltage Reference values V rms 20 30 75 85 95 105 Short circuit current For a correct detection of the short cir cuit current a connector must be pre pared that generates a downstream short circuit between the three alterna tor cables M Start the engine and with an ammeter clamp measure each single cable If there is a significant difference be tween the measure of the single cables other than 10 A this means that the alternator is defective and must be re placed CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 2 3 A L
28. width at hand guards 905 mm 35 63 in Max height 1185 mm 46 65 in Saddle height 900 mm 35 43 in Wheelbase 1505 mm 59 25 in Kerb weight 206 kg 454 Ib Dry weight unfuelled 196 kg 432 Ib CHAR 12 DORSODURO FACTORY ABS Engine Specification Model Type No of cylinders Total engine capacity Bore stroke Intake valve clearance Exhaust valve clearance Compression ratio Electric Engine idle speed Clutch Lubrication system Air filter Cooling Specification Type Transmission Specification Gear ratio 1st gear ratio 2nd gear ratio 3rd gear ratio 4th gear ratio 5th gear ratio 6th gear ratio Final drive gear ratio Capacities Specification Fuel capacity reserve included Fuel reserve Engine oil Fork oil check also the correct air level in the stem Coolant Seats Maximum weight limit Characteristics ENGINE Desc Quantity M551M 90 longitudinal V twin 4 stroke 4 valves per cylinder 2 over head camshafts 2 749 9 cm 45 76 cu in 92 x 56 4 mm 3 62 x 2 22 cu in 0 11 0 18 mm 0 0043 0 0071 in 0 16 0 23 mm 0 0063 0 0091 in 11 0 1 Electric starter 1400 100 rpm Multiple disk oil bathed clutch with control on the left side of the handlebar Wet crankcase Pressure system regulated by a trochoidal pump With dry cartridge filter Fluid GEARBOX Desc Quantity Mechanical 6 speeds with foot lever on the left hand side of the engine GEAR RATIOS Des
29. 1 Quantity 1 1 1 6 Torque 30 Nm 22 13 Ib ft 12 Nm 8 85 Ib ft 100 Nm 73 75 Ib ft 25 Nm 18 44 Ib ft 50 Nm 36 88 Ib ft Notes Steering package settlement OPTION 02 Steering upper plate with a headstock cut pos Description Headstock ring nut pre tightening Headstock ring nut tightening Headstock nut pre tightening Headstock nut Stainless steel TCC screw fastening stanchions to upper and lower yokes TCEI screw fastening U bolt onto fork yoke Steering upper plate clamp closing screw STEERING Type M25x1 M25x1 M22x1 M22x1 M8x30 M10x60 M8x30 Quantity 1 O L Torque 30 Nm 22 13 Ib ft 12 Nm 8 85 Ib ft 10 Nm 7 37 Ib ft 25 Nm 18 44 Ib ft 25 Nm 18 44 Ib ft 50 Nm 36 88 Ib ft 25 Nm 18 44 Ib ft Notes Steering package settlement Loctite 243 Loctite 243 Loctite 243 SUSP 286 DORSODURO FACTORY ABS Suspensions Removing the fork legs Remove the front wheel Support the stanchion and loosen the screws on the upper and then the lower plate Remove the stanchion Disassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS e Using the appropriate tool fasten the t2 x fork in the vice iv Specific tooling AP8140149 Protection for fitting operations Operating on the upper screw unload the spring SUSP 287
30. 13 5 V 450 W at 6000 rpm Desc Quantity NGK CR7EKB 0 6 0 7 mm 0 024 0 028 in 5 kOhm Desc Quantity 12 V 60 W H4 12V 50 W H4 12V 6W H6 12V 10W LED 12V 5W LED LED Desc Quantity LED LED LED LED LED LED LED LED Desc Quantity Component chassis bolted Die cast aluminium plates and high strength steel tubular chassis 25 8 108 mm 4 25 in DORSODURO FACTORY ABS Characteristics SUSPENSION Specification Desc Quantity Front Sachs upside down stanchions with adjustable hydraulic damping and 43mm 1 69 in diameter stanchions Travel 160 mm 6 3 in Rear Oscillating swingarm with Sachs piggy back single shock ab sorber and adjustable spring preloading wheelbase and hy draulic compression and rebound damping Wheel travel 155 mm 6 1 in SIZES AND B Specification Desc Quantity Size A 693 1 mm 27 29 in Size B 369 8 mm 14 56 in na 0 D A Brakes BRAKES Specification Desc Quantity Front Double floating disc 320 mm 12 60 in radially mounted calliper with four 32 mm 1 26 in pistons and two calliper pads Rear 240 mm 9 45 in disc brake with 34 mm 1 34 in single piston calliper Wheels and tyres WHEEL RIMS Specification Desc Quantity Type Light alloy rims with extractable bolt Front 3 50 x 17 Rear 6 00 x 17 TYRES Specification Desc Quantity Tyre type standard PIRELLI CORSA III DUNLOP SPORTMAX QUALIFIER Front tyre 120 70 ZR17 Front tyre pres
31. 17 Double circuit hydraulic pump ABS 18 Rear brake reservoir 19 Front brake reservoir ABS OPERATION General specifications The front circuit is similar to the rear circuit The ABS inlet valve 10 12 is normally open and it is closed only when the system inter venes to avoid wheel locking The outlet valve 13 15 is normally closed and it is opened only when the system intervenes to avoid wheel locking When the system is in standby the ABS processor never stops monitoring the speed of the wheels in order to assess potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coincides with danger recognition wheel slippage above threshold the system closes the inlet valve 10 12 and opens the outlet valve 13 15 temporarily At this stage the rider cannot increase the pressure on the callipers 8 9 and the system reduces the pressure on the callipers partially The excess fluid temporarily fills the front reservoir 18 19 until the ABS pump 17 self activates and delivers the fluid back to the brake pump 2 5 C Pressure maintained the pressure in the callipers 8 9 remains low until total recovery of speed whe
32. 37 Ibf ft bar 4 Screw fastening clutch control M6 1 10 Nm 7 37 Ibf ft mounting on flywheel side crankcase half 5 TBEI tank fixing screw M5x10 1 6 Nm 4 42 Ibf ft 6 TBEI plate fixing screw M6x12 1 10 Nm 7 37 Ibf ft s CHAR 22 DORSODURO FACTORY ABS Characteristics pos Description Pipe union fastening brake pipe to pump Fastener for front brake pump on handlebar TBEI screw fastening the brake tank to the plate Plate fixing screw Screw fastening the brake pipe to steering base Type M10x1 M6x20 M6x12 M6x25 FRONT BRAKE PUMP Quantity 1 2 1 Torque 25 Nm 18 44 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft Notes CHAR 23 Characteristics DORSODURO FACTORY ABS HEADLAMP pos Description Type Quantity Torque Notes 1 TE screw fastening headlamp to M6x16 2 10 Nm 7 37 Ibf ft E headlamp mounting and mudguard to steering base 2 Fastener for front turn indicators M5 2 3 Nm 2 21 Ibf ft 3 TCEI screw fastening headlamp M6 3 10 Nm 7 37 Ibf ft mounting to fork yoke PR 2 D m E EM d M 7 H fj CHAR 24 DORSODURO FACTORY ABS Characteristics FRONT BODYWORK pos Description Type Quantity Torque Notes 1 TBEI screw fastening front side pan M5x9 6 4 Nm 2 95 Ibf ft els to tank 2 TBEI scr
33. 5 35 Level in electrical circuit diagram Lambda probe Location on the vehicle exhaust pipe connector over the clutch side housing Electrical characteristics Oxygen probe with preheating circuit power 7W It generates voltage within 0 1000 mV Heater circuit continuity 7 9 Ohm at ambient temperature Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater ground connection white 4 Heater power supply white THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Lambda probe example value 0 1000 mV If there is a short circuit at 5 V or above the lambda probe parameter is not equal to the value read by the control unit a recovery value is displayed instead Lambda sensor correction example value 1 00 In closed loop the value must be close to 1 00 values not within the 0 90 1 10 interval indicate a fault for example value 0 75 corresponds to 25 with respect to the reference injection time 1 25
34. 50 Nm 36 88 Ib ft fork yoke 5 Steering upper plate clamp closing M8x30 1 25 Nm 18 44 Ib ft Loctite 243 screw CHAR 19 Characteristics DORSODURO FACTORY ABS INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 screw fastening instrument M6x20 2 10 Nm 7 37 Ibf ft panel mounting to fork yoke FRONT MUDGUARD pos Description Type Quantity Torque Notes 1 TBEI screw fastening fork guard to 5 9 6 6 Nm 4 42 Ibf ft Loct 243 calliper mounting bracket CHAR 20 DORSODURO FACTORY ABS pos Description TBEI screw fastening mudguard to stanchions Screw fastening number panel to headlamp Type M5x9 Quantity 4 4 Torque 4 Nm 2 95 Ibf ft 1 Nm 0 74 Ibf ft Characteristics Notes pos Description TCEI screw fastening counterweight to handlebar end Stainless steel TCC screw fastening upper U bolt to lower clamp Screws fastening light switch assem bly HANDLEBAR Type Quantity M6x50 2 8 25 4 4 2 Torque 10 Nm 7 37 Ibf ft 25 Nm 18 44 Ibf ft 1 5 Nm 1 11 Ibf ft Notes CHAR 21 Characteristics DORSODURO FACTORY ABS CLUTCH PUMP pos Description Type Quantity Torque Notes 1 Clutch cylinder fastener M6 2 10 Nm 7 37 Ibf ft 2 Union with breather and fixing pipe M10x1 1 1 25 Nm 18 44 Ibf ft 3 Fastener for clutch pump on handle 2 10 Nm 7
35. ABS Engine Installing the chain tensioner Refit the removed timing system chain tensioner on the cylinder head Fit the timing chain on the crankshaft and on the intermediate gear Remove the screw and collect the washer and the spring Fit the chain tensioner body on the cyl inder and insert a new paper gasket Tighten the two screws to the prescri bed torque Insert the spring and tighten the screw together with the washer Cam timing Timing Rotate the crankshaft until the front cylinder piston reaches the top dead centre Lock the crankshaft with the specific special tool Specific tooling 020720Y Timing tool ENG 227 Engine DORSODURO FACTORY ABS If necessary remove the timing system gears from the camshafts Place the camshaft with the timing sys tem gear on a vice and protect the cams of the camshaft adequately o Unscrew and remove the nut ANTICLOCKWISE NUT FOR BOTH REAR CYLINDER SHAFTS AN ANTICLOCKWISE ARROW HAS BEEN PUNCHED ON IT Collect the washer Remove the timing system gear from the camshaft Clean gears surfaces camshaft cone and gear cone with System MC 217 spray metal cleaner Pre fit the gear on the camshaft so that it can turn freely Place the two camshafts in the head seats and align the two camshaft holes with the head holes Align the clearance recovery gear to the main timing system gear using the
36. C Regulator Connector CENTRAL SECTION TABLE O Front cylinder coil and rear cylinder coil connectors Filter Housing Connectors ECU and Ground Lead Connectors for the filter casing CENTRAL SECTION TABLE C Fuel Pump Connector Se nt PS Iw 10 Key Connector Right Light Switch Connectors Left Light Switch Connectors Connectors inside the housing behind the radiator FRONT SECTION TABLE B THE CONNECTORS LISTED ARE CONSIDERED CRITICAL IN COMPARISON WITH ANY OTHER BECAUSE THE VEHICLE WILL STOP IF THEY ARE ACCIDENTALLY DIS CONNECTED Undoubtedly the connection of the rest of connectors is also important and essential for the correct operation of the vehicle Front side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION ELE SYS 96 DORSODURO FACTORY ABS Electrical system TABLE A RECOVERY 1 12V 30A Relay Fasten cable harness with retaining straps as shown in the figure TABLE B FASTENING SWITCH CABLE HAR NESSES Fasten switch cable harnesses with rubber retainer TABLE C FRONT ABS SENSOR FASTENER 1 Cable grommets 2 Front ABS sensor Leave the cable loosen so that it makes a slight curve and the cable grommet must be turned towards the outside of the for
37. CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER Insert the cylinder head unit on the stud bolts Working in a diagonal sequence and in stages screw the four nuts once the stud bolt threads have been greased e Screw the screw located outside the cylinder ENG 239 Engine DORSODURO FACTORY ABS Tighten the three screws on the intake and discharge sides Screw the two head fixing screws lo cated inside the timing chain compart ment Check that the intermediate gear pin lubrication holes are clean With a hook hold the timing chain Fit the timing chain on the intermediate gear Slide in the pin together with a new Ring and a washer e Check that the axial clearance be tween the pin and the gear is between 0 30 and 0 60 mm 0 0118 0 0236 in ENG 240 DORSODURO FACTORY ABS Engine Loctite residues are thoroughly re moved and a high strength threadlock is applied on the thread Make sure that both timing chain slid ers are correctly fitted Refit the overhead camshafts following the procedure described in the Tim ing section See also Selecting the base gasket Selecting the base gasket Place the specific special tool on the piston which should have sealing rings and be fitted on the connecting rod Lock the special tool with the clamp Specific tooling AP8140302 tool for sealing ring fitting Temp
38. D disconnect the right connector and see the value displayed by Navigator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open shorted to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable ground insulation from the throttle grip sensor connector or the control unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the switch key set to ON check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is continuity replace the control unit if not restore the wiring NAVIGATOR LOGIC ERRORS Left side Throttle Grip Position tracks A B P0154 illogical signals Error cause Two illogical voltage signals have been detected at PINS 42 and 40 of the VEHICLE nector tracks A B Troubleshooting ELE SYS 134 DORSODURO FACTORY ABS Electrical system Check the parameters of the left Throttle Grip Position Sensor tracks A and B if one of the two values clearly deviates from 600 1400 mV it means that this potentiometer is
39. ECU control unit pin configuration PIN 1 GND Ground PIN 2 PCC1 Vehicle identification ground connection PIN 4 IGN Injection PIN 8 WL Alarm warning light PIN 11 R SIGN Rear ABS sensor signal PIN 12 R_GND Rear ABS sensor ground connection PIN 13 F GND Front ABS sensor ground connection PIN 14 F SIG Front ABS sensor signal PIN 15 PCC2 Vehicle identification ground connection BRAK SYS 325 Braking system DORSODURO FACTORY ABS PIN 16 ISO_K K line diagnosis PIN 18 KL30 Power supply Foreword key 1 Rear brake calliper Modulator Front bleed valve Front brake reservoir Front brake callipers Rear brake pump po Gee ae Rear brake reservoir BRAK SYS 326 Braking system DORSODURO FACTORY ABS Operating diagram ABS functional diagram key Front system circuit m 2 Front brake pump 3 Front brake lever 4 Rear system circuit BRAK SYS 327 Braking system DORSODURO FACTORY ABS 5 Rear brake pump 6 Rear brake pedal control 7 ABS control unit 8 Rear brake calliper 9 Front calliper 2 callipers 10 Front brake circuit intake solenoid valve normally open 11 Humidifier 12 Rear brake circuit intake solenoid valve normally open 13 Rear brake exhaust circuit solenoid valve normally closed 14 Rear front brake circuit low pressure accumulator 15 Front brake exhaust circuit solenoid valve normally closed 16 DC electric motor
40. ELE SYS 114 DORSODURO FACTORY ABS Electrical system Check goal this control is to check if a cable or a circuit is in contact with the vehicle ground connection Tester set the tester on the continuity symbol and place one tester probe on the vehicle ground connection or on the battery terminal and the other probe on the cable being inspected the tester sends out a sound signal only if there is continuity The tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm CAUTION IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIR CUIT VOLTAGE check Check goal this control is to check if a cable is energised i e if it receives power supply from the battery or the control unit Tester set the tester on the direct current symbol and place the tester red probe on the cable being inspected and the black probe on the vehicle ground connection or on the battery terminal CAUTION IN CASE OF TEMPORAL MALFUNCTIONING CARRY OUT ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED Dashboard In case the EFI warning light turns on and the words SERVICE or URGENT SERVICE are shown on the display due to an error detected in the injection ECU the malfunction indication will be deactivated only after the vehicle has been used for a pre set number of minute
41. Front brake pads Removal Turn the pins and remove both split pins Remove both pins Collect the anti vibration springs BRAK SYS 339 Braking system DORSODURO FACTORY ABS Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Rear brake pads Removal Remove the safety circlip Unscrew and remove the pin Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper BRAK SYS 340 DORSODURO FACTORY ABS Braking system The presence of air is signalled by the sponginess of the brake control and poor braking efficiency CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY TO BOTH CALLIPERS THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QU
42. Ibf ft Loct 243 calliper mounting bracket BODYW 361 Bodywork DORSODURO FACTORY ABS pos Description Type Quantity Torque Notes 2 TBEI screw fastening mudguard to M5x9 4 4 Nm 2 95 Ibf ft stanchions 3 Screw fastening number panel to 4 1 Nm 0 74 Ibf ft headlamp FRONT BODYWORK pos Description Type Quantity Torque Notes 1 TBEI screw fastening front side pan M5x9 6 4 Nm 2 95 Ibf ft els to tank 2 TBEI screw fastening front side pan M6x16 4 6 Nm 4 42 Ibf ft els and duct to radiator 3 TBEI screw fastening ignition block M5x9 3 4 Nm 2 95 Ibf ft cover to spacer Front tank fastener spacer M6 2 10 Nm 7 37 Ibf ft BODYW 362 DORSODURO FACTORY ABS Bodywork REAR BODYWORK 1 pos Description Type Quantity Torque Notes 1 Screws fastening battery cover to M5 2 1 4 Nm 2 95 Ibf ft compartment 2 TBEI screw fastening battery com M5x9 2 6 Nm 4 42 Ibf ft partment to saddle mounting BODYW 363 Bodywork pos Description 1 TBEI screw fastening LH RH covers to silencer 2 TBEI screw fastening tail fairing to saddle mounting Screw fastening tail fairing to battery compartment Type M6x20 M5x9 DORSODURO FACTORY ABS REAR BODYWORK 2 Quantity 4 2 3 Torque 10 Nm 7 37 Ibf ft 6 Nm 4 42 lof ft 4 Nm 2 95 Ibf ft Notes pos Description TBEI screw fastening
43. Place the retention plate Tighten the screw Clutch side OPTION 01 ENG 203 Engine DORSODURO FACTORY ABS WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 13 13 Nm 9 59 Ibf ft 2 Fastener screw for Pump Cover M6 3 13 Nm 9 59 Ibf ft Clutch side cover 3 Screw fastening Pump Cover M6 2 13 Nm 9 59 Ibf ft Clutch Cover clutch side crankcase half 4 Nut fastening pump drive input gear M6 1 12 Nm 8 85 Ibf ft Loctite 244 on shaft 5 Water pump rotor 1 4 50 Nm 3 32 Ibf ft OPTION 02 ENG 204 DORSODURO FACTORY ABS Engine pos Description Clutch side cover fastener screw Fastener screw for Pump Cover Clutch side cover Screw fastening Pump Cover Clutch Cover clutch side crankcase half Nut fastening water pump drive gear sprocket Water pump rotor Screw fastening chain tensioner slid er to water pump Water pump support fixing screw Water pump support plug WATER PUMP Type M6 M6 M6 M6 M6 M6 M6x10 Quantity 11 3 2 Torque 13 Nm 9 59 Ibf ft 13 Nm 9 59 Ibf ft 13 Nm 9 59 Ibf ft 12 Nm 8 85 Ibf ft 4 50 Nm 3 32 Ibf ft 8 10 Nm 5 90 7 38 Ibf ft 12 Nm 8 85 Ibf ft 6 5 Nm 4 79 lof ft Notes 3M SCOTCH GRIP 2353 Remove the water pump cover Undo and remove the eleven screws working in a diagonal sequence Collect the gasket ENG
44. SYS 103 Electrical system DORSODURO FACTORY ABS TABLE S 15 Side stand switch output sheath 16 Battery compartment bleed pipe 17 Cable grommet TABLE T The cables fastened to the engine ground must face downwards 18 Main cable harness engine earthing on the left 19 Battery ground lead on the right TABLE U 2 4 5x180 0 18x7 08 Clamps TABLE V LAMBDA PROBE Place the cable harness of the lambda probe in the cable grommet on the clutch crankcase 20 Fasten the cable harness to the chassis with the clamp 21 Place the cable harness of the lambda probe behind the cable grommet on the clutch crankcase ELE SYS 104 DORSODURO FACTORY ABS Electrical system TABLE 2 Connector insertion on Demand and secondary lock closing TABLE ZA ZB Tables with tips on filter box cable harness fitting ELE SYS 105 Electrical system DORSODURO FACTORY ABS TABLE ZC ZD Tables with tips for fitting ground lead and start up cable 22 Cable grommet 23 ABS cable harness connecting cable 24 Starter motor cable coiled with pigtail wire L 10 cm 3 93 in 25 4 5x290 0 18x11 42 Clamp 26 2 5x160 0 10x6 30 Clamp ZD engine battery ground connection cable path TABLE ZE Procedure for the correct insertion of the ABS control unit connector The initial position of the lever that couples the connector must be as shown in figures 1 and 2 ELE SYS 106 DORSODURO FACTORY ABS Electrical system
45. TABLE ZF Place the connector on the opposite side of the control unit and lower the driving lever until the click that signals the end of the stroke is heard TABLE ZG When the connector is fully inserted the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in If the initial position of the connector and the driving lever is not as shown in figure ZE the connector will not get properly coupled and the distance measured will be longer 12 mm approx 0 47 in In this case repeat the operation as described in the ZF ZG picture It is advisable to create a template to check the correct connector insertion ELE SYS 107 Electrical system DORSODURO FACTORY ABS TABLE ZH 27 Fasten the cable harness with a clamp Insert the housing as shown in the figure Back side TABLE A Taillight cable harness fitting 1 2 5x98 0 10x3 86 Clamp 2 4 5x180 0 18x7 08 Clamp TABLE B SPEED SENSORS FRONT AND REAR WHEEL ABS FITTING TABLE B1 2 5x160 mm 0 01x6 30 in Clamps ELE SYS 108 DORSODURO FACTORY ABS Electrical system TABLE B1 A 3 2 5x160 mm 0 01x6 30 in Clamps TABLE B2 4 2 5x160 mm 0 01x6 30 in Clamps 5 4 5x180 mm 0 18x7 08 in Clamps 6 Cable grommet TABLE B2 A Spiral length 110 mm 4 33 in 110 mm 4 33 in 10 mm 0 39 in ELE SYS 109 Electrical system TABLE B3 Cable guide TABLE B4 2 5x160 mm 0 1x6 30 in Clamps ELE SYS 11
46. THE CORRECT POSITION END 71 ACCORDING TO THE FAILURE REFER TO CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS GEAR IN NEUTRAL SENSOR or CLUTCH LEVER SEN SOR or SIDE STAND SENSOR END TROUBL 89 Troubleshooting DORSODURO FACTORY ABS 72 REPLACE THE CONTROL UNIT END TROUBL 90 INDEX OF TOPICS Evectricat SYSTEM ELE SYS Electrical system Demand 1 master Front Stop Switch Position lamp Right Front Turn Indecatar Front Headlamp DORSODURO FACTORY ABS Air Temp Sensor Lights Relay a YLO Main Switch Rear Stop Switch Fan Rear ignition Right Switch 1 Recovery Relay njection Relay 1 EE f 5 y call y Right Switch 2 Injection Relay 2 ig itch 2 Resistence Bex Retain Relay Left Switch I cider ele Switch 2 AIR r Voltage Regulator Fan Relay ia nee 3 _ air Box 2 p Front Ignition Coil Demand slave Clutch 4 High Beam Relay Antenna E Left Front Turn Indicator Dashboard ELECTRICAL SYSTEM 1 pos Description Type Quantity Torque Notes M6x30 frame 10 Nm 7 37 Ibf ft ELE SYS 92 Secondary Fuses Dil Pressure y ECU Ground J 1 ecu e E Pickup Side stand swatch Gear Sensor Horn Temp Sensor Lambda E Speed sensor Bo Engine Ground
47. VEHICLE INCLINED HANDLE BAR TURNED ON UN EVEN OR SLIPPERY ROADS OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE THEREFORE RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADU ALLY BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN ABS CAN ELIMINATE When the sensors 3 detect a significant speed difference between the rear and the front wheels for example when rearing up on the back wheel the ABS system could take this as a dangerous situation In this case two things may occur The ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel It is not possible to brake for an instant if the speed difference lasts long the system may detect an error and deactivate the ABS system As a consequence the system works like any regular braking system BRAK SYS 329 Braking system DORSODURO FACTORY ABS Riding with an active ABS system At engine start up the ABS warning light 5 on the instrument panel 4 turns on and remains on until the vehi cle exceeds 5 km h 3 1 mph If the ABS warning light remains on when the vehicle is running it means that a fault has been detected and the ABS system has been automatically deactivated 20 A fuse ABS Main fuse 6 Protects ABS Control unit Guide to diagnosis PREMISE Each time the key is ON at least one current or stored error of the ABS sys
48. activate the component with Navigator and check the voltage on the grey green cable on the filter box small con nector towards the Marelli control unit if there is voltage restore the cable harness between the filter box connector and the Marelli control unit If there is no voltage reconnect the ELE SYS 149 Coil COIL Function Spark generation Operation Operating principle Inductive discharge system Level in electrical circuit diagram coils and in jectors Location Electrical system DORSODURO FACTORY ABS connector and check if there is voltage at PIN if there is voltage restore the filter box cable harness If there is no voltage replace the sensor shorted to negative disconnect the injector connector set the key to ON and check if there is a ground connection on the grey red cable if there is voltage restore the cable harness between the filter box connector and the Marelli control unit if there is no voltage reconnect the connector and disconnect the injector connector and check if there is a ground connec tion on PIN if there is voltage restore the filter box cable harness If there is no voltage replace the injector the circuit is open check the component correct electrical characteristic if it is not correct replace the component if it is correct check the filter box small connector the connector on the component and the Marelli control unit connector If not OK restore If OK check
49. and remove the lower screw and retrieve the nut Remove the shock absorber SUSP 311 INDEX OF TOPICS Cassis CHAS DORSODURO FACTORY ABS Swinging arm Chassis SWINGARM pos Description Type Quantity Torque Notes 1 owingarm Pin adjustment bushing 1 12 Nm 8 85 Ib ft 2 Swingarm pin ring nut 1 60 Nm 44 25 Ib ft 3 Swingarm pin nut 1 90 Nm 66 38 Ib ft 4 TPSI screw fastening rear stand M6x40 2 10 Nm 7 37 Ib ft bushing 5 TBEI screw fastening chain guard to M5x9 1 6 Nm 4 42 Ibf ft swingarm 6 TBEI screw fastening rear mudguard M5x9 2 6 Nm 4 42 Ibf ft Loctite 243 to swingarm 7 TBEI screw fastening chain guard to M5x9 1 4 Nm 2 95 Ibf ft rear mudguard 8 TBEI screw fastening chain guide to M5x9 2 6 Nm 4 42 Ibf ft swingarm Wheel axle nut M25x1 5 1 120 Nm 88 5 Ibf ft 10 Flanged TBEI screw fastening chain M5x9 2 4 Nm 2 95 Ibf ft Loctite 243 casing Removing Remove the exhaust system Support the vehicle by means of the engine service stand and a hoist with belts fastened to the rear section of the frame e Remove the rear wheel CHAS 313 Chassis Slide off the rear calliper holding plate keeping it linked to the brake pipe CAUTION DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER REMOVING THE WHEEL OTHERWISE THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT RESULTING IN BRAKE FLUID LEAKAGE Unscrew and remove the two lower s
50. and the exhaust system have cooled down FRONT Unscrew and remove the two nuts on the head exhaust stud bolts Loosen the clamp e Remove the exhaust manifold CHAS 320 DORSODURO FACTORY ABS Chassis REAR See also Removing the manifold tail pipe Removing the lambda sensor Loosen the exhaust pipe between the manifold and the exhaust end Unscrew and remove the two nuts on the head exhaust stud bolts Unscrew and remove the fixing screw of the lambda probe connector brack et Move the breather pipe andthe bracket M with the lambda probe connector fixed to it Disconnect the lambda sensor con nector CHAS 321 Chassis DORSODURO FACTORY ABS Unscrew and remove the lambda sen SOF CHAS 322 INDEX OF TOPICS Brana SYSTEM BRAK SYS Braking system DORSODURO FACTORY ABS Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM ABS ABS SYSTEM pos Description Type Quantity Torque Notes ABS ECU fastener screw zx 10 Nm 7 37 Ibf ft Loctite 243 ABS ECU fastener nut 10 Nm a 37 Ibf ft BRAK SYS 324 DORSODURO FACTORY ABS Braking system key Battery ECU AR WD Key 10 Fuses ABS ECU control unit Front ABS sensor Hear ABS sensor Main relay Instrument panel K line diagnosis ABS
51. are contactless therefore no electrical diagnosis is possible for the throttle body only for the circuits connected to it Throttle body activation takes place every time the key is set to ON correct activation is indi cated when the stop lights turn on ELE SYS 152 DORSODURO FACTORY ABS Electrical system If during activation the engine is started the activation is not completed and the stop lights do not turn on Every 150 key ONs however the throttle valves are forced to activation If start up is attempted during this activation which requires 3 seconds the engine will not start Level in electrical circuit diagram throttle control unit Location e on the vehicle inside the filter box connector on the throttle body Pin out 1 potentiometer signal 1 2 supply voltage 5V 3 throttle valve control 4 potentiometer signal 2 5 throttle valve control 6 ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Front throttle Potentiometer 1 voltage Example value 800 mV The value in the example refers to engine conditions with key set to ON Front throttle Potentiometer 2 voltage Example value 3878 mV The value in the example refers to engine conditions with key set to ON R
52. as to remove the flywheel from the crankshaft Specific tooling 020713Y Flywheel extractor Unscrew and remove the anticlockwise bolt of the special tool from the external body e Unscrew the screw from the crankshaft Specific tooling 020713Y Flywheel extractor Remove the flywheel together with the freewheel Remove the start up transmission gear In case of malfunction the start up transmission gear cannot be over hauled Therefore the complete trans mission gear should be replaced ENG 201 Engine M Collect the crankshaft woodruff key Freewheel removal Heat the magneto flywheel with the specific heater Undo and remove the six screws Remove the freewheel from the mag neto flywheel Installing the flywheel Insert the woodruff key on the crank shaft Insert the start up transmission gear after applying a layer of grease ENG 202 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Engine Insert the flywheel on the crankshaft M Screw the screw together with the washer but without tightening Place the appropriate tool for locking the flywheel Locking the flywheel in position using the specific tool tighten the screw on the crankshaft CAUTION TO APPLY THE CORRECT TIGHTENING TOR QUE CHECK THE MEASURE OF THE SCREW THAT CAN BE M12 OR M14 Remove the special tool Specific tooling 020713Y Flywheel extractor
53. by disconnecting it from the cable har ness If they are not correct replace the relay if correct restore the cable harness pink blue cable If shorted to negative check the relay electrical specifications are correct by disconnecting it from the cable har ness If they are not correct replace the relay if correct restore the cable harness pink blue cable If the circuit is open check the relay connector and the Marelli control unit VEHICLE connector If not OK re store if OK restore the cable harness red blue cable Electrical system ELE SYS 169 Electrical system DORSODURO FACTORY ABS RUN STOP switch Run stop switch Function It tells the control unit if the driver wishes to enable engine start up or to keep the engine running Operation Operating principle If the driver wants to shut off the engine or to dis able engine start up the switch should be open i e the Marelli control unit should not detect volt age at VEHICLE connector PIN 26 Level in electrical circuit diagram Start up ena bling switches Location on the vehicle right light switch x connector fixed to the L support bracket placed over the clutch housing Electrical characteristics STOP position the circuit is open RUN position closed circuit continui ty Pin out 1 Yellow grey cable 2 Red black cable Voltage 12V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY R
54. cable continuity between the ENGINE PIN 34 and component PIN and restore the cable harness on the vehicle on the cylinder head connector if available Electrical characteristics Pin out Primary circuit resistance approx 1 Ohm at 20 C between PIN 1 and 3 Secondary circuit resistance MOhm value range with positive probe on Coil 1 Supply batt V 2 Secondary circuit ground connection 3 Activation from control unit ELE SYS 150 DORSODURO FACTORY ABS Electrical system FRONT CYLINDER REAR CYLINDER Az Ar 0 75 35 Az V 0 75 35 R M 1 D11 R M 1 D11 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Rear coil ignition advance Front coil ignition advance NAVIGATOR STATUSES NAVIGATOR ACTIVATION Front coil The auxiliary injection relay No 40 in the wiring diagram placed under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the sky blue orange cable of the coil is closed to ground for 2 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indica
55. check is completed make sure that the Handle self learning status indicates carried out CAUTION THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED MARK OR CHECK THE CONNECTOR MARKING BEFORE RE MOVING THEM BLUE STAMP BLUE BAND THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED TO THE LEFT THE CONNECTOR AND THE WHITE BAND SHOULD BE PLACED TO THE RIGHT NOTES The two connectors which get to the throttle grip sensor are the same but they should NEVER be inverted Mark or check the connector marking before removing them blue stamp blue band ELE SYS 135 Electrical system DORSODURO FACTORY ABS Removal When required disconnect the corre sponding connectors undo and re move the two screws and remove the throttle grip position sensor Intake pressure sensor INTAKE AIR PRESSURE SENSOR Function The pressure sensors one per cylinder are fundamental not only for the injection configuration at low and stabilised speeds but also for checking the Ride by wire system their signal is connected to a TORQUE CHAIN for checking the correct opening of the throttle valves Operation Operating principle Diaphragm sensor which translates the diaphragm position into electrical voltage when in contact with the intake air Level in electrical circuit diagram intake air pressure sensor Location on the vehicle inside the filter box connector the sensor Pi
56. clutch housing with the oil pump driven gear Disassembling the clutch Re UN D EAT De LM x Piir E E AW EF T AQUI CLUTCH pos Description Type Quantity Torque Notes 1 Clutch spring fastener screw M6 6 12 Nm 8 85 Ibf ft ENG 207 Engine DORSODURO FACTORY ABS Remove the clutch side housing Unscrew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate e Remove the mushroom head clutch control rod Remove the discs Remove the shim and the cup spring ENG 208 DORSODURO FACTORY ABS Engine Fasten the clutch housing using the specific tool Specific tooling 9100896 Clutch housing locking tool A 7 ae i i L1 e Undo and remove the clutch hub nut retrieving the washer Remove the clutch hub Retrieve the special washer between the clutch hub and the clutch housing Collect the clutch housing ENG 209 Engine DORSODURO FACTORY ABS Collect the spacer and the needle bearings e Collect the shim washer Checking the clutch plates Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions Maximum distortion allowed 0 20 mm 0 0079 Measure the
57. control output Air temperature sensor input Front throttle reset output Rear throttle reset output Engine stop input Electric fan relay control output STOP light relay control output Lambda heater control output Lambda sensor input Lambda sensor input Purge Canister valve control output optional Control unit direct power supply Power ground connection 1 Power ground connection 2 Power ground connection 3 Power ground connection 4 Reference voltage output 5V tracks A C and pressure sensor Reference voltage output 5V tracks B D and speed sensor Analogue ground connection 1 Analogue ground connection 2 CAN H Line high speed CAN L Line high speed Timing sensor ELE SYS 172 Desc Quantity Vehicle connector 12 29 Engine connector 9 Engine connector 23 Vehicle connector 49 Vehicle connector 42 Vehicle connector 40 Engine connector 30 Engine connector 44 Vehicle connector 34 Vehicle connector 5 Engine connector 45 Vehicle connector 6 Vehicle connector 14 Vehicle connector 50 Engine connector 8 Engine connector 16 Engine connector 2 Vehicle connector 10 Vehicle connector 62 Engine connector 17 Engine connector 19 Engine connector 50 Engine connector 34 Engine connector 63 Vehicle connector 56 Vehicle connector 55 Vehicle connector 26 Vehicle connector 54 Vehicle connector 59 Engine connector 32 Engine connector 43 Engine connector 60 Engine connector 51 Vehicle con
58. corre ELE SYS 145 Electrical system DORSODURO FACTORY ABS sponds to 25 In an open circuit the lambda probe signal is too low Therefore the control unit takes itas a lean combustion condition and will try to enrich it The value read will be 0 75 once this correction has been tried the value shifts to 1 00 fixed and the Lambda probe error is signalled NAVIGATOR STATUSES Lambda Example value Start up Lean Fault due to rich value Fault due to lean value If the probe connector is removed voltage almost equal to zero the status is Fault due to lean value Lambda check Example value Open loop Closed loop Rich in closed loop Lean in closed loop enriched Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value NAVIGATOR ACTIVATION Lambda probe heating The auxiliary injection relay No 40 in the wiring diagram placed under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised and the heating circuit is closed to ground 5 times pin 3 of the lambda probe connector The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation NAVIGATOR ELECTRICAL ERRORS Lambda probe P0130 Shorted to positive Error cause Excessive voltage battery voltage has be
59. cycle is counted if the following occurs key ON and speed over 20 km h Ambient parameter error reading 5 If for example 5 is shown it means that the last time the error has been measured was 5 cycles ago Error clearing 1 Press enter to transfer errors from the memory MEM to the historical record STO Error clearing 2 In the next connection between Navigator and the control unit the historical errors STO are no lon ger shown ERRORS screen page This screen page shows potential errors detected in the vehicle ATT or stored in the control unit MEM and it allows to check error clearing STO BRAK SYS 334 DORSODURO FACTORY ABS Characteristic Front speed sensor 5D90 electric malfunction Front speed sensor 5D91 the signal works irregularly Front speed sensor 5D92 the signal decreases periodically Front speed sensor no signal or speed measured too low in relation to the rear wheel 5D93 Front speed sensor 5D94 no accel eration after pressure reduction Front speed sensor 5D95 excessive measured speed Rear speed sensor 5DAO electric malfunction Rear speed sensor 5DA1 the signal works irregularly Rear speed sensor 5DA the signal decreases periodically Rear speed sensor 5DA3 no signal or speed measured too low in rela tion to the front wheel Rear speed sensor 5DA4 no accel eration after pressure reduction Rear speed sensor excessive meas ured speed 5DA
60. cylinder p j Rod from fronts cylinder a COOLING SYSTEM pos Description Type Quantity Torque Notes 1 Fan fastener screw 3 3 Nm 2 21 Ibf ft 2 Flanged TE screw fixing LH side ra M6x25 2 10 Nm 7 37 Ibf ft diator to trellis frame and radiator bracket to engine Electric fan e Remove the radiator R ore Undo and remove the three screws x ese denn AAA and collect the washers remove the CO MERI 88 electric fan fr dni ho UNNE EF f jak i LS S Perap rtrt mq Ee fi i See also Removing the radiator COOL SYS 347 Cooling system DORSODURO FACTORY ABS Coolant replacement Remove the right side fairing Place a container of suitable capacity mp T Loosen the screw move the clamp and a slide off the sleeve Remove the cap Empty the system into the specific container Loosen the screw and move the clamp Slide off the sleeve and empty the sys tem completely CAUTION SHOULD GREASE BE NOTED IN THE WATER THIS IS TO BE CONSIDERED NORMAL BECAUSE DURING THE AS SEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LU BRICATION OF THE SAME IS REQUIRED IN ORDER TO PREVENT DAMAGE Refit both sleeves place the corresponding clamps and tighten their screws Fill the expansion tank up to the marked level After bleeding the air from the tank fit the expansi
61. diagram DORSODURO FACTORY ABS key Main gear shaft Z 14 2nd gear on primary Z 17 4th gear on secondary Z 20 22 5th gear on primary Z 23 6th gear on primary Z 24 Thrust washer Circlip Thrust washer PD Thrust washer 10 Circlip ENG 192 DORSODURO FACTORY ABS Engine 11 Transmission shaft 12 1st gear on primary Z 36 13 2nd gear on secondary Z 32 14 3rd gear on secondary Z 30 15 4th gear on secondary Z 28 16 5th gear on secondary Z 26 17 6th gear on secondary Z 25 18 Thrust washer 19 Circlip 20 Thrust washer 21 Thrust washer 22 Thrust washer 23 Floating bushing 24 Floating bushing 25 Floating bushing Disassembling the gearbox Remove the gear selector as descri bed in the Crankcase Opening section Remove the two bolts of the forks ENG 193 Engine DORSODURO FACTORY ABS e Slide off the desmodromic drum con trol Remove the three gear selection forks CAUTION THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE Carefully rotate the engine support ENG 194 DORSODURO FACTORY ABS Engine e Carefully slide off the whole gear unit Refitting Repeat the removal operations but in reverse order make sure that the shim washer is fitted to the secondary shaft See also Splitting the crankcase halves Gear selector
62. filter support partition Release the cable harness from the clamps BODYW 381 Bodywork DORSODURO FACTORY ABS Unscrew and remove the two screws after loosening the front and rear mani fold clamps Loosen the clamp to slide off the bleed pipe Lift the filter box and working on both cylinders loosen and move the clamp and slide off the oil vapour recovery pipe BODYW 382 DORSODURO FACTORY ABS Bodywork Working on the left side disconnect the two control unit connectors CAUTION THE CONNECTORS ARE MARKED BY THE LETTERS V VEHICLE AND E ENGINE DO NOT INTERCHANGE THEM WHEN REFITTING Unscrew and remove the screw and remove the ground lead Disconnect the two connectors Remove the filter box together with the throttle body by lifting it up from be hind CAUTION COVER THE SLEEVE OPENINGS SO THAT NO FOREIGN BODIES COME IN Should the throttle body be removed disconnect either the map sensor pipes or the intake ducts it is necessary to check the air system tightness Using Navigator check the following parameters a take the vehicle temperature to 90 C 194 F or above b front cylinder throttle valve correction between 60 and 60 b rear cylinder throttle valve correction between 60 and 60 BODYW 383 Bodywork DORSODURO FACTORY ABS C potentiometer 1 front throttle valve value is 0 5 or above d potentiometer 1 rear thr
63. from a suitable di ameter Suspensions SUSP 305 Suspensions DORSODURO FACTORY ABS Fit the specific upper seal ring with the lip placed upwards and the surface with the words downwards Enter it on the column and place it on the upper rim of the headstock Finish inserting until the stop with the teflon buffer and rubber hammer Pass with a brush on the seal ring to lay down potential grease storage Place the tightening ring nut with the rim placed downwards Carry out the steering bearings clear ance adjustment See also Assembling SUSP 306 DORSODURO FACTORY ABS Suspensions Rear REAR WHEEL pos Description Type Quantity Torque Notes 1 Lower self locking nut fastening M10 5 50 Nm 36 88 Ib ft sprocket to sprocket carrier 2 TCEI screw fastening flexible cou M10x30 5 50 Nm 36 88 Ib ft Loctite 270 pling mounting on wheel Removing the rear wheel Place the vehicle on its rear service stand Fasten the vehicle handlebar to the bench using belts To facilitate operations it is advisable to remove the chain protection by un screwing the two screws SUSP 307 Suspensions DORSODURO FACTORY ABS CAUTION RIMUOVERE IL SENSORE VELOCITA PRIMA DI PROCEDERE CON LA RIMOZIONE DELLA RUOTA POSTERIORE EVITANDO QUINDI DI DANNEGGIARLO SUSP 308 Fully slacken the gearing chain ten sion Make the wheel move
64. gear transmission connecting rod keeping it linked to the gear shift lever through the rod M Slacken the gearing chain tension Unscrew and remove the screw col lect the washer and the spacer Slide off the pinion from the chain and remove Disconnect the generator connections See also Air box Removing the radiator ENG VE 185 Engine from vehicle DORSODURO FACTORY ABS Removing the engine from the vehicle Carry out the operations described un der Vehicle preparation Support the engine by means of belt and hoist Working on the left side unscrew and remove the two upper nuts Working on the right side slightly slide off the two upper bolts Collect the spacers on the opposite side Check spacers length so as not to in terchange them upon refitting Remove the two upper bolts and col lect the washers ENG VE 186 DORSODURO FACTORY ABS Engine from vehicle Working on the left side unscrew and remove the lower bolt Working on the right side slightly slide off the lower bolt Collect the spacer on the opposite side Remove the lower pin and collect the washer Lower the engine See also Vehicle preparation Installing the engine to the vehicle Place the engine on a suitable lower stand Lift the engine Place the engine so that the rear attachments on the chassis are aligned Working on the right
65. is allowed Radial clearance none If one or both bearings do not fall within the control parameters Replace both wheel bearings REAR WHEEL GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage LN ALWAYS REPLACE BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE REAR WHEEL AXLE or excessive wear Use a dial gauge to check the wheel axle eccentricity 1 Replace the wheel axle if the eccentricity exceeds the limit value 1 Characteristic Maximum eccentricity 0 25 mm 0 0098 in REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2 mm 0 0079 in SUSP 310 DORSODURO FACTORY ABS Suspensions Shock absorbers REAR SUSPENSION pos Description Type Quantity Torque Notes Upper TCE mounting screw M10x50 50Nm 36 88lbfft 2 Lower TCEI mounting screw M10x90 1 50 Nm 36 88 Ibf ft Removing Place the optional under sump and rear wheel service stands Unscrew and remove the upper screw and collect the washer Loosen the under sump optional serv ice stand to lower the engine Unscrew
66. is received by the throttle control unit Troubleshooting ELE SYS 176 DORSODURO FACTORY ABS Electrical system Check the filter box large connector and the throttle control unit connector if not OK restore if OK check the continuity of the two lines from the filter box large connector to the VEHICLE connector of the Marelli control unit if not OK restore the cable harness if OK check the continuity of the two lines from the filter box large connector to the throttle control unit con nector if not OK restore the cable harness if OK replace the throttle control unit NAVIGATOR LOGIC ERRORS CAN Line to throttle control unit U1706 no message update Error cause No updated signal is received from the throttle control unit ELE SYS 177 INDEX OF TOPICS FROM VEHICLE ENG VE DORSODURO FACTORY ABS pos Description TCEI screw fastening shock absorb er counterplate to RH frame bracket TC TORX screw fastening trellis frame to frame side panels to LH plate roller bracket to LH plate FRONT CHASSIS Type Quantity M10x30 M12x53 M8x35 M8x45 M8x20 1 4 1 Torque 50 Nm 36 88 Ibf ft 80 Nm 59 Ibf ft Screw fastening chain roller bracket 25 Nm 18 44 Ibf ft Screw fastening chain roller to chain 25 Nm 18 44 Ibf ft Screw fastening chain roller bracket 25 Nm 18 44 Ibf ft Engine from vehicle Notes Loctite 243 Loctite 243 Loc
67. l v Semi bushing type B blue Semi bushing type C yellow Class 6 main journal l v Semi bushing type E green Semi bushing type A red Class 7 main journal l f Semi bushing type A red Semi bushing type B blue Class 8 main journal l f Semi bushing type B blue Semi bushing type C yellow Class 9 main journal l f Semi bushing type E green Semi bushing type A red Crankcase class internal marking onfirst gen Nd RU eration crankcases E vm a i Two different crankcase classes A or B are avail p d ad ey z able selected in relation to the centre to centre iy T DANA X UCM N C v f oe 1 distance between the primary reduction gears pu i The class is indicated on the clutch side crankcase y 2 dic 7 amp W i NN f be E i zd half near the front cylinder area en ENDS a Mo NOTE XN wn T oJ WP 1 IN THE EVENT OF CRANKCASE REPLACEMENT THE PRI MARY REDUCTION GEAR IS SUPPLIED READY MESHED CHAR 57 DORSODURO FACTORY ABS CRANKCASE CLASSES 01 Characteristics Specification Crankcase class A Crankcase class B See also Removing the flywheel cover Crankcase class internal marking on second generation crankcases Two different crankcase classes A or B are avail able selected in relation to the centre to centre distance between the primary reduction gears The class is indicated on the clutch side crankcase half in the gearbox control mechanism area N
68. not operational Error cause Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status A D converter P0607 circuit not operational Error cause Replace injection ECU Level 2 safety reset P0608 Error cause As the level 2 safety system comparison between requested torque and calculated torque has detected a fault the control unit has reset engine C gravity Troubleshooting Continue fault search for the other errors detected Safety Engine Stop P0609 Error cause As the level 3 safety system control EEPROM has detected a fault the control unit has shut off the engine D gravity Troubleshooting Replace Marelli control unit Reset lines error P0610 circuit not operational Error cause Problems on the reset lines PINS 55 and 56 of the VEHICLE connector of the throttle motors lines used to interrupt motor functioning for safety reasons Troubleshooting Check the VEHICLE connector of the Marelli control unit the filter box large connector and the throttle control unit connector if not OK restore If OK check continuity between the Marelli control unit and the throttle control unit connector from VEHICLE PIN 55 to PIN B7 and from PIN 56 to PIN A7 if not OK restore If OK check that with throttle control unit connector disconnected and with key set to ON there is no voltage on PINS A7 and B7 if there is voltage replace the cable harness If t
69. of the connector Pin out see the CONNECTORS section NAVIGATOR STATUSES Engine status Example value Indefinite Key ON Running engine Stopped Powerlatch Powerlatch 2_ Power latch finished Engine mode Example value Indefinite Start up Stable Idle Acceleration Deceleration Enters Cut Off Cut Off Exits Cut Off Immobilizer signal Example value yes no Indicates whether the control unit has received the consent by the instrument panel regarding the im mobilizer coded key or user code entered manually Potential errors will be shown on the Instrument Panel Errors screen page on the DIAGNOSIS section of the instrument panel Start up signal Example value yes no Indicates whether the control unit will enable start up when requested in case the safety measures are not respected side stand neutral sensor and clutch in correct position or if the immobilizer does not send the start up consent to the control unit the status is NO NAVIGATOR FUEL INJECTION SYSTEM PARAMETERS Target idle rpm NAVIGATOR ELECTRICAL ERRORS EEPROM Error P0601 circuit not operational Error cause Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status RAM Error P0604 circuit not operational Error cause ELE SYS 123 Electrical system DORSODURO FACTORY ABS Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status ROM Error P0605 circuit
70. oils with performance equivalent to or exceeding API SJ JASO MA ACEA JASO MA2 specifica tions AGIP FORK 5W Fork oil Showa SAE 5W FUCHS TITAN SAF 1091 Sachs Fork oil AGIP MP GREASE Black smooth textured lithium calcium ISO L X BCHB 2 DIN 51 825 KP2K 20 soap based grease containing EP ex treme pressure additives with optimal water repellent properties AGIP CHAIN LUBE SPRAY Spray lubricating grease AGIP BRAKE 4 Brake fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 synthetic fluid AGIP BRAKE 5 1 Clutch fluid FMVSS 116 DOT 5 1 Non silicone syn thetic fluid AGIP PERMANENT SPECIAL Ethylene glycol based antifreeze fluid ASTM D 3306 ASTM D 4656 ASTM D with organic inhibition additives Red 4985 CUNA NC 956 16 ready to use CHAR 60 INDEX OF TOPICS SPECIAL TOOLS S TOOLS Special tools Stores code 020709Y 020710Y AP8140187 020711Y 020712Y 020713Y S TOOLS 62 DORSODURO FACTORY ABS SPECIAL TOOLS Description Engine support Engine plate Engine support stand Engine pinion locking Handle for Flywheel cover removal Flywheel extractor DORSODURO FACTORY ABS Special tools Stores code 020714Y 020715Y 9100896 020716Y 020470Y AP8140302 Description Dial gauge mounting Tone wheel removal Clutch housing locking tool Connecting rod locking Pin snap ring fitting tool tool for sealing ring fitting S TOOLS 63
71. or wrongly fixed If it is not OK replace the tone wheel and if it is OK check that the tyre size is the correct one If itis not OK replace it If it is OK check that the tyre pressure is the correct one If it is not OK restore it if itis OK replace the speed Sensor VEHICLE REAR SPEED SENSOR FUNCTION To indicate the vehicle speed by read ing the rear wheel turning speed OPERATION OPERATING PRINCIPLE Magne toresistive sensor a square wave pulse is gener ated with voltage approx between 11 55 V and 11 25 V WIRING DIAGRAM Level in wiring diagram ABS ELE SYS 127 Electrical system DORSODURO FACTORY ABS REMOVAL LOCATION ON THE VEHICLE on the swingarm right side under the chain tension screw CONNECTOR LOCATION if available under the saddle right side PINS PIN 1 Ground connection yellow PIN 2 Power supply voltage Output signal yellow brown NAVIGATOR Parameters Speed km h Vehicle speed ELECTRICAL ERRORS Speed sensor 5DAO electric malfunction Electrical fault in sensor or cable harness Troubleshooting Check the sensor connector and the ABS control unit connector If they are not OK restore the connectors If they are OK check continuity of the yellow brown cable between PIN 2 of the sensor on the cable harness side and PIN 11 of the ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor on the cable harness side with the sensor
72. other turn indicator Now it is possible to separate the front section of the plate from the rear Remove the clamp and release the ca ble harness Turn the turn indicators by 180 degrees and remove them BODYW 378 DORSODURO FACTORY ABS Bodywork Remove the license plate light fixing screw in order to remove the lamp holder and be sure to collect the nut Remove the lamp holder to replace the license plate light bulb Release the opening cable and re move it Remove the fork spring BODYW 379 Bodywork DORSODURO FACTORY ABS Remove the hose control plate Remove the lock block Air box AIR FILTER BOX pos Description Type Quantity Torque Notes 1 Cross head self tapping screw fas M5x20 10 3 Nm 2 21 Ibf ft tening separator filter box 2 SWP self tapping screw M2 9x12 TCCR 2 3 Nm 2 21 Ibf ft 3 Cross head self tapping screw fas M5x20 8 3 Nm 2 21 Ibf ft tening cover filter box 4 Cross head self tapping screw fas M5x20 3 3 Nm 2 21 Ibf ft tening lateral cap filter box Cross head self tapping screw M5x10 2 3 Nm 2 21 Ibf ft BODYW 380 DORSODURO FACTORY ABS Bodywork e Remove the air filter Slide off the electrical components fas tened to the air filter box Undo and remove the eight screws Unscrew and remove the inner screw Unscrew and remove the screw Remove the
73. pos Description Crankshaft primary gear fastener nut 2 Connecting rod screw CRANKSHAFT Type Quantity M24x1 5 1 M10 4 Torque 270 Nm 199 14 Ibf ft 15 30 Nm 11 06 22 13 lbf ft 50 2 final control torque 65 78 Nm 47 94 57 53 Ibf ft Notes Anticlockwise nut Lubricate the threads before tight ening CHAR 47 Characteristics DORSODURO FACTORY ABS OiL PUMP pos Description Type Quantity Torque Notes 1 Oil drainage plug M16x1 5 1 19 Nm 14 01 Ibf ft 2 Fastening oil sensor on clutch side 1 13 Nm 9 59 Ibf ft crankcase half 3 Fastening oil filter union on clutch 1 20 Nm 14 75 Ibf ft side crankcase half 4 Oil filter 1 14 Nm 10 33 Ibf ft 5 Cil pressure regulator valve 3 4 Unf 16 1 43 Nm 31 72 Ibf ft 6 Oil pump fastener screw M6 2 5 50 Nm 4 06 Ibf ft Loctite 242 7 Rose pipe fastener screw 2 12 Nm 8 85 Ibf ft 8 Complete oil pump gear fastener 1 9 11 Nm 6 64 8 11 Ibf ft 9 Oil pump cover fastener screw M3 2 0 80 Nm 0 59 Ibf ft CHAR 48 DORSODURO FACTORY ABS Characteristics pos Description Gear retainer pawl fastener screw Selector plate fastener screw Screw fastening Desmodromic se lector drum Selector sprocket Gear sensor fastener screw Selector pin fastener onto clutch side crankcase half Gear retainer pawl fastener pin Gear retainer pawl fastener flanged nut GEAR SELECT
74. servicing Using this function the odometer can be reset only once within the first 200 km 124 mi of the vehicle provided this has not been done by the Quality Check UPDATE This function is used to program the instrument panel again This screen page shows the software version currently loaded the LCD reads INSTRUMENT PANEL DISCONNECTED NOW CONNECT THE DIAGNOSIS INSTRU MENT The instrument panel will restart to work normally after the key is inserted extracted Modify Keys With this function the instrument panel can update the keys Up to 4 keys can be stored The user code is first requested to be entered ENTER THE CODE After entering the correct code the following message should be shown on the display INSERT THE X KEY INSERT THE X 1 KEY At least one key must be programmed for the next start ups If no other key is inserted within 20 seconds or if there is no power or after the fourth key is programmed the procedure finishes and all the functions of the vehicle and the instrument panel must be enabled even if only one key has been programmed KM MILES This menu selects the unit of measurement either for the speed or the total or partial odometers e KM M MILES LANGUAGES ELE SYS 117 Electrical system DORSODURO FACTORY ABS Select the user interface language from this menu ITALIANO ENGLISH FRANCAIS e DEUTSCH ESPANOL Service warning light reset VEHICLE SERVICING RESET This fun
75. the cable har ness If there is continuity with the throttle body connector connected check that the resistance from the throttle control unit connector between PIN A1 and C1 is within 1 and 2 5 Ohm if it is not replace the throttle body if it is check that the throttle body is not mechanically blocked if blocked solve the problem and replace the body if it is not replace the throttle control unit Rear throttle supply voltage during self acquisition P0184 Example value low supply voltage Error cause The throttle power supply voltage is too low to carry out the self acquisition test correctly at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting The throttle test is not carried out when the key is set to ON because the test could show unreal errors because the voltage is too low Voltage is detected by the Marelli control unit Rear throttle control circuit P0186 Example value short circuit to positive short circuit to negative open circuit overcurrent excessive internal temperature Error cause If shorted to positive excessive voltage has been detected at PIN 8A of the throttle control unit connector If shorted to negative no voltage has been detected If the circuit is open there is overvoltage or excessive internal temperature an interruption or excessive ampere input or control unit overheating has been detected Troublesho
76. the vehicle left side un screw and remove the pin and collect the nut and the washer from the right side Disconnect the front turn indicator ca ble harness Disconnect the headlamp connector and remove the headlamp assembly See also Instrument cluster support Bodywork BODYW 367 Bodywork DORSODURO FACTORY ABS Taillight assy USA Version TAILLIGHT pos Description Type Quantity Torque Notes 1 TE screw fastening tail light to li M6x45 3 10 Nm 7 37 Ibf ft cense plate mounting frame 2 Fastener for rear turn indicators M6 2 3 Nm 2 21 Ibf ft 3 Reflector fastener M5 2 2 Nm 1 47 Ibf ft 4 Fastener for license plate light M5 1 5 Nm 3 69 Ibf ft Remove the license plate support Unscrew and remove the four screws BODYW 368 DORSODURO FACTORY ABS Bodywork Unscrew and remove the screw Unscrew and remove the three internal SCrews Working from both sides unscrew and remove the screw Disconnect the taillight connectors Remove the taillight See also Tail guard BODYW 369 Bodywork DORSODURO FACTORY ABS Footrest FOOTPEGS pos Description Type Quantity Torque Notes 1 Upper screw fastening passenger M8x35 2 25 Nm 18 44 Ibf ft Loct 243 footrests to frame side panels 2 Lower TCEI screw fastening passen M8x35 2 25 Nm 18 44 Ibf ft Loct 243 ger footrests to rider footrest mount ing 3 T
77. to the rear wheel faulty sensor or missing sensor tone wheel Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5D94 no acceleration after pressure reduction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5D95 excessive speed measured Faulty sensor or tone wheel or tone wheel with wrong number of teeth or wrong tyre size Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed
78. tone wheel with wrong number of teeth or wrong tyre size Possible control unit fault Possible control unit fault Possible control unit fault Possible control unit fault Possible control unit fault Voltage too low measured for 30 seconds at PIN 18 of the ABS control unit Possible control unit fault Excessive voltage measured at PIN 18 of the ABS control unit Inconsistency detected between memory coding INFO ECU Vehicle code and what is measured at cable harness identification PIN INFO ECU screen page Vehicle identification line Pins 2 15 of ABS control unit Possible control unit fault BRAK SYS 335 DORSODURO FACTORY ABS Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters ADJUSTMENTS Characteristic Value example Unit of Notes measure ment Coding 1 Used for re coding the control unit or coding a new one Coding 2 Vehicle identification is done according to the con nection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory Coding 3 The identification can be read in the INFO ECU screen page in the line Vehicle code aprilia FA Temm gt Shiver X AS i E T jJ u f Mana X Dorsoduro NOTE the X in the table identifies the con nector pin is grounded PIN2 15 BRAK SYS 336 DORSODURO FACTORY ABS Braking system Modulator MODULATOR REMOVAL
79. unit VEHICLE connector if not OK restore if OK check the ground insulation of the two CAN lines from PIN 20 and PIN 51 of the VEHICLE connector If not OK restore the cable harness if OK check continuity of the two CAN lines from the Marelli control unit VEHICLE connector to the filter box large connector and to the instrument panel connector if not OK restore the cable harness if OK check that the two lines are not shorted to positive testing each of the 3 connectors Marelli control unit connector filter box large connector and instrument panel connector with 1 connector disconnected at a time and by setting the key to ON If not OK restore if OK replace the Marelli control unit Mute Node CAN Line U1601 Mute Node Error cause The injection ECU cannot send CAN signals it receives signals from the instrument panel and the throttle control unit the control unit may need replacing Troubleshooting Replace the Marelli control unit CAN line to instrument panel U1701 no signal Error cause No signal is received from the instrument panel Troubleshooting Check the connector of the instrument panel if OK restore if OK check the continuity of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli control unit if not OK restore the cable harness if OK replace the instrument panel CAN line to the throttle control unit U1705 no signal Error cause No signal
80. voltage has been detected at PIN B5 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN B5 of the throttle control unit Troubleshooting shorted to positive check the value shown by the parameter of the Rear throttle Potenti ometer 2 voltage disconnect the left connector and see the value displayed by Navigator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle body if the voltage drops to zero if the circuit is open shorted to negative check the throttle body connector and the throttle valve connector If not OK restore if everything is OK check circuit continuity between the two terminals If not OK restore the cable harness if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body Front throttle supply voltage during self acquisition P0164 Example value low supply voltage Error cause The throttle power supply voltage is too low to carry out the self acquisition test correctly at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting The throttle test is not carried out when the key is set to ON because the t
81. 0 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Electrical system General wiring diagram PER L dm x LT ix key MULTIPLE CONNECTORS FRONT RIGHT TURN INDICATOR COMPLETE HEADLAMP TAIL LIGHT BULB TWIN HIGH LOW BEAM BULB FRONT LEFT TURN INDICATOR LOGIC RELAY WITH N C MATING CLUTCH SWITCH HORN 10 Left light switch 11 INSTRUMENT PANEL 12 Right light switch Oo CO N O oOo A O N ELE SYS 111 Electrical system 13 0IL PRESSURE SENSOR 14 INSTRUMENT PANEL DIAGNOSIS 15 SIDE STAND SWITCH 16 ECU AND ABS DIAGNOSIS 17 IMMOBILIZER AERIAL 18 IGNITION SWITCH 19 REAR LEFT TURN INDICATOR 20 Rear right turn indicator 21 LICENSE PLATE LIGHT BULB 22 23 COMPLETE TAILLIGHT WITH LED 24 REAR STOP SWITCH 25 FRONT STOP SWITCH 26 SPEED SENSOR 2 Fall sensor 28 NEUTRAL SENSOR 29 TIMING SENSOR OPTIONAL 30 Secondary fuses 31 Flywheel 32 Voltage regulator 33 STARTER MOTOR 34 START UP RELAY 35 MAIN FUSE 36 BATTERY 37 START UP MAINTENANCE RELAY 38 CONTROL RELAY START UP LOGIC 39 MAIN INJECTION RELAY POLARISED 40 AUXILIARY INJECTION RELAY 41 FAN 42 FAN CONTROL RELAY 43 FUEL LEVEL SENSOR 44 FUEL PUMP 45 REAR CYLINDER COIL 46 FRONT CYLINDER COIL 47 REAR CYLINDER SPARK PLUG 48 FRONT CYLINDER SPARK PLUG 49 INTAKE AIR TEMPERATURE SENSOR 50 Water Temperature Sensor ELE SYS 112 DORSODURO FACTORY ABS DORSODURO FACTORY ABS 51 L
82. 0 14 147 51 Ib ft 9 Nm 6 64 Ib ft Screw fastening Stator Flywheel 3 50 Nm 2 58 Ibf ft 13 Nm 9 59 Ib ft 13 Nm 9 59 Ibf ft 4 Nm 2 95 Ib ft 8 Nm 5 90 Ibf ft 13 Nm 9 59 Ibf ft Screw fastening bracket to starter 3 Nm 2 21 Ibf ft Engine Notes Loctite 242 Removing the flywheel cover NOTE SCREW 2 ON THE FLYWHEEL COVER IS SHORTER Remove the flywheel cover inspection cap Unscrew and remove the ten screws 1 0 THAN SCREWS 1 _ V 7 ENG 199 Engine DORSODURO FACTORY ABS Remove the flywheel cover using the specific tool Specific tooling 020712Y Handle for Flywheel cover removal Removing the flywheel cover components Remove the two pick up fixing screws Remove the three stator fixing screws CAUTION THE PICK UP AND STATOR SHALL BE REMOVED SIMUL TANEOUSLY AS THEY ARE PART OF THE SAME ELEC TRICAL BRANCH Magneto flywheel removal Remove the flywheel cover e Unscrew and remove the screw and remove the retention plate ENG 200 DORSODURO FACTORY ABS Engine Heat the magneto flywheel with the specific heater Lock the flywheel using the specific tool and loosen the screw Specific tooling 020713Y Flywheel extractor Screw the anticlockwise bolt of the special tool on the external body Keeping the external body blocked and gripping the key screw the anticlock wise bolt so
83. 1 12V 30A Fan relay 2 Relay with ignition maintenance diode serv ice 12V 20A Main injection relay Resistance module High and low beam lights relay Auxiliary injection relay Control relay N O oo A CO Logic relay TABLE J 4 5x290 0 18x11 42 Clamp TABLE K Plastic cable guide that holds the lambda probe branch the rear stop switch branch and the rear wheel speed sensor ELE SYS 101 Electrical system DORSODURO FACTORY ABS TABLE L First of all connect the light switches connectors and the key switch inside the rubber cap and po sition the latter as in the figure then the Demand Master BLUE tape connector and then the reg ulator connector 9 Regulator connector 10 Rubber cap that hosts light switch and key switch connectors 11 Demand 1 Master Connector TABLE M The clamp holds the cables going out from the light switches and the immobilizer aerial cable going out from the key switch 4 5x180 0 18x7 08 Clamp TABLE N 2 5x160 0 10x6 30 Clamp TABLE O 12 Cable grommet 13 2 5x98 0 10x3 86 Clamps 14 4 5x290 0 18x11 42 Clamps ELE SYS 102 DORSODURO FACTORY ABS Electrical system TABLE O1 Clamp TABLE P Engine attachment clamps that coil the main cable AAA an lt L E harness and the engine battery ground connec tion cable harness TABLE Q Rubber clamp TABLE R Metallic cable guide ELE
84. 1 994 mm 1 65307 1 65330 in 3 41 982 41 988 mm 1 65283 1 65307 in See also Removing the flywheel cover Selecting bushings There is only one dimension class for the connecting rod As a result the bushings used must be selected in accordance with the dimension class of the crank pin BUSHINGS Crank pin diameter Connecting rod class 1 Crankshaft class 0 semi bushing type E green Crankshaft class 1 Semi bushing type A red Crankshaft class 2 Semi bushing type B blue Crankshaft class 3 Semi bushing type C yellow Selecting connecting rods Not all weight classes are available as spare parts Only the two most significant weight classes are available refer to the following table for selection CONNECTING RODS Class according to crankshaft weight Original connecting rod class E1 Brown connecting rod E2 Blue connecting rod E3 Yellow connecting rod E4 Green connecting rod E5 Pink connecting rod E6 Black connecting rod E7 White connecting rod CAUTION THE CONNECTING RODS INSTALLED ON THE SAME ENGINE MUST BE OF THE SAME COLOUR AND MUST USE THE SAME TYPE OF ASSEMBLY WITH THE CRANKSHAFT CHAR 59 Characteristics DORSODURO FACTORY ABS WHEN REFITTING ALSO ENSURE THAT THE SEMI BUSHINGS ARE ALL OF THE SAME CLASS See also Removing the flywheel cover Recommended products chart RECOMMENDED PRODUCTS TABLE Product Description Specifications ENI i RIDE PG 15W 50 Engine oil Use branded
85. 2 3 Injector fastener screw M6 2 12 Nm 8 85 Ib ft Loctite 242 4 Injection Throttle Body fastener M6 8 12 Nm 8 85 Ib ft Loctite 242 screw Ride by Wire RIDE BY WIRE Operating logic Those riding motorbikes do not require a specific throttle valve opening from their engines but actually a specific torque The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit Therefore there is a Throttle map to which the control unit refers in order to decide the position at which the throttle valves should be and at what speed they should reach the pre set position The main parameters which influence the throttle map are Throttle position and opening closing speed Engine rom Inlet pressure read at each inlet manifold Rear and front throttle valve position Air temperature The functions required from the Marelli control unit therefore are P SUPP 275 Power supply DORSODURO FACTORY ABS 1 Ride by Wire system control throttle map 2 Injection ignition control 3 System safety checks 1 Ride by Wire system control THROTTLE GRIP POSITION SENSOR The throttle grip is the part to which the throttle control cables arrive its task is to translate the rider s power request into an electrical signal to be sent to the electronic control unit The two throttle cab
86. 3 CHAR 27 Characteristics DORSODURO FACTORY ABS CENTRE FRAME pos Description Type Quantity Torque Notes 1 TCEI screws fastening side panels to M12x282 3 80 Nm 59 Ibf ft engine 2 TCEI screw fastening lambda probe M4x10 2 3 Nm 2 3 Ibf ft plate to RH frame pre fit on RH side panel 3 SWP self tapping screw fastening M5x14 4 2 6 Nm 1 92 Ibf ft demand sensor mounting to demand sensor 4 Flanged TE screw fastening demand M6x20 3 10 Nm 7 37 Ibf ft sensor to frame CHAR 28 Characteristics DORSODURO FACTORY ABS 9 e FOOTPEGS pos Description Type Quantity Torque Notes 1 Upper screw fastening passenger M8x35 2 25 Nm 18 44 Ibf ft Loct 243 footrests to frame side panels 2 Lower TCEI screw fastening passen M8x35 2 25 Nm 18 44 Ibf ft Loct 243 ger footrests to rider footrest mount ing 3 TCEI screw fastening rider footrest M8x35 4 28 Nm 20 65 Ibf ft Loctite 243 mounting to frame CHAR 29 Characteristics pos Description Stand screw Thin nut Spring fixing pin TCEI screw fastening stand switch DORSODURO FACTORY ABS STAND ASSEMBLY Type M10x1 25 M10x1 25 M5x16 Quantity 1 1 1 2 Torque 10 Nm 7 37 Ibf ft 30 Nm 22 13 Ibf ft 7 5 Nm 5 53 Ibf ft 7 Nm 5 16 Ibf ft Notes Loctite 243 Loctite 243 pos Description 2 Rear TE screw fastening tank FUEL TANK Type M6x90
87. 30 Nm 22 13 Ibf ft 10 Nm 7 37 Ibf ft Notes Loctite 243 CHAR 39 Characteristics DORSODURO FACTORY ABS USA Version TAILLIGHT pos Description Type Quantity Torque Notes 1 TE screw fastening tail light to li M6x45 3 10 Nm 7 37 Ibf ft cense plate mounting frame 2 Fastener for rear turn indicators M6 2 3 Nm 2 21 Ibf ft 3 Reflector fastener M5 2 2 Nm 1 47 Ibf ft 4 Fastener for license plate light M5 1 5 Nm 3 69 Ibf ft CHAR 40 DORSODURO FACTORY ABS Characteristics REAR BODYWORK 1 pos Description Type Quantity Torque Notes 1 Screws fastening battery cover to M5 241 4 Nm 2 95 Ibf ft compartment 2 TBEI screw fastening battery com M5x9 2 6 Nm 4 42 Ibf ft partment to saddle mounting E REAR BODYWORK 2 pos Description Type Quantity 1 TBEI screw fastening LH RH covers M6x20 4 to silencer 2 TBEI screw fastening tail fairing to M5x9 2 saddle mounting 3 Screw fastening tail fairing to battery 3 compartment Torque 10 Nm 7 37 Ibf ft 6 Nm 4 42 lof ft 4 Nm 2 95 lof ft Notes CHAR 41 Characteristics DORSODURO FACTORY ABS pos Description 1 TBEI screw fastening license plate mounting to mounting 2 Fastener for license plate mounting frame assembly to gusset plate saddle lock ing cover to license plate mounting 3 Screw fastening license plate mount Typ
88. 374 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Bodywork Remove the screws 5 that secure the license plate holder to the internal structure and be sure to collect the in ternal nuts M Separate the license plate holder 6 by removing the rear cable harness 7 from the internal structure 8 Turn the turn indicators by 180 degrees and remove them Remove the four screws 9 that se cure the two components of the inter nal structure of the license plate holder and be sure to collect the internal nuts BODYW 375 Bodywork Release the opening cable and re move it Remove the fork spring Remove the hose control plate Remove the license plate light fixing screw in order to remove the lamp holder and be sure to collect the nut BODYW 376 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Bodywork Remove the lamp holder to replace the license plate light bulb e Remove the lock block OPTION 02 Remove the saddle unlocking cable 1 from the taillight and release the cable harness 2 Remove the taillight Remove the screw 3 Remove the three rear screws 4 BODYW 377 Bodywork DORSODURO FACTORY ABS Remove the screw 5 and the same from the opposite side Remove the screw 6 that secures the turn indicator to the license plate holder and to the rear section Repeat the operation for the screw that secures the
89. 5 Control unit missing valve calibra tion 5DD2 Control unit 5DD3 Recirculation pump 5DFO Recirculation pump 5DF1 Control unit 5DF2 Low electric voltage long period measurement 5DF3 Control unit 5DF5 High electric voltage 5DF7 Vehicle code 5E59 Control unit F000 ERRORS Value example Unit of measure ment Braking system Notes Electrical fault in sensor or cable harness Faulty sensor or signal interference Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing sur face In very rare cases abnormal tone wheel vibrations Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Faulty sensor tone wheel or tone wheel with wrong number of teeth or wrong tyre size Electrical fault in sensor or cable harness Faulty sensor or signal interference Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing sur face In very rare cases abnormal tone wheel vibrations Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Faulty sensor or
90. 9 59 Ibf ft Loctite 243 2 Screw fastening flywheel side M6 8 13 Nm 9 59 Ibf ft clutch side crankcase halves 3 Screw fastening flywheel side M8 9 29 Nm 21 39 Ibf ft clutch side crankcase halves 4 Special calibrated screw for gearbox 1 18 Nm 13 28 Ibf ft lubrication Splitting the crankcase halves Fit the special tool tightly fastening the four screws securing the tool onto the crankcase Unscrew remove the crankshaft fastener nut anticlockwise using the special tool retrieving the washer Specific tooling 020711Y Engine pinion locking ENG 245 Engine DORSODURO FACTORY ABS Use a commercially available extractor to remove the crankshaft gear Remove the gearbox control rod re trieving the washer ENG 246 DORSODURO FACTORY ABS Unscrew and remove the screw fixing the speed sensor Remove the speed sensor with cau tion Heat the screws of the gearbox selec tor mounting plate Unscrew and remove the three screws fastening the gearbox selector mount ing plate Remove the plate complete with selec tor Engine ENG 247 Engine e Unscrew the two neutral sensor fas tener screws e Remove the neutral sensor Retrieve the sensor contact complete with spring If the pinion has been removed refit fastening with the special tool Specific tooling 9100896 Clutch housing locki
91. ABLE HARNESS 42 CHECK INJECTORS AND ENGINE FOR CORRECT MECHANICAL OPERATION CHECK FUEL CIRCUIT PRESSURE M 43 WHEN THE STARTER BUTTON IS PRESSED DOES THE VOLTAGE TO THE YEL LOW PINK WIRE OF THE CONTROL RELAY START LOGIC 38 CHANGE TO APPROX ZERO YES go to 44 NO go to 45 e 44 CHECK FOR VOLTAGE ON THE RED BLACK WIRES OF THE COMMAND RELAY START LOGIC 38 YES go to 50 NO go to 51 M 45 CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW PINK CABLE FROM THE RELAY TO THE ENGINE CONNECTOR PIN 2 OK go to 47 NOT OK go to 46 e 46 RESTORE THE CABLE HARNESS END e 47 CHECK THE CONTROL UNIT CONNECTOR OK go to 49 NOT OK go to 48 e 48 RESTORE THE CABLE HARNESS END e 49 REPLACE THE CONTROL UNIT END e 50 WHILE PRESSING THE STARTER BUTTON DISCONNECT THE CONNECTOR FOR THE WHITE SKY BLUE AND WHITE RED WIRES OF THE STARTER RELAY 34 AND CHECK FOR VOLTAGE ON YELLOW RED WIRE OF THE START LOGIC CONTROL RELAY 38 OK go to 52 NOT OK go to 53 e 51 REPLACE THE RELAY END e 52 PRESSING THE STARTER BUTTON CHECK IF THERE IS VOLTAGE TO THE YEL LOW RED CABLE OF THE START UP RELAY OK go to 54 NOT OK go to 55 e 53 REPLACE THE RELAY END e 54 CHECK IF THE BLUE WIRE OF THE STARTER RELAY 34 IS GROUNDED OK go to 56 NOT OK go to 57 TROUBL 88 DORSODURO FACTORY ABS Troubleshooting 55 RESTORE THE CABLE HARNESS END 56 WITH THE IGNITION OFF CHECK FOR VOLTAGE ON THE REAR RED WIRE WITH CAP OF
92. AK SYS CLU SYS COOL SYS BODYW PRE DELIVERY re 8 2 gt lt a 5115 2 8 J o lt 7 lt o o m m z z INDEX OF TOPICS Characteristics CHAR Characteristics DORSODURO FACTORY ABS Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle please ensure that you do so in an open or very well ventilated area Never run the engine in an enclosed area If you do work in an enclosed area make sure to use a fume extraction system CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH Fuel CAUTION LN THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA POURS AVOIDING ANY CONTACT WITH NAKED FLAMES SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down Coolant Th
93. AMBDA PROBE 52 PURGE VALVE OPTIONAL 53 REAR CYLINDER PRESSURE SENSOR 54 FRONT CYLINDER PRESSURE SENSOR 55 REAR CYLINDER INJECTOR 56 FRONT CYLINDER INJECTOR 57 EFG 1X THROTTLE CONTROL UNIT 58 REAR CYLINDER THROTTLE 59 FRONT CYLINDER THROTTLE 60 DEMAND CONTROL UNIT 61 PICK UP 62 ECU 63 64 LOW HIGH BEAM PASSING LIGHT RELAY WITH N C MATTING 65 RECOVERY LOGIC RELAY URGENT SERVICE 66 PROTECTION RESISTANCES 67 ABS CONTROL UNIT 68 FRONT ABS SENSOR 69 REAR ABS SENSOR 70 ABS CONTROL UNIT FUSE Colour key Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red Ro Pink V Green Vi Purple Conceptual diagrams Checks and inspections GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING Electrical system ELE SYS 113 Electrical system DORSODURO FACTORY ABS THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE ON THE VEHICLE CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V CONNECTOR CHECK PROCEDURE The procedure includes the following checks 1 Observation and check of the connector correct position on the component or on the coupling con i Biar i nector making sure that
94. ANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con tainer to collect the fluid e Remove the front brake fluid reservoir cap Quickly press and release the front brake lever several times and then keep it fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before the lever reaches its end of stroke Repeat the operation until the fluid draining into the container is air bubble free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and block the front brake oil reservoir cap Refit the rubber protection cover BRAK SYS 341 Braking system DORSODURO FACTORY ABS Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper The pr
95. CEI screw fastening rider footrest M8x35 4 28 Nm 20 65 Ibf ft Loctite 243 mounting to frame RIGHT FOOTREST e Undo and remove the two external SCrews BODYW 370 DORSODURO FACTORY ABS Bodywork Remove the right footrest e Unscrew and remove both rear brake pump internal fixing screws LEFT FOOTREST e Unscrew and remove the two external SCrews Loosen the gear shift lever rod screw M Slide off the gear shift lever rod e Remove the left footrest Side body panels Unscrew and remove the screw BODYW 371 Bodywork Unscrew and remove the rear screw Remove the side fairing License plate holder PLATE HOLDER REMOVAL Remove the saddle Remove the tail fairing Unscrew and remove the three screws Disconnect the taillight connector Release the taillight cable harness from the clamps BODYW 372 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Bodywork Disconnect the saddle unlocking ble Slide off the license plate holder to wards the back See also Seat Tail guard LICENCE PLATE HOLDER REMOVAL OPTION 01 Remove the saddle unlocking cable 1 from the taillight and release the cable harness 2 BODYW 373 Bodywork Remove the three rear lower screws 3 e Remove the rear cover of the license plate holder assembly 4 Remove the cable harness clamp e Disconnect the connectors BODYW
96. D THAT THE ALARM WARNING LIGHT AND THE ENGINE OIL PRESSURE ICON DO NOT TURN ON SIMULTANEOUSLY ON THE DISPLAY CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTRAURBAN CONDITIONS ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE MAIN 75 Maintenance DORSODURO FACTORY ABS MAX maximum level MIN minimum level Shut off the engine Keep the vehicle upright with both wheels on the ground Check the correct oil level through the appropriate sight glass on the engine crankcase The oil level is correct when it is close to the MAX reference Replacement Check the engine oil level frequently To change the oil CAUTION HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY IDEAL TEMPERATURE IS REACHED AFTER THE ENGINE HAS RUN FOR ABOUT TWENTY MINUTES OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW MAIN 76 Use a cloth to wipe off any mud deposit on the area next to the filler plug 1 Place a container with 4000 cm 244 cu in capacity under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler plug 1 Drain the oil into the container allow several minutes for o
97. DORSODURO FACTORY ABS Suspensions Loosen the cover without unscrewing it completely Place the fork vertically locking it in a tb vice by the specific tool Completely unscrew the plug Specific tooling AP8140149 Protection for fitting operations Using the specific tool fixed the loading pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Pliers for pre fill pipe Unscrew the cap and remove it SUSP 288 DORSODURO FACTORY ABS Suspensions Remove the spring preload pipe Remove the lock nut and the washer Remove the spring paying attention to drain the oil correctly e Drain the oil into a container of suitable DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE capacity to collect fluids SUSP 289 Suspensions DORSODURO FACTORY ABS Discharge the fork remove the internal dipstick of the pumping member pin 1 and the washer 2 e Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Remove the retainer ring Take out the sleeve from the stem using the stem as a ha
98. E BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE CAUTION UPON INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE ONE AND PERFORM THE REVERSE OPERATION UPON REMOVAL WARNING THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS IT CON TAINS SULPHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Hydraulic braking system fluid level Clutch system fluid level if present Gearbox oil level if present Transmission oil level if present Engine coolant level if present Engine oil level Mixer oil level if present Road test Cold start Instrument panel operation PRE DE 394
99. EAD THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS NAVIGATOR STATUSES Run stop switch Example value Run Stop Indication on Navigator always STOP disconnect the connector and with the switch set to RUN check if there is continuity toward the switch of the two yellow grey and red black cables if there is no con tinuity replace the sensor if there is check the connector If not OK restore the cable harness if it is OK with key set to ON check if there is voltage to the red black cable if there is no voltage restore the cable harness if there is check the yellow grey cable ground insulation if there is continuity to ground restore the cable harness if it is correct take the key to OFF and check the VEHICLE connector ELE SYS 170 DORSODURO FACTORY ABS Electrical system is in good conditions and the continuity of the grey yellow cable between the sensor in question and the VEHICLE connector PIN 26 if not OK restore the cable harness if OK replace the Marelli control unit Indication on Navigator always RUN disconnect the connector and with the switch set to STOP check if there is continuity between the two cables of the switch if there is continuity replace the switch if there is not it means that with key set to ON the yellow grey cable is shorted to positive restore the cable harness
100. EM pos Description Type Quantity Torque Notes 1 SERPRESS self locking nut fasten M8 4 25 Nm 18 44 Ibf ft ing flange on head 2 Primary Clamp between front rear M6 2 7 Nm 5 16 Ibf ft manifolds and central manifold 3 Silencer Clamp between central M6 1 7 Nm 5 16 Ibf ft manifold and silencer 4 Self tapping TE screw fastening si M8x20 2 25 Nm 18 44 Ibf ft lencer mounting bracket to saddle mounting 5 Self tapping TE screw fastening front M8x35 2 35 Nm 25 81 Ibf ft silencer fixture to silencer mounting bracket REAR WHEEL pos Description Type Quantity Torque Notes 1 Lower self locking nut fastening M10 5 50 Nm 36 88 Ib ft sprocket to sprocket carrier 2 TCEI screw fastening flexible cou M10x30 5 50 Nm 36 88 Ib ft Loctite 270 pling mounting on wheel CHAR 38 DORSODURO FACTORY ABS Characteristics pos Description Rear brake lever pin Flanged TE screw fastening pump to footrest mounting TBEI screw fastening oil pipe to swingarm and rubber pipe to footrest mounting Flanged self locking nut Screw nut fastening pedal to brake lever Brake pipe union Flanged TE screw fastening rear disc Flanged TE screw REAR BRAKE Type Quantity M6 1 M6x20 2 M5x12 4 M6 1 M6 1 1 M10x1 2 M8x20 5 M6x16 1 Torque 25 Nm 18 44 Ibf ft 10 Nm 7 37 Ibf ft 6 Nm 4 42 lof ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 25 Nm 18 44 Ibf ft
101. ENTS WITH A CLEAN CLOTH ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES RINSE THEM IMMEDIATELY WITH ABUNDANT COLD CLEAN WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS IF THE FLUID GETS IN CONTACT WITH YOUR EYES WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCES ENSURE ADE QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR IT OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT TERY TO BE ACTIVATED Maintenance rules GENERAL PRECAUTIONS AND INFORMATION When repairing dismantling and reassembling the vehicle follow the recommendations given below care
102. EPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR STATUSES Gear in neutral Example value yes no NAVIGATOR NOTES Indication on the instrument panel always gear engaged check the correct position of the cable terminals on the connector and the correct connection of the cables on the terminals If they are not correct restore the cable harness if correct disconnect the connector and with gear in neutral check continuity to terminal ground connection sensor side if there is no continuity replace the sensor after checking cable continuity on the sensor side and the correct mechanical position If there is check the correct position of the terminal on the ELE SYS 164 DORSODURO FACTORY ABS Electrical system control unit connector and the correct connection of the cables on the terminals If they are not correct restore the cable harness if OK check the cable continuity between the sensor connector and ENGINE connector PIN 16 if there is no continuity restore the cable harness If there is replace the instrument panel if the vehicle performance is correct the engine starts with gear in neutral but the neutral warning light is off or replace the control unit if the vehicle performance is not correct the engine does not start with gear in neutral Indication on the instrument panel always gear in neutral disconnect the terminals from the sensor a
103. ESS THAN THOSE DETECTED WITH THE ENGINE COLD WARNING NEVER KEEP THE ENGINE RUNNING FOR MORE THAN ONE MINUTE FAILURE TO DO SO COULD CAUSE SERI OUS OVERHEATING DAMAGES TO THE MOTORCYCLE CIRCUITS ELE SYS 120 DORSODURO FACTORY ABS Electrical system COLD SHORT CIRCUIT CURRENT RPM 2000 4000 6000 8000 RMS DC current Arms average of the 3 stage 26 31 26 31 26 31 26 31 currents Voltage on battery poles with engine speed always between 3000 5000 RPM Start the engine after about one minute of operating bring the speed to 3000 5000 RPM then measure with a tester the voltage at the battery poles that must always be between 13V and 15V Otherwise if the correct operation of the alternator has already been checked replace the regulator CAUTION PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION START VOLTAGE ABOUT 13V MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIR CUIT level indicators Fuel reserve sensor Check proper operation of the sensor by adding a 2W bulb in series to the sensor Place a bulb between the battery power supply cable and the connector terminal and connect the negative terminal to the ground connection if the sensor is submerged in petrol sensor high electrical resistance approx 5 7 kOhm the bulb should remain off if the sensor is not submerged in petrol the bulb should turn on Lights list Front headlamp Characteristic Front dayli
104. FACTORY ABS Power supply Working on the body in question re move the injector slide off the clip and the injector itself CAUTION NEVER UNDO THE SCREWS IN THE FIGURE Use of diagnostics instrument for injection system The complete list of all the parameters device status errors etc is available at the home page of the website www serviceaprilia com in the search section Parameters Navigator The same parameters device status errors etc are grouped per type of component they refer to in the Electrical system chapter Checks and Controls P SUPP 279 INDEX OF TOPICS DORSODURO FACTORY ABS Suspensions Front ABS Version FRONT WHEEL pos Description Type Quantity Torque Notes Wheel axle nut Oo o 1 80Nm B9ibff 2 TE flanged screw fastening front disc M8x20 12 30 Nm 22 13 Ibf ft Loctite 243 Removing the front wheel Hold the vehicle front part Unscrew the screws fixing the front pli ers and slide them off the disc SUSP 281 Suspensions DORSODURO FACTORY ABS Remove the wheel axle fixing nut Retrieve the sealing washer Loosen the screws on the wheel axle clamps Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is exposed Remove the wheel axle by inserting a screwdriver in the holes on the pin During extraction support the wheel and then remove it Collect the spacer from the front wheel right side S
105. FUNCTIONING OR MISPLACED FIL TERING ELEMENT REFITTING DORSODURO FACTORY ABS Upon refitting pay attention when inserting intake ducts and check that the bayonet joint is released once every duct has been inserted and rotated MAIN 78 DORSODURO FACTORY ABS Maintenance Checking the valve clearance The following operation can be carried out also with the engine fitted on the vehicle Remove both head covers CAUTION WHENEVER THE HEAD COVER IS REMOVED ALL FOUR RUBBER RINGS AND THE GASKET SHOULD BE REPLACED e Using a thickness gauge measure the distance between the tip of the crank shaft and the valve bowl Take note of the measurement If valve clearance is not within the tolerance range adjust as follows Take the engine to the TDC Lock the camshafts by using the cor responding timing pins Specific tooling 020719Y Timing pin Characteristic Intake valve clearance 0 11 0 18 mm 0 0043 0 0071 in Exhaust valve clearance 0 16 0 23 mm 0 0063 0 0091 in e Remove one camshaft at a time Leave the other camshaft assembled and blocked by means of the timing pin CAUTION IF BOTH CAMSHAFTS ARE REMOVED THE ENGINE SPINS MAKING TIMING NECESSARY e Remove the bowl tappets and the ad et i ae ee justment shims using a magnet NOTE GREASE THE BOWL TAPPETS AND THE ADJUSTMENT 2 SHIMS PROPERLY EACH TIME THEY ARE REMOVED MAIN 79 Maintenance Replace c
106. HE RIGHT HAND CRANKCASE HALF Specific tooling 020724Y Gear control rod roller cage punch INSTALLATION Place the left hand crankcase in a press and install the roller cage with the specific tool CAUTION TO INSTALL THE ROLLER CAGE IN THE RIGHT HAND CRANKCASE HALF WORK WITH THE CYLINDER ON THE SIDE OF THE 1 mm STEP ON THE TOOL TURNED TO WARD THE ROLLER CAGE WHEREAS TO INSTALL THE CAGE IN THE LEFT HAND CRANKCASE HALF USE THE CYLINDER ON THE SIDE OF THE 2 mm STEP ON THE TOOL Specific tooling 020724Y Gear control rod roller cage punch Starter motor ENG 197 Engine DORSODURO FACTORY ABS Removing the starter motor Disconnect the starter motor power supply cable Undo and remove the four screws and remove the starter motor Generator side ENG 198 DORSODURO FACTORY ABS pos Description Spark plug Freewheel Ring fastener screw Screw fixing rotor Crankshaft 12 mm 0 47 in Screw fixing rotor Crankshaft 14 mm 0 55 in Cover Screw fastening pick up Flywheel cover Flywheel cover fastener screw Screw fastening starter motor brack et to crankcase Crankshaft access cap Retainer plate fastener screw motor Pick up cable retainer screw IGNITION Type M6 M12x1 25 M12x1 25 M6 M5 M6 M6 M6 M6x14 M5 Quantity 2 6 1 1 Torque 13 Nm 9 59 Ibf ft 14 Nm 10 33 Ibf ft 130 Nm 95 88 Ib ft 190 200 Nm 14
107. ING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR STATUSES ELE SYS 166 DORSODURO FACTORY ABS Electrical system Side stand Example value up down Indication on Navigator always down check the connector if not OK restore if it is OK disconnect the two terminals from the sensor and check continuity to ground of PIN 1 if there is no continuity restore the cable harness if there is replace the sensor Indication on Navigator always up disconnect the terminals from the sensor and check if there is continuity between the two PINS with stand down if there is continuity replace the sensor if the circuit is open it means that the brown green cable from sensor PIN 2 to ENGINE connector PIN 6 is short circuit to ground restore the cable harness Bank angle sensor FALL SENSOR Function it tells the vehicle position to the control unit Operation Operating principle When the sensor is inverted the circuit is closed to ground When the Marelli control unit detects this ground connection it does not enable start up or shuts off the engine Level in electrical circuit diagram Start up ena bling switches Ro Bi 0 5 35 Location e on the vehicle under the saddle connector near the sensor Electrical characteristics Sensor in vertical position open circuit resistance 62 kOh
108. INGS ARE MISSING OR DAMAGED THE WHOLE CHAIN UNIT PINION SPROCKET AND CHAIN SHOULD BE REPLACED LUBRICATE THE CHAIN ON A REGULAR BASIS PARTICULARLY IF YOU DETECT DRY OR RUSTY PARTS FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED A THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE ADJUST LUBRICATE WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION CLEANING AND LUBRICATION Do not wash the chain with water jets steam jets high pressure water jets and highly flammable sol vents Wash the chain with fuel oil or kerosene Maintenance operations should be more frequent if there are signs of quick rust Lubricate the chain atthe intervals specified on the routine maintenance table and whenever necessary Wash the chain allow to dry and lubricate with spray grease for sealed chains Stand pe STAND ASSEMBLY Description Type Quantity Torque Notes T ID IM RN M10x1 25 1 10Nm 7 37 Ibf ft Loctite 243 2 hnm M10x1 25 30 Nm 22 13 Ibf ft Loctite 243 Spring fixing pin 7 5 Nm 5 53 Ibf ft CHAS 317 Chassis DORSODURO FACTORY ABS pos Description Type Quantity Torque Notes 4 TCEI screw fastening stand switch M5x16 2 7 Nm 5 16 Ibf ft Exhaust EXHAUST SYSTEM pos Description Type Quantity Torque Notes 1 SERPRESS self locking nut fasten M8 4 25 Nm 18 44 Ibf ft ing flange on head 2 Prima
109. Ib ft 2 Cylinder plate fastener screw M6 4 7 84 9 81 Nm 5 78 7 23 Ib ft 3 Chain tensioner adjustment screw M6 2 5 50 Nm 4 06 Ib ft Removing the cylinder Remove the timing chain Unscrew and remove the two head fas tener screws located in the timing chain compartment ENG 231 Engine DORSODURO FACTORY ABS Unscrew and remove the outer screw M Unscrew and remove the four nuts proceeding in stages and in a diagonal pattern Ease the cylinder head assembly off the stud bolts Remove the three nuts fastening the cylinder head on the intake and ex haust sides Remove the gasket between the cylin der and the crankcase See also Chain removal Disassembling the piston Remove the head and cylinder Take out the pin locking ring ENG 232 DORSODURO FACTORY ABS Engine Lock the connecting rod using the spe cific tool Slide off the pin and remove the piston Specific tooling 020716Y Connecting rod locking Lock the connecting rod using circlips FOR SAFETY REASONS COVER THE CRANKCASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE Remove the top ring the intermediate ring and the three oil scraper rings ENG 233 Engine DORSODURO FACTORY ABS See also Removing the cylinder head Removing the cylinder Checking the cylinder All seal surfaces must be cl
110. M THE RIGHT WAY ROUND TIGHTENING TORQUES CAUTION IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED IT IS NECESSARY TO REPLACE IT WITH A NEW ONE CAUTION REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS BRAKES WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES CHECK THE TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period This ensures that components operate in loaded conditions and then unloaded conditions allowing the engine components to cool CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUNNING IN PERIOD Follow these guidelines Do not twist the throttle grip abruptly and completely when the engine is working at a low revs either during or after run in During the first 100 Km 62 miles use the brakes gently a
111. MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Specific tooling AP8140149 Protection for fitting operations SUSP 297 DORSODURO FACTORY ABS Suspensions Oil level 135 mm 5 31 in from the sleeve edge without a spring and with preload pipe Characteristic z Fork oil check also the correct air level in the stem El E 441 cm 26 91 cu in for each stanchion e Steering bearing Ju Si X E 3 n 3 3 H 4r OPTION 01 Steering upper plate without a headstock cut STEERING OPTION 1 pos Description Type Quantity Torque Notes 1 Headstock ring nut pre tightening M25x1 1 30 Nm 22 13 Ib ft Steering package settlement 1 Headstock ring nut tightening M25x1 1 12 Nm 8 85 Ib ft 2 Headstock cap M22x1 1 100 Nm 73 75 Ib ft 3 Stainless steel TCC screw fastening M8x30 6 25 Nm 18 44 Ib ft stanchions to upper and lower yokes 4 TCEI screw fastening U bolt onto M10x60 2 50 Nm 36 88 Ib ft fork yoke OPTION 02 Steering upper plate with a headstock cut SUSP 298 DORSODURO FACTORY ABS Suspensions STEERING pos Description Type Quantity Torque Notes 1 Headstock ring nut pre tightening M25x1 1 30 Nm 22 13 Ib ft Steering package settlement 1 Headstock ring nut tightening M25x1 1 12 Nm 8 85 Ib ft 2 Headstock nut pre tightening M22x1 1 10 Nm 7 37 lb ft Locti
112. N PUMP INSTALLATION Fit the oil pump in its seat ENG 270 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Engine Tighten both oil pump fixing screws e Fit the shim washer Fit the oil pump gear Fit the safety washer By means of a commercial hook span ner lock the pump and tighten the nut to the prescribed torque ENG 271 Engine DORSODURO FACTORY ABS By means of a screwdriver lift and bend the safety washer opposite the fitting tabs until it rests on the nut ENG 272 INDEX OF TOPICS Power supply DORSODURO FACTORY ABS Fuel pump FUEL PUMP pos Description Type Quantity Torque Notes 1 TEFL screw fastening fuel pump M5x16 6 6 Nm 4 42 Ibf ft Electrical characteristics Resistance 0 7 0 2 Ohm NAVIGATOR ELECTRICAL ERRORS Fuel pump relay control P0230 Example value shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 62 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 62 of the VEHICLE connector Injection P SUPP 274 DORSODURO FACTORY ABS Power supply Diagram THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake union fastener screw M6 8 12 Nm 8 85 Ib ft Loctite 242 2 RBW control unit fastener screw M5 2 3 50 Nm 2 58 Ibf ft Loctite 24
113. NNECTED CHECK THE CONTINUITY BETWEEN PIN 87 AND PIN 30 OK go to 31c NOT OK go to 31d 31b RESTORE THE CABLE HARNESS 31c CHECK CONTINUITY ON GREEN WHITE CABLE FROM THE LIGHT LOGIC RELAY 7 TO SECONDARY FUSE B OK go to 31e NOT OK go to 31f 31d REPLACE THE RELAY END 31e CHECK CONTINUITY ON RED BLACK CABLE FROM SECONDARY FUSE B THE TO MAIN INJECTION RELAY 39 OK go to 4 NOT OK go to 31g 31f RESTORE THE CABLE HARNESS 31g RESTORE THE CABLE HARNESS 32 CHECK CONTINUITY OF PINK BLACK CABLE FROM STARTER MAINTENANCE RELAY POLARISED 37 TO START BUTTON CONNECTOR OK go to 34 NOT OK go to 35 33 RESTORE THE CABLE HARNESS 34 CHECK THAT THE STARTER MAINTENANCE RELAY POLARISED 37 WORKS CORRECTLY OK go to 36 NOT OK go to 37 s 35 RESTORE THE CABLE HARNESS 36 CHECK CONTINUITY OF PINK BLACK CABLE FROM STARTER MAINTENANCE RELAY POLARISED 37 TO PIN14 ON VEHICLE CONNECTOR OK go to 38 NOT OK go to 39 37 REPLACE THE STARTER MAINTENANCE RELAY POLARISED 37 38 CHECK THE VEHICLE CONNECTOR PIN 14 OK go to 40 NOT OK go to 41 TROUBL 87 Troubleshooting DORSODURO FACTORY ABS 39 RESTORE THE CABLE HARNESS 40 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS ENGINE REVOLUTION SENSOR FOLLOW THE TROUBLESHOOTING STEPS IN THE SECTION REFERRING TO NAVIGATOR ELECTRICAL ERRORS CAUTION failure NOT identified go to 42 failure identified END M 41 RESTORE THE C
114. ON SECOND GENERATION CRANKCASES Crankcases are classified in two classes 1 or 2 depending on the diameter of the main bearing seat The class is indicated on both crankcase halves specifically in the starter gear area on flywheel side crankcase halves and in the gearbox control mechanism area on clutch side crankcase halves See also Removing the flywheel cover CHAR 56 DORSODURO FACTORY ABS Characteristics There are three crankshaft classes selectable for each bearing 4 5 6 for the flywheel side 7 8 9 for the clutch side The class is stamped on the outer face of the crankshaft counterweight NOTE TWO DIFFERENT CRANKSHAFT CLASSES MAY BE POS SIBLE ON THE TWO BEARINGS CRANKSHAFT CLASSES Specification Desc Quantity Crankshaft classes 4 7 Main journals diameter 49 978 49 984 mm 1 9676 1 9679 in Crankshaft classes 5 8 Main journals diameter 49 972 49 978 mm 1 9674 1 9676 in Crankshaft classes 6 9 Main journals diameter 49 990 49 984 mm 1 9681 1 9679 in Once the categories below are checked crankcase flywheel side main journal clutch side main journal choose the bushings used for assembly from the following table See also Removing the flywheel cover MAIN BUSHINGS Main journal Crankcase class 1 Crankcase class 2 Class 4 main journal l v Semi bushing type A red Semi bushing type B blue Class 5 main journal
115. OR Type M6 M5 M8 M5 M10x1 5 Quantity 1 3 1 Torque 12 Nm 8 85 Ib ft 5 50 Nm 4 06 Ib ft 20 Nm 14 75 Ib ft 5 50 Nm 4 06 Ib ft 16 Nm 11 80 Ib ft 11 13 Nm 8 11 9 59 Ib ft 10 12 Nm 7 38 8 85 Ib ft Notes Loctite dry loc 2040 3M SCOTCH GRIP 2353 3M SCOTCH GRIP 2353 Loctite 270 Loctite 242 CHAR 49 Characteristics DORSODURO FACTORY ABS CLUTCH COVER pos Description Type Quantity Torque Notes 1 Fastener screw for Clutch Cover M6 4 13 Nm 9 59 Ibf ft Clutch side cover 2 Clutch fastener nut M24x1 5 1 180 Nm 132 76 Ibf ft Chamfer 5 3 Fastening oil filler plug on Clutch cov 1 2 Nm 1 48 Ibf ft 4 Screw fastening fixing Plate Clutch M5 3 5 50 Nm 4 06 Ibf ft control Mounting 5 Screw fastening clutch control M6 2 13 Nm 9 59 Ibf ft mounting on flywheel side crankcase half 6 Clutch Cover Clutch side Cover M6x55 2 10 Nm 7 38 Ibf ft TCEI fixing screw inox protection CHAR 50 DORSODURO FACTORY ABS Characteristics CLUTCH pos Description Type Quantity Torque Notes 1 Clutch spring fastener screw M6 6 12 Nm 8 85 Ibf ft OPTION 01 CHAR 51 Characteristics DORSODURO FACTORY ABS WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 13 13 Nm 9 59 Ibf ft 2 Fastener screw for Pump Cover M6 3 13 Nm 9 59 Ibf ft Clutch s
116. ORSODURO FACTORY ABS Electrical system Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5DA4 missing acceleration after pressure reduction Faulty sensor or missing sensor tone wheel or excessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5DA5 excessive measured speed Faulty sensor or tone wheel or tone wheel with wrong number of teeth or wrong tyre size Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK check that the tyre size is the correct one If i
117. OTE IN THE EVENT OF CRANKCASE REPLACEMENT THE PRI MARY REDUCTION GEAR IS SUPPLIED READY MESHED Desc Quantity Centre to centre distance 110 50 110 54 mm 4 3504 4 3519 in Centre to centre distance 110 46 110 50 mm 4 3488 4 3504 in CRANKCASE CLASSES 02 Specification Crankcase class A Crankcase class B Class one Two different pinion classes A or B are available selected in relation to the centre to centre dis tance between the primary reduction gears On class B pinions only the class is indicated on the pinion itself See also Removing the flywheel cover CHAR 58 Desc Quantity Centre to centre distance 110 50 110 54 mm 4 3504 4 3519 in Centre to centre distance 110 46 110 50 mm 4 3488 4 3504 in DORSODURO FACTORY ABS Characteristics Crankshaft class crank pin There are four different classes of crankshaft avail able 0 1 2 3 selected in relation to crank pin 2 Q diameter E i RA t ax cum L a There are four different classes of crankshaft avail able E1 E2 selectable in relation to connect Bx ing rod weight N Key Class according to connecting rod weight Class according to crank pin diameter Serial number for traceability and indicating date SHAFT CATEGORY Class Crank pin diameter mm 0 42 000 42 006 mm 1 65354 1 65377 in 1 41 994 42 000 mm 1 65330 1 65354 in 2 41 988 4
118. Operation Operating principle When the control unit detects a temperature of approx 102 C it closes the fan control relay pickup circuit to ground Level in electrical circuit diagram electric fan Location the relay is located under the fuel tank left side first front relay CHECK however the identification of the relay with the colour of the cables Electrical characteristics relay normally open drive coil resistance 110 Ohm 10 NAVIGATOR STATUSES Fan relay Example value on off NAVIGATOR ACTIVATION Fan The fan relay No 44 in the wiring diagram placed under fuel tank left side first front relay CHECK however the identification of the relay with the colour of the cables is energised for 10 seconds The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation ELE SYS 168 DORSODURO FACTORY ABS NAVIGATOR ELECTRICAL ERRORS Cooling fan relay P0480 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive volt age has been detected at PIN 54 of the VEHICLE connector If shorted to negative short circuit to ground detected If the circuit is open interrupted circuit detected Excessive voltage can only be detected after the fan relay gets ac tivated Troubleshooting If shorted to positive check the relay electrical specifications are correct
119. S 174 Ar V 1 D1 0 5 1 Vi M 1 4 G 1 1 Desc Quantity Front throttle body PIN Front throttle body PIN Front throttle body PIN Front throttle body PIN Rear throttle body PIN Rear throttle body PIN Rear throttle body PIN 4 Rear throttle body PIN Front throttle body PIN Front throttle body PIN Rear throttle body PIN Rear throttle body PIN B V 1 D2 B V 1 D2 B 755430 1 ON C COM Az R 1 4 DORSODURO FACTORY ABS Dashboard NOTE THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR INSTRUMENT PANEL PIN Specification 1 GREY BODY Live 2 GREY BODY Right indicator control 3 GREY BODY 4 GREY BODY High beam lights input 5 GREY BODY 6 GREY BODY Select 3 Set 7 GREY BODY Select 2 Down 8 GREY BODY Select 1 Up 9 GREY BODY Fuel reserve sensor 10 GREY BODY 11 GREY BODY Battery 12 GREY BODY Left indicator control 13 GREY BODY Hazard control 14 GREY BODY 15 GREY BODY 16 GREY BODY Indicator reset 17 GREY BODY Oil sensor input 18 GREY BODY 750 1200 Selection 19 GREY BODY 20 GREY BODY K Line 21 BLACK BODY Battery 22 BLACK BODY Front left turn indicator activation 23 BLACK BODY Front right turn indicator activation 24 BLACK BODY Aerial 2 25 BLACK BODY 26 BLACK BODY CAN H 27 BLACK BODY CANL 28 BLACK BODY ABS warning
120. S ON AND THE WORD SERVICE IS SHOWN or THE EFI WARNING LIGHT IS FLASHING AND THE WORDS URGENT SERVICE ARE SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE 2 CONNECT TO THE CONTROL UNIT THROUGH NAVIGATOR BY SELECTING SELF DIAGNOSIS APRILIA DORSODURO 750 i e ARE CURRENT ATT or STORED MEM ERRORS SHOWN IN THE ERRORS DISPLAY SCREEN PAGE YES go to 4 NO go to 12 4 IF THE ERROR IN THE CENTRAL WINDOW IS SELECTED AND IS DISPLAYED PRESS THE KEY TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 7 READ THE ACTIVATION PROCEDURE FOR A NEW CONTROL UNIT ON THE ELEC TRICAL SYSTEM CHECKS AND CONTROLS ECU MARELLI CONTROL UNIT CHAP TER END 8 SELECT ERROR CLEARING FROM THE DEVICES ACTIVATION INJECTOR SCREEN PAGE 9 WAS THE PROBLEM SOLVED BY REPLACING THE THROTTLE GRIP SENSOR DEMAND OR THE THROTTLE BODY NO END YES go to 10 10 READ THE RESET PROCEDURE ON THE ELECTRICAL SYSTEM CHECKS AND CONTROLS THROTTLE GRIP POSITION SENSOR OR THROTTLE BODY CHAPTER END 11 CHECK IF THERE ARE CURRENT OR STORED ERRORS DETECTED BY THE IN
121. S REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL RH Remove the rubber cap PRE DE 396 DORSODURO FACTORY ABS Pre delivery Remove the shock absorber protection on the exhaust Fit a right bracket fasten then with a TEFL M8x35 mm screw at the top and with a TCEI M8x35 mm screw at the bottom NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE THE SPECIFIC WRENCH Refit the shock absorber protection on the exhaust HAND GUARDS PRE DE 397 Pre delivery DORSODURO FACTORY ABS e Remove the TCEI M6 X 50 screw which fastens the antivibration weight Fit the rubber ring in the hand guards Place the lower spacer on the rear view mirror hole Place the hand guards fastening them on the sides using TCEI M6 X 50 screw being careful when inserting the bush ing PRE DE 398 DORSODURO FACTORY ABS Pre delivery Place the upper spacer on the rear view mirror hole Fit the rear view mirror screwing the corresponding support column NOTE PERFORM THE SAME PROCEDURE FOR BOTH HAND GUARDS PRE DE 399 A ABS 324 332 Air filter 77 384 Air temperature sensor 143 Battery 118 125 Brake 338 340 343 Brake calliper 338 339 Brake pads 339 340 Brake pump 343 Bulbs Bushings C CAN line 175 Chain 14 224 227 232 315 Chain tensioner 224 227 Clutch 165 203 206 207 210 213 345 Coil 150 Conn
122. SEAL CHECK THAT THE WATER DRAINAGE HOLE UNDER THE OIL SEAL ITSELF IS NOT OBSTRUCTED Specific tooling 020885Y Water pump oil seal punch 2 mm 0 078 in Fit a new shaft and integrated seal as sembly using the specific tool Specific tooling 020725Y Punch for water pump overall sealing Fit the rotor drive gear Fit the rotor drive gear fastener nut plying leverage on the hexagonal in sert on the gear itself COOL SYS 355 Cooling system DORSODURO FACTORY ABS Fit the rotor and tighten with the relative nut while preventing the pump shaft from turning with a spanner Fit the water pump cover fastening the five screws OPTION 02 COMPLETE H20 PUMP INSTALLATION Insert the drive chain and position the H2O pump in its seat Insert the three 2 pump fixing screws and tighten then to the prescri bed torque COOL SYS 356 DORSODURO FACTORY ABS Cooling system Spread grease generously on the side of the H2O pump thereby facilitating insertion of the cover CAUTION DURING ASSEMBLY OF THE COVER BE CAREFUL TO IN SERT IT PERPENDICULARLY TO THE CRANKCASE WITH UNIFORM PRESSURE ON THE ENTIRE SURFACE THERE FORE AVOIDING DAMAGE TO THE O RINGS Removing the radiator Drain off the cooling system Undo and remove the screw e Remove the filler Remove both clamps and slide off the corresponding pipes e Disconnect the electri
123. SODURO FACTORY ABS km x 1 000 1 5 10 15 20 25 30 35 40 Safety switches Clutch control fluid 2 Brake fluid 2 2 Fork oil 7 Engine oil R R Light aiming Fork oil seals Flexible coupling 6 Tyres pressure wear 5 Wheels Bolts and nuts tightening Suspension and setting Fault warning light on instrument panel 4 Fuel lines 3 Clutch wear Brake pad wear Labour time minutes 230 10 30 10 340 10 30 10 400 Spark plug At regular intervals remove the spark plug and clean off any carbon deposits or replace as required CAUTION ALWAYS REPLACE BOTH SPARK PLUGS EVEN IF ONLY ONE NEEDS REPLACING Remove the saddle Remove the lower air deflector Remove the side fairings In order to reach the spark plugs CAUTION BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE FRONT SPARK PLUG e Working on the left side of the vehicle unscrew remove the screw MAIN 72 DORSODURO FACTORY ABS Maintenance Undo and remove the screw remove the horn e Turn the radiator forwards and lower it to act on the coil Undo and remove the screw e Slide off the front coil MAIN 73 Maintenance DORSODURO FACTORY ABS Unscrew remove the front spark plug REAR SPARK PLUG e Lift the t
124. SOR FUEL PRESSURE INJECTORS MECHANICAL OPERATION COILS SPARK ENGINE MECHANICS END Note A SEE THE ELECTRICAL SYSTEM CHECKS AND CONTROLS AIR TEMPERATURE SEN SOR CHAPTER Note B SEE THE ELECTRICAL SYSTEM CHECKS AND CONTROLS ENGINE TEMPERATURE SENSOR CHAPTER Note C SEE THE ELECTRICAL SYSTEM CHECKS AND CONTROLS LAMBDA PROBE CHAP TER Note D SEE THE ELECTRICAL SYSTEM CHECKS AND CONTROLS THROTTLE BODY CHAP TER See also Checks and inspections TROUBL 84 DORSODURO FACTORY ABS Troubleshooting Engine The engine does not start THE ENGINE DOES NOT START CAUTION NAVIGATOR SHOULD BE WORKING PROPERLY AND UPGRADED CAUTION BEFORE ANY TROUBLESHOOTING MAKE SURE THAT 1 BATTERY VOLTAGE IS ABOVE 12V 2 THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED 3 SECONDARY FUSES ARE NOT DAMAGED AND ARE ADEQUATELY FITTED NOTE THE RELAY NUMBER SPECIFIED REFERS TO THE WIRING DIAGRAM THE POSITION OF THE RELAY ON THE VEHICLE IS INDICATED IN THE ELECTRICAL SYSTEM COMPONENT LAYOUT RELAY LAYOUT CHAPTER 1 WITH THE KEY TURNED TO ON THE INSTRUMENT PANEL LIGHTS UP BUT NO FAILURE INDICATION IS SHOWN IS THE FUEL PUMP ACTIVATED YES go to 27 NO go to 2 2 DOES NAVIGATOR COMMUNICATE WITH THE CONTROL UNIT YES go to 3 NO go to 4 s 3 ACTIVATE ONE INJECTOR BY MEANS OF NAVIGATOR DEVICES ACTIVATION SCREEN PAGE INJECTOR ICON IS THE INJECTOR ACTIVATED YES go to 17 NO go to 12 e 4
125. ST TYPE THE TIGHTENING TORQUE GOES TO 12 14 Nm 8 85 10 32 Ib ft THE PRE TIGHTENING IS THE SAME THE SCREWS AND CAM TOWER CANNOT BE INTERCHANGED WITH THE PREVIOUS ONES CAUTION INSTALL THE CAMSHAFT TIGHTENING NUTS WITH THE MARK FACING UP Pre tighten the gear nut on the camshaft REFIT THE NUT WITH THE MACHINED SURFACE FACING THE GEAR THE MATERIAL ACRO NYM SHOULD BE VISIBLE Locking torques N m Nut fixing camshaft gears pre tightening M15x1 4 30 Nm 22 13 Ib ft Remove the camshaft lock it on a vice with aluminium jaws then tighten it to the prescribed torque N DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE ULTIMATE TIGHTENING TORQUE WITH THE SHAFT MOUNTED ON THE CYLINDER THIS OPERATION WOULD IRRETRIEVABLY DAMAGE THE HEAD Locking torques N m Nut fixing camshaft gears M15x1 4 90 Nm 66 38 Ib ft Remove the gear alignment tool Specific tooling 020718Y Camshaft gear alignment pin Release the crankshaft from the specific special tool Rotate the crankshaft in the riding direction until the rear cylinder piston reaches the top dead centre Lock the crankshaft with the specific special tool Carry out the timing operations performed for the front cylinder Specific tooling 020720Y Timing tool ENG 230 DORSODURO FACTORY ABS Engine Cylinder piston assembly CYLINDER pos Description Type Quantity Torque Notes 1 Chain tensioner fastener screw M6 4 13 Nm 9 59
126. STRUMENT PANEL REFERRING TO THE DIAGNOSIS CHAPTER INSTRUMENT TROUBL 83 Troubleshooting DORSODURO FACTORY ABS PANEL ERRORS SECTION IF THERE ARE ERRORS PRESENT SOLVE THE FAULT AND SELECT CLEAR ERRORS IF THERE ARE NO ERRORS PRESENT go to 12 12 IN THE ENGINE PARAMETER READING SCREEN PAGE DOES THE AIR TEM PERATURE PARAMETER INDICATE A VALUE EQUIVALENT TO ROOM TEMPERA TURE YES go to 13 NO note A 13 IN THE ENGINE PARAMETER READING SCREEN PAGE DOES THE ENGINE TEMPERATURE PARAMETER WITH COLD ENGINE INDICATE A VALUE SIMILAR TO THAT OF THE AIR TEMPERATURE PARAMETER AFTER STARTING THE ENGINE DOES THE PARAMETER INCREASE GRADUALLY INDICATING A CORRECT VALUE YES go to 14 NO note B 14 IN THE ENGINE PARAMETER READING AND THE LAMBDA SENSOR CORREC TION SCREEN PAGES WITH ENGINE AT IDLE AND ENGINE TEMPERATURE AT gt 90 C DOES THE VALUE VARY WITHIN THE 0 9 1 1 RANGE YES go to 15 NO note C 15 IN THE ENGINE PARAMETER READING SCREEN PAGE AND WITH ENGINE IDLE ARE FRONT THROTTLE CORRECTION PARAMETERS OR REAR THROTTLE CORRECTION WITHIN THE 0 4 0 4 RANGE AND IN THE SAME SCREEN PAGE ARE THE FRONT THROT POT 1 DEGREES AND REAR THROT POT 1 DE GREES WITH ENGINE AT IDLE gt OR A 0 5 CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN THE REAR AND FRONT CYLINDER MUST NOT BE 50 4 YES go to 16 NO note D 16 CHECK ENGINE SPEED SEN
127. Special tools Stores code 020718Y 020719Y 020720Y AP8140179 020721Y 020722Y 020376Y S TOOLS 64 DORSODURO FACTORY ABS Description Camshaft gear alignment pin Timing pin Timing tool Valve spring compressor Adaptor for valve removal Guide for oil seal Adapter handle DORSODURO FACTORY ABS Special tools Stores code Description 020629Y 8 mm 0 31 in guide 020412Y 15 mm Oil seal guide 020439Y 17 mm guide for oil seal 020263Y Sheath for fitting the driven pulley 020365Y 22 mm 0 87 in guide 020364Y 25 mm Guide S TOOLS 65 Special tools DORSODURO FACTORY ABS Stores code Description 020483Y 30 mm guide 020441Y Oil seal punch 020358Y 37 x 40 mm adaptor 020357Y 32 x 35 mm adaptor 020360Y 52 x 55 mm adaptor 020359Y 42 x 47 mm adaptor S TOOLS 66 Special tools DORSODURO FACTORY ABS Description Stores code Jig for timing overhead camshafts 020723Y WA E T 020724Y Gear control rod roller cage punch me 1 020661Y Water pump overall seal replacement kit a Lae 020725Y Punch for water pump overall sealing E ou 020885Y Water pump oil seal punch 020726Y Extractor for bushings 020727Y Punch for bushings S TOOLS 67 Special tools Stores code AP8140180 8140181 AP8140199 8202222 8140426 020880Y AP8140149 S TOOLS 68 DORSODURO FACTORY ABS Description Ext
128. THE STARTER RELAY 34 OK go to 58 NOT OK go to 59 57 RESTORE THE CABLE HARNESS END 58 WITH THE STARTER BUTTON PRESSED CHECK FOR VOLTAGE ON THE FRONT RED WIRE OF THE STARTER RELAY 34 OK go to 60 NOT OK go to 61 59 RESTORE THE CABLE HARNESS 60 CHECK FOR CONTINUITY ON THE RED WIRE BETWEEN THE STARTER RELAY 34 AND THE STARTER MOTOR YES go to 62 NO go to 63 61 REPLACE THE STARTER RELAY 34 END 62 REPLACE THE STARTER MOTOR END 63 RESTORE THE CABLE HARNESS END 64 WHAT DOES THE FALL SENSOR STATUS ON NAVIGATOR DEVICE STATUS ICON 0 1 SCREEN PAGE MEAN If NORMAL is shown go to 65 If TIP OVER is shown go to 68 65 WITH THE SWITCH SET TO RUN WHAT DOES THE RUN STOP SWITCH STA TUS ON NAVIGATOR DEVICE STATUS ICON 0 1 SCREEN PAGE MEAN If RUN is shown go to 66 If STOP is shown go to 67 66 USING NAVIGATOR CHECK THAT THE SIDE STAND NEUTRAL SENSOR AND CLUTCH SENSOR FUNCTION CORRECTLY OPERATE ANY DEVICE AND CHECK THE SUITABLE INDICATION ON THE DEVICE STATUS ICON 0 1 SCREEN PAGE If MALFUNCTION is shown go to 71 If CORRECT OPERATION is shown go to 72 67 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSOR INDICATION ON NAVIGATOR ALWAYS STOP END 68 IS THE SENSOR VERTICAL YES go to 69 NO go to 70 69 REFER TO THE CHAPTER ON ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSOR INDICATION ON NAVIGATOR ALWAYS TIP OVER END 70 SET THE SENSOR TO
129. USP 282 DORSODURO FACTORY ABS Suspensions Checking the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Replace both wheel bearings RADIAL AND AXIAL CLEARANCE CHECK Check the radial and axial clearance Axial clearance a minimum axial clearance is allowed Radial clearance none If one or both bearings do not fall within the control parameters Replace both wheel bearings LN ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage ALWAYS REPLACE BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE WHEEL AXLE or excessive wear e Use a dial gauge to check the wheel axle eccentricity Replace the wheel axle if the eccentricity exceeds the limit value Characteristic Maximum eccentricity 0 25 mm 0 0098 in SUSP 283 Suspensions DORSODURO FACTORY ABS Using a dial gauge check that the ra dial A and the axial B eccentricities of the rim do not exceed the limit value An excessive eccentricity is usually caused by wo
130. a Notes Loctite 270 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Vehicle preparation Remove the air filter box Remove the coolant radiator Remove the exhaust system Place the optional under sump and rear wheel service stands Unscrew and remove the screw and move the coll ENG VE 181 Engine from vehicle Disconnect the engine temperature sensor connector Disconnect the engine oil pressure sensor connector Disconnect the starter motor power supply cable e Unscrew and remove the screw and collect the washer Disconnect the ground leads ENG VE 182 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Engine from vehicle Move the breather pipe Disconnect the speed sensor connec tor e Unscrew and remove the three screws Remove the clutch control cylinder Lock the plunger using a clamp Unscrew and remove the two screws Remove the chain guard ENG VE 183 Engine from vehicle DORSODURO FACTORY ABS e Unscrew and remove the three screws fixing the chain guide Remove the clutch pin CAUTION UPON REFITTING PROPERLY GREASE THE O RING IN DICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT Disconnect the gear in neutral sensor connector e Disconnect the side stand sensor con nector ENG VE 184 DORSODURO FACTORY ABS Engine from vehicle Loosen the screw and slide off the
131. a chart is displayed showing potential errors in the immobilizer and the sensors connected to it DSB 01 Immobilizer fault key code read but not recognised DSB 02 Immobilizer fault key code not read key not present or transponder not working DSB 03 Immobilizer fault aerial not working open or short circuited DSB 04 Internal controller fault DSB 05 DSB 06 Error cause An oil sensor fault is signalled when it is detected that the sensor circuit is open or shorted to positive DSB 07 Oil pressure sensor Error cause An oil sensor fault is signalled when with engine off it is detected that the sensor circuit is open Troubleshooting ELE SYS 116 DORSODURO FACTORY ABS Electrical system The test is performed only once when the key is set to ON This error is signalled by the bulb icon and the general warning light turns on as well DSB 08 Oil pressure sensor Error cause An oil sensor fault is signalled when with engine running it is detected that the sensor circuit is closed There is an error when the general warning light turns on Troubleshooting This error is signalled by the bulb icon and the general warning light turns on as well The instrument panel must keep all previous errors stored in its memory DELETE ERRORS This option deletes all instrument panel errors a further confirmation is requested Use Navigator to reset ECU errors VEHICLE SERVICING RESET This function is used to reset vehicle
132. able in four size types A B C D to be coupled to the four cylinder types A B C D Only one type of piston ring is available CYLINDER PISTON COUPLING Specification Piston cylinder coupling Type A Piston cylinder coupling Type B Piston cylinder coupling Type C Piston cylinder coupling Type D Fitting clearance Desc Quantity Cylinder 91 990 91 977 mm 3 6216 3 6219 in Piston 91 933 91 940 mm 3 6217 3 6197 in Cylinder 91 997 92 004 mm 3 6219 3 6222 in Piston 91 940 91 947 mm 3 6197 3 6199 in Cylinder 92 004 92 011 mm 3 6222 3 6225 in Piston 91 947 91 954 mm 3 6199 3 6202 in Cylinder 92 011 92 018 mm 3 6225 3 6227 in Piston 91 954 91 961 mm 3 6202 3 6205 in 0 050 0 064 mm 0 00197 0 00252 in CHAR 55 Characteristics DORSODURO FACTORY ABS Crankcase crankshaft connecting rod INTERNAL MARKING ON FIRST GENERATION CRANKCASES Crankcases are classified in two classes 1 or 2 depending on the diameter of the main bearing seat The class is indicated on both crankcase halves specifically in the rear cylinder area on flywheel side crankcase halves and in the front cylinder area on clutch side crankcase halves CRANKCASE CLASSES Specification Desc Quantity Crankcase class 1 Bushing seat diameter 53 954 53 960 mm 2 1241 2 1244 in Crankcase class 2 Bushing seat diameter 53 960 53 966 mm 2 1244 2 1246 in INTERNAL MARKING
133. ach key ON Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Rear throttle minimum mechanical position self acquisition P0182 test failed Error cause Position of the throttle stop not within the expected range at each key ON Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Detection of the rear throttle Recovery conditions air T water T P0183 possible presence of ice Error cause A correct throttle rotation cannot be detected given low ambient and engine temperatures some ice may have formed in the duct at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check that the throttle body is clean and that there is no ice or condensation in the intake duct If they are replace the throttle body Rear throttle first self acquisition NOT performed P0185 test not carried out Error cause The first throttle self acquisition process has not been successful or has not been carried out The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting ELE SYS 161 Electrical system DORSODURO FACTORY ABS Delete errors hindering throttle self learning Rear throttle position error P0187 misalignment between control and activation Error cause
134. alibrated pads with a pad thick enough to correct the valve clear ance previously detected List of calibrated break pads Calibrated pad 2 60 Calibrated pad 2 65 Calibrated pad 2 70 Calibrated pad 2 75 Calibrated pad 2 80 Calibrated pad 2 85 Calibrated pad 2 90 Calibrated pad 2 95 Calibrated pad 3 00 10 Calibrated pad 3 05 11 Calibrated pad 3 10 12 Calibrated pad 3 15 13 Calibrated pad 3 20 14 Calibrated pad 3 25 15 Calibrated pad 3 30 16 Calibrated pad 3 35 17 Calibrated pad 3 40 18 Calibrated pad 2 55 19 Calibrated pad 2 50 20 Calibrated pad 2 45 21 Calibrated pad 2 40 CAUTION O e I3 o d X I9 DORSODURO FACTORY ABS BEFORE REFITTING HEAD COVERS CLEAN HEAD AND COVER SURFACES CAREFULLY Apply THREEBOND on the head cover perimeter along the gasket housing MAIN 80 DORSODURO FACTORY ABS Maintenance e Apply THREEBOND on the head in the areas indicated in the figure See also Removing the head cover MAIN 81 INDEX OF TOPICS TROUBLESHOOTING TROUBL DORSODURO FACTORY ABS Troubleshooting TROUBLESHOOTING PROCEDURE IF THE EFI WARNING LIGHT ON THE INSTRUMENT PANEL TURNS ON OR IF THERE IS ABNORMAL ENGINE PERFORMANCE CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER 1 THE EFI WARNING LIGHT I
135. alve stem 3 maximum eccentricity allowed 0 05 mm 0 00197 in valve head 4 maximum eccentricity allowed 0 05 mm 0 00197 in Check that the fixing grooves 5 of the valve cot ters are in proper conditions VALVE SPRINGS Carry out a measurement and a visual inspection of the valve springs for damage distortion or loss of tension Measure the spring length at release position Valve springs minimum wear limit 6 42 5 mm 1 673 in Valve springs minimum wear limit 7 38 mm 1 496 in Checking the cylinder head Using a round scraper clean off any carbon deposits in the combustion chamber CAUTION DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK PLUG THREADS OR THE VALVE SEATS Check the head for damage or scratches and replace it if necessary Check there are no mineral deposits or rust in the head water cooled jacket clean off if required Use checking ruler a thickness gauge positioned diagonally to the ruler to measure the cylinder head distortion Maximum cylinder head distortion 0 03 mm 0 0012 in Check that the tappet covers and the camshaft toothed wheel cover damaged worn replace the defective part s Installing the overhead camshaft The camshaft refitting procedure is described in the Timing section See also Timing ENG 222 DORSODURO FACTORY ABS pos Description Camshaft gear fastener nut pre tig
136. anic malfunction replace the whole unit Pressure sensors The pressure sensors one per cylinder are fundamental not only for the injection map at low and stabilised speeds but also for checking the Ride by Wire system their signal is connected to a TORQUE CHAIN for checking the correct opening of the throttle valves Intake air temperature sensor The signal coming from the sensor is used to calculate the estimated torque since the oxygen in the air also depends on its density which varies according to temperature 2 Injection ignition control Map for injection type alpha D rpm where alpha is the throttle position D is the pressure measured at inlet ducts Rpm are the engine revolutions At idle and for slow and stabilised speeds D n P SUPP 276 DORSODURO FACTORY ABS Power supply For medium high throttle openings alpha n For temporary speed speed change alpha n The main parameters that correct the injection map are Engine temperature Atmospheric pressure calculated Lambda probe signal Air temperature 3 System safety checks The checks are structured in several levels Level 1 sensor correct operation Level 2 comparison between requested torque and estimated torque generated by the engine Level 3 a microprocessor controls the correct operation of the regular microprocessor The consequent maintenance operations may be of different gravity according to the level and the
137. ank e Unscrew and remove the rear coil fix ing screw e Slide off the rear coil Unscrew and slide off the rear spark plug Check the gap between the electrodes with a feeler gauge CAUTION DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP MAIN 74 DORSODURO FACTORY ABS Maintenance The electrode gap should be between 0 6 0 7 mm 0 023 0 027 in Otherwise replace the 0 6 0 7 mm 0 023 0 027 in spark plug Make sure the washer is in good con ditions Installation Once the washer is fitted screw the spark plug carefully to avoid damaging the thread Tighten it using the spanner supplied in the toolkit make each spark plug com plete 1 2 a turn to press the washer CAUTION N TIGHTEN THE SPARK PLUG CORRECTLY OTHERWISE THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE DAMAGED USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG OTHERWISE THE ENGINE DURATION AND PERFORMANCE COULD BE COMPROMISED Locking torques N m Spark plug 13 Nm 9 59 Ibf ft Engine oil Check Check the engine oil level frequently NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM IF YOU CHECK LEVEL WHEN THE ENGINE IS COLD OIL LEVEL COULD TEMPORARILY DROP BELOW THE MIN MARK THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDE
138. arnesses how they are fixed to the motorcycle and potential problems are defined on the following sections in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harness 1 Filter Box Cable Harness 1 Taillight Cable harness 1 Relay Starter Motor Cable 1 Battery Engine Ground Cable 2 Caps for Magura Switches 1 Injection Main Relay 6 Relays 12 1 Start up Relay Medium black clamps 178 x 4 7 01 x 0 16 in ELE SYS 95 Electrical system DORSODURO FACTORY ABS Small black clamps 98 x 2 5 3 86 x 0 01 in e 110 3 94 in spiral for start up cable e 1 Pick Up divider cable harness if fitted Motorcycle division The wiring timing is subdivided in three essential sections as indicated in the figure 1 Front section 2 Central section 3 Rear part SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Carry out the checks described below once the electrical system is refitted connectors recon nected and clamps and retainers restored Check the connector block for connections and correct tightening in the following connec tors Instrument panel connector FRONT SECTION Handgrip sensor connectors CENTRAL SECTION TABLE G Pick Up Connector CENTRAL SECTION Side Stand Switch Connector CENTRAL SECTION TABLE
139. asons Not all versions models shown in this publication are available in all countries The availability of individual models should be confirmed with the official aprilia sales network The Aprilia trademark is the property of Piaggio amp C S p A Copyright 2013 Piaggio amp C S p A All rights reserved Reproduction of this publication in whole or in part is prohibited Piaggio amp C S p A Viale Rinaldo Piaggio 25 56025 PONTEDERA Italy www piaggio com SERVICE STATION MANUAL DORSODURO FACTORY ABS This manual provides the main information to carry out regular maintenance operations on your vehicle This manual is intended to aprilia Dealers and their qualified mechanics several concepts have been deliberately omitted as they are considered unnecessary As it is not possible to include complete mechanical notions in this manual users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters Without this knowledge repairing or checking the vehicle may be inefficient or even dangerous As the vehicle repair and check procedures are not described in detail be extremely cautious so as not to damage components or injure individuals In order to optimise customer satisfaction when using our vehicles Piaggio amp C S p a commits itself to continually improve its products and the relative documentation The main technical modifications and changes in repair procedures a
140. box connector and disconnect the sensor connector if the value does not vary it means that the cable is shorted between the filter box connector and the sensor connector restore the cable harness Replace the sensor if the value varies ELE SYS 137 Electrical system DORSODURO FACTORY ABS If the circuit is open short circuit to negative check filter box large connector the Marelli control unit connector and the sensor connector If not OK restore If everything is OK and with key set to OFF check if there is continuity between the VEHICLE PIN 34 of the Marelli control unit and the sensor connector PIN 3 if there is no continuity restore the cable har ness If there is continuity check the cable ground insulation if there is continuity to ground restore the cable harness if not with key set to ON check that the voltage on sensor con nector PIN 1 is approx 5 V if this is not correct set the key to OFF and check continuity between the ENGINE connector PIN 15 and the sensor connector PIN 1 If not OK restore the cable harness if it is OK replace the control unit if there is 5V voltage at PIN 1 and with key set to ON check the continuity to ground of the sensor connector PIN 3 if not OK restore the cable harness if OK replace the sensor Rear cylinder air pressure sensor P0106 short circuit to positive open circuit short circuit to neg ative Error cause If shorted to positive excessive voltage has been
141. c Quantity Gear primary drive 38 71 14 36 Secondary 17 32 Secondary 20 30 Secondary 22 28 secondary 23 26 Secondary 24 25 secondary 16 46 CAPACITY Desc Quantity 12 2 64 UKgal 3 17 US gal 2 8 0 62 UKgal 0 74 US gal 3 0 without oil filter change 0 66 UKgal 0 79 USgal 3 2 with oil filter change 0 70 UKgal 0 85 USgal 441 cm 26 91 cu in for each stanchion 1 8 0 40 UKgal 0 48 USgal 2 400 kg 882 Ib CHAR 13 Characteristics Drive chain Specification Type Model Electrical system Specification Battery Main fuses Secondary fuses Alternator permanent magnet type Specification Standard spark plugs Spark plug electrode gap Resistance Specification High beam light Low beam light Front daylight running light Turn indicator light Rear daylight running light stop light License plate light Rpm indicator lighting Multifunction display lighting Specification High beam light Right turn indicator Left turn indicator General warning Gear in neutral Side stand down Fuel reserve ABS Frame and suspensions Specification Type Steering inclination angle Trail CHAR 14 DORSODURO FACTORY ABS DRIVE CHAIN Desc Quantity Endless without master link and with sealed links No of links ELECTRICAL SYSTEM SPARK PLUGS BuLBs WARNING LIGHTS CHASSIS 108 525 ZRPK Desc Quantity 12 V 10 Ah YTX 12 BS 30A 3A 10A 15A 20A
142. c fan connector COOL SYS 357 DORSODURO FACTORY ABS Cooling system Undo and remove the screw remove the horn Working on the left side of the vehicle unscrew and remove the screw Lower the radiator from the upper fixing side to the chassis and remove it by sliding it off toward the vehicle right hand side To install the radiator follow the operations explained above but in reverse order and re place all the clamps removed e Hestore the correct coolant level See also Coolant replacement Removing the expansion tank Remove the right side fairing COOL SYS 358 DORSODURO FACTORY ABS Loosen and move the clamp e Slide off the pipe Release the clamp Slide off the pipe e Undo and remove the screw and col lect the washer Slide off the expansion tank Thermostatic valve Traditional circuit three way thermostatic valve 1 Hot water inlet from the heads 2 Outlet towards the short circuit direct to the pump 3 Outlet towards the radiator 2 EU Cooling system COOL SYS 359 INDEX OF TOPICS Bopvwonk BODYW DORSODURO FACTORY ABS Bodywork INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 screw fastening instrument M6x20 2 10 Nm 7 37 Ibf ft panel mounting to fork yoke FRONT MUDGUARD pos Description Type Quantity Torque Notes 1 TBEI screw fastening fork guard to M5x9 6 6 Nm 4 42
143. case of recovery this value is set by the control unit Air Temp before Recovery Example value 40 C Value drawn from the signal read without taking into account any recovery the value in the example refers to an open circuit NAVIGATOR ELECTRICAL ERRORS ELE SYS 143 Electrical system DORSODURO FACTORY ABS air temperature sensor P0110 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 63 of the ENGINE connector If shorted to negative voltage equal to zero has been detected at PIN 63 of the ENGINE connector Troubleshooting If the circuit is open shorted to positive check the sensor connector and the Marelli control unit connector If they are OK check sensor continuity replace the sensor if not OK if it is OK check continuity between the ENGINE connector PIN 63 and the sensor PIN 1 restore cable harness if there is not continuity if it is OK reconnect the control unit connector and with key set to key ON check the continuity between the sensor connector PIN 2 and the vehicle ground connection if it is OK it means that the error cause is that the cable is short circuit to positive and it is necessary to restore the cable harness between the ENGINE PIN 63 and the sensor PIN 1 check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If OK check continuit
144. chain intermediate gear Slide off the timing chain from the crankshaft NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED See also Removing the chain sliders Removing the chain tensioner Removing the chain sliders Remove the chain tensioner and the camshafts from the corresponding head FRONT HEAD e First remove the clutch cover in order to remove the chain sliders from the front head Unscrew and remove the movable chain tensioner slider screw e Slide it off from the head to remove it ENG 225 Engine DORSODURO FACTORY ABS Unscrew and remove the fixed chain tensioner slider screw e First remove the head in order to re move it REAR HEAD First remove the flywheel in order to remove the chain sliders from the front head Unscrew and remove the movable chain tensioner slider screw e Slide it off from the head to remove it Unscrew and remove the fixed chain tensioner slider screw e First remove the head in order to re move it See also Removing the chain tensioner Removing the head cover Magneto flywheel removal Checking the chain Check the timing chain for damage or stiffness while moving If required replace both the timing chain and the camshaft sprocket wheels Check the timing chain guide for damage If necessary replace the parts ENG 226 DORSODURO FACTORY
145. ck C disconnect the right connector and see the value displayed by Navigator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open shorted to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable ground insulation from the throttle grip sensor connector or the control unit connector if the cable is not ground insu lated restore the wiring If itis ground insulated and with the key set to ON check that there is power supply for the potentiometer PIN A and that PIN C is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is continuity replace the control unit if not restore the wiring Right side Throttle Grip Position sensor track D P0153 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 44 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 44 of the ENGINE connector Troubleshooting e shorted to positive check the value shown by the parameter of the right Throttle Grip Position Sensor track
146. ction is used to reset vehicle servicing Using this function the odometer can be reset only once within the first 200 km 124 mi of the vehicle provided this has not been done by the Quality Check In order to activate this function follow the instructions in the DIAGNOSIS section See also Diagnosis Battery recharge circuit RECHARGING SYSTEM Remove the tank and the filter casing Disconnect the three way connector 1 white NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER A Measurement of resistance with engine off For a correct detection of the alternator resistance an ambient temperature measurement must be carried out and afterwards a heat stabilisation after turning fan on by using a tester using alternatively the 3 connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 ELE SYS 118 DORSODURO FACTORY ABS Electrical system Take the measurement The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted obtained by touching the two lugs Example Resistance of stage 1 read on the display 0 65 Ohm jimo B Nus 2 Ah he Hi ma F ae E L3 V m pA E d mda d Effective resistance stage 1 0 65 0 47 0 18 Ohm If there is a significant difference between one stage and another other than 0 15 Ohm
147. ctor and the correct connection of the cables on the terminals If they are not correct restore the cable harness if correct disconnect the two terminals from the sensor and with key set to ON check continuity to ground connection of PIN 2 if there is no con tinuity restore the cable harness if there is replace the sensor Indication on Navigator always pulled disconnect the terminals from the sensor and check if there is continuity between the two PINS with clutch released if there is continuity replace the sensor If the circuit is open it means that the brown purple cable from sensor PIN 1 to ENGINE connector PIN 50 is shorted to ground restore the cable harness Side stand sensor SIDE STAND SENSOR Function lt tells the side stand position to the control unit Operation Operating principle If the gear is engaged and the side stand is unfol ded and therefore the circuit is open the control unit does not enable vehicle start up or shuts off the engine if it is rotating Level in electrical circuit diagram Start up ena bling switches Location on the vehicle on the side stand connector left side near the Marelli control unit Electrical characteristics Side Stand Up closed circuit continu ity Side Stand Down open circuit infinite resistance Pin out 1 Ground connection 2 Voltage 12V CAUTION M V 0 5 55 M V 0 5 33 B V 0 5 D4 BEFORE CARRYING OUT ANY TROUBLESHOOT
148. d so as to check vertical oscillation of the chain in other positions too clearance should remain constant at all wheel rotation phases If clearance is uniform but over 30 mm 1 18 in or below 25 mm 0 98 in ad justment is necessary ADJUSTMENT CAUTION GET A SPECIFIC REAR SERVICE STAND OPT TO AD JUST THE CHAIN I uM ee mb res C If you need to adjust chain tension after the check S F So Place the vehicle on its rear service stand OPT Loosen the nut 1 completely Loosen both lock nuts 4 Actuate on the adjuster screws 5 and adjust the chain clearance checking thatthe references 2 3 match on both sides of the vehicle Tighten both lock nuts 4 Tighten the nut 1 Check chain clearance CAUTION TO ENSURE THAT THE WHEEL IS CORRECTLY CEN TRED THERE ARE FIXED REFERENCE MARKINGS 2 3 INSIDE THE CHAIN TENSIONER SLIDER SEATS ON THE SWINGARMS IN FRONT OF THE WHEEL AXLE CHECKING THE CHAIN THE PINION AND THE SPROCKET FOR WEAR Furthermore check the following parts and make sure the chain the pinion and the sprocket do not show damaged rollers loosened pins dry rusty flattened or jammed chain links excessive wear missing sealing rings excessively worn damaged pinion or sprocket teeth CHAS 316 DORSODURO FACTORY ABS Chassis IF THE CHAIN ROLLERS ARE DAMAGED THE PINS ARE LOOSE AND OR THE SEAL R
149. defective Check the throttle grip sensor connector and the control unit connector if not OK restore If OK check that cable resistance between the throttle grip sensor connector and the control unit is a few tenths of Ohm if this is not the case restore wiring If the value is correct replace the complete throttle grip sensor Right side Throttle Grip Position tracks C D P0155 illogical signal Error cause Two illogical voltage signals have been detected at PINS 30 and 44 of the ENGINE con nector tracks A B Troubleshooting Check the parameters of the left Throttle Grip Position Sensor tracks C and D if one of the two values clearly deviates from 600 1400 mV it means that this potentiometer is defective Check the throttle grip sensor connector and the control unit connector if not OK restore If OK check that cable resistance between the throttle grip sensor connector and the control unit is a few tenths of Ohm if this is not the case restore wiring If the value is correct replace the complete throttle grip sensor Throttle Grip position P0156 illogical signal Error cause The value of the left side sensor tracks A B does not coincide with the value of the right side sensor tracks C D Troubleshooting Replace the throttle grip sensor RESET PROCEDURE If the Marelli control unit or the throttle grip sensor is replaced check the Handle self learning with the diagnosis instrument once the
150. defective component A the malfunction does not affect riding in safety the warning light turns on the word Service is dis played the signal recovery value considered not reliable is used and the engine works regularly B the malfunction may affect riding in safety the warning light turns on the message Urgent Service is displayed the torque demands are not fully activated reduced torque C the malfunction may affect riding in safety the warning light turns on the message Urgent Service is displayed the engine operates in Limp Home function accelerated idle the throttles which are at the position exclusively depending on the springs are not moved The engine may shut off during the operation if it is running at idle speed and the gear is in neutral D the malfunction may affect riding in safety the warning light turns on the message Urgent Service is displayed the engine stops running Removing the throttle body Remove the filter casing Working on both bodies undo and re move the four screws and slide off the filter support P SUPP 277 Power supply Remove the upper plate Remove both bodies UPON REFITTING REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE Working on both bodies undo and re move the two plate screws Remove the plate Working on both bodies undo and re move the screw and detach the body P SUPP 278 DORSODURO FACTORY ABS DORSODURO
151. detected at PIN 5 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 5 of the VEHICLE connector Troubleshooting If short circuit to positive see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx 1200 mbar disconnect the large connector from the filter box if the value does not vary it means that the cable is short circuited between the filter box connector and the control unit connector restore the cable harness If the value varies reconnect the filter box connector and disconnect the sensor connector if the value does not vary it means that the cable is short circuited between the filter box connector and the sensor connector restore the cable harness Replace the sensor if the value varies If the circuit is open short circuit to negative check the filter box large connector the Marelli control unit connector and the sensor connector If not OK restore If everything is OK and with key set to OFF check if there is continuity between the VEHICLE PIN 5 of the Marelli control unit and the sensor connector PIN 3 if there is no continuity restore the cable har ness If there is continuity check the cable ground insulation if there is continuity to ground restore the cable harness if not with key set to ON check that the voltage on sensor con nector PIN 1 is approx 5 V if this is not correct set the key to OFF a
152. disconnected and key set to ON must have 12V voltage approximately if there is no voltage check PIN 2 for continuity with the vehicle ground connection if itis grounded restore the cable harness If OK replace the control unit If PIN 2 has approx 12 V check continuity of the yellow cable between PIN 1 of the sensor on the cable harness side and PIN 12 of the ABS control unit connector If this is not OK restore the cable harness If it is OK replace the sensor LOGIC ERRORS Speed sensor 5DA1 the signal works irregularly faulty sensor or signal interference Troubleshooting Check speed sensor retainer If it is not OK restore it If itis OK check if the tone wheel is dirty deformed or wrongly fixed If any of this happens replace the tone wheel Otherwise replace the speed sensor 5DA2 the signal decreases periodically Possible tone wheel fault due to deformations or dirt pos sible alterations on the wheel bearing surface In very rare cases abnormal tone wheel vibrations Troubleshooting Check if the tone wheel is dirty deformed or wrongly fixed If the tone wheel is not OK replace it If it is OK check for possible faults in the wheel bearings and if it is not OK replace the bearings 5DA3 no signal or speed measured too low in relation to the front wheel Faulty sensor or missing sensor tone wheel Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth ELE SYS 128 D
153. driving plate thickness at four positions replace them all if not complying with specifications CAUTION THE STEEL DISCS MUST SHOW NO SCORES OR TEM PERING COLOUR Measure the thickness of the clutch discs at four positions replace them if not complying with specifications Thickness of nine drive discs 2 5 mm 0 10 in Driven disc thickness 2 75 2 85 mm 0 108 0 112 in ENG 210 DORSODURO FACTORY ABS Engine MUSHROOM VALVE CHECK Check if the valve slides freely without jamming Blow compressed air into the valve and check that the lubricating oil passage holes open Checking the clutch housing e Remove the clutch bell Remove the seeger ring Remove the oil pump control gear UPON REFITTING THE GEAR COLLAR MUST ALWAYS BE FACING THE CLUTCH BELL Remove the rotation locking pin from the oil pump control gear Check the clutch bell for damage and wear that may result in clutch irregular operation Deburr the teeth or replace the bell MAIN DRIVEN GEAR CHECK ENG 211 Engine DORSODURO FACTORY ABS Check the main driven gear for damage and wear and if necessary replace the main transmission driving gear and the clutch bell all together Make sure there is not excessive noise during operation if necessary replace the main transmission driving gear and the clutch bell all together Checking the pusher plate Check the thrust plate and the bearing for dama
154. e M6 M12x1 25 M12x1 25 M6 M5 M6 M6 M6 M6x14 M5 Quantity 2 6 1 1 Torque 13 Nm 9 59 Ibf ft 14 Nm 10 33 Ibf ft 130 Nm 95 88 Ib ft 190 200 Nm 140 14 147 51 Ib ft 9 Nm 6 64 Ib ft 3 50 Nm 2 58 Ibf ft 13 Nm 9 59 Ib ft 13 Nm 9 59 Ibf ft 4 Nm 2 95 Ib ft 8 Nm 5 90 lof ft 13 Nm 9 59 Ibf ft 3 Nm 2 21 Ibf ft Notes Loctite 242 CHAR 53 Characteristics DORSODURO FACTORY ABS pos Description Bearing retainer fastener screw 2 Piston oil jet fastener screw 3 Tapered plug for crankshaft main bearing lubrication 4 Calibrated Brass dowel fixed to com plete crankcase CRANKCASE 1 Type M6 M5 M8x1 M8 Quantity 3 2 Torque 10 Nm 7 38 Ibf ft 5 50 Nm 4 06 Ibf ft 15 Nm 11 06 Ibf ft 5 50 Nm 4 06 lof ft Notes Loctite 270 Loctite 242 CHAR 54 DORSODURO FACTORY ABS pos Description 1 Engine speed sensor fixing screw 2 Screw fastening flywheel side clutch side crankcase halves 3 Screw fastening flywheel side clutch side crankcase halves 4 Special calibrated screw for gearbox lubrication Type M6 M6 M8 CRANKCASE 2 Characteristics Quantity Torque Notes 1 13 Nm 9 59 Ibf ft Loctite 243 8 13 Nm 9 59 Ibf ft 9 29 Nm 21 39 Ibf ft 1 18 Nm 13 28 Ibf ft Overhaul data Assembly clearances Cylinder piston assy The pistons are avail
155. e M5x9 M6 REAR BODYWORK 3 Quantity 3 4 Torque 6 Nm 4 42 Ibf ft 10 Nm 7 37 Ibf ft 0 8 Nm 0 59 Ibf ft Notes CHAR 42 DORSODURO FACTORY ABS Characteristics ABS SYSTEM pos Description Type Quantity Torque Notes a ABS ECU fastener screw M6x25 10 Nm 7 37 Ibf ft Loctite 243 M6 2 ABS ECU fastener nut 10 Nm 7 37 Ibf ft Engine HEAD COVER pos Description Type Quantity Torque Notes 1 Special screw for fastening head M6 8 9 Nm 6 64 Ibf ft cover CHAR 43 Characteristics N DORSODURO FACTORY ABS pos Description Water Temperature Sensor Threaded plug for water sensor seat Head stud bolt fastener nut pre tightening Head stud bolt fastener nut tighten ing Fastener for Head Cylinder Outer side crankcase Fastener for Head Cylinder Inner side crankcase Nut fastening Stud Bolts Head Nut fastening Stud Bolts Head Bleed union fastener screw Water bleed union steel Water bleed union brass Type M12x1 5 M12x1 5 M10x1 25 M10x1 25 M6 M6 M6 M8 M5 Quantity 1 1 8 0 Torque 23 Nm 16 96 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 4 90 13 Nm 9 59 Ibf ft 12 Nm 8 85 Ibf ft 12 Nm 8 85 Ibf ft 6 5 Nm 4 79 Ibf ft 2 Nm 1 48 lbf ft Notes Loctite Drise AL 506 Lubricate the threads before tight ening 13 Nm 9 59 Ibf ft 90
156. e and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber protection cover BRAK SYS 342 DORSODURO FACTORY ABS Front brake pump Braking system pos Description Pipe union fastening brake pipe to pump Fastener for front brake pump on handlebar TBEI screw fastening the brake tank to the plate Plate fixing screw Screw fastening the brake pipe to steering base Type M10x1 M6x20 M6x12 M6x25 FRONT BRAKE PUMP Quantity 1 2 1 Torque 25 Nm 18 44 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft BRAK SYS 343 INDEX OF TOPICS SYSTEM CLU SYS DORSODURO FACTORY ABS Clutch system CLUTCH PUMP pos Description Type Quantity Torque Notes 1 Clutch cylinder fastener M6 2 10 Nm 7 37 Ibf ft 2 Union with breather and fixing pipe M10x1 1 1 25 Nm 18 44 Ibf ft 3 Fastener for clutch pump on handle 2 10 Nm 7 37 Ibf ft bar 4 Screw fastening clutch control M6 1 10 Nm 7 37 Ibf ft mounting on flywheel side crankcase half 5 TBEI tank fixing screw M5x10 1 6 Nm 4 42 Ibf ft 6 plate fixing screw M6x12 1 10 Nm 7 37 Ibf ft CLU SYS 345 INDEX OF TOPICS Cooune SYSTEM COOL SYS DORSODURO FACTORY ABS Cooling system Circuit diagram from rear
157. e coolant contains ethylene glycol which under certain conditions can become flammable When it burns ethylene glycol produces an invisible flame which however can cause burns CAUTION TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO NENTS THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES WHEN CARRYING OUT MAINTENANCE OPERATIONS IT IS ADVISABLE TO WEAR LATEX GLOVES EVEN THOUGH IT IS TOXIC COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC TIVE TO ANIMALS NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES SIBLE TO ANIMALS AS THEY MAY DRINK IT CHAR 8 DORSODURO FACTORY ABS Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE HICLE THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM PON
158. e original semi bushings on the crankcase e To reduce the installation force neces Sary score an incision approximately 0 5 mm 0 02 in deep without cutting into the steel shell in each semi bush ing in the area indicated in the figure Remove the bushings with the crank case cold using a press and the spe cific tool and pushing inward from the outside of the crankcase Specific tooling 020726Y Extractor for bushings Installing The orientation of the semi bushings must match the specifications indica ted in the drawing as closely as possi ble NOTE WHEN REPLACING THE SEMI BUSHINGS ALONE THE NEW COMPONENTS MUST BE THE SAME COLOUR AS THE REMOVED COMPONENTS IF THE COLOUR OF THE OLD COMPONENTS IS NO LONGER VISIBLE USE THE TABLE TO IDENTIFY THE CORRECT COMPONENTS RE FERRING TO THE CRANKCASE AND CRANKSHAFT CLASSES Key Semi bushing joint line ENG 256 DORSODURO FACTORY ABS Engine Fit the new bushings with the crank case cold using a press and the spe cific tool and pushing outward from the inside of the crankcase until the punch comes into contact with the crankcase surface Specific tooling 020727Y Punch for bushings Assembling the connecting rod CAUTION TO FIT THE CONNECTING RODS CHECK THE COUPLING TYPES INDICATED IN THE CRANK CASE CRANKSHAFT CONNECTING ROD SECTION IN THE CHARACTERISTICS CHAPTER OF THE WORKSHOP MANUAL Installing the crank
159. e the pinion ENG 259 Engine DORSODURO FACTORY ABS Place the gear selector drum and check that it is correctly timed thrust the desmo drum axially from the fly wheel side so that the timing roller pro trudes Tighten the gear selector drum fixing Screw e Position the tone wheel Tighten the tone wheel with the special tool Use Loctite medium strength for sealing Specific tooling 020715Y Tone wheel removal ENG 260 DORSODURO FACTORY ABS Engine Tighten the pinion fixing nut using the special tool Specific tooling 9100896 Clutch housing locking tool Position the sensor contact together with the spring e Place the neutral sensor and lubricate its seat to facilitate refitting BE CAREFUL NOT TO DAMAGE THE O RING WHEN IN SERTING THE SENSOR IN ITS POSITION Tighten the two screws fixing the neu tral sensor ENG 261 Engine DORSODURO FACTORY ABS Position the plate together with the se lector Tighten the three screws fixing the gear selector plate by applying Loctite medium strength Place the speed sensor with caution Tighten the speed sensor fixing screw e Place the transmission control rod with the washer Remove the grease off the primary pin ion tapered pins crankshaft coupling surfaces Position the crankshaft gear ENG 262 DORSODURO FACTORY ABS Engine e Position the washer and the crankshaft
160. e to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are dis played in case of lack of activation Rear injector The auxiliary injection relay No 40 in the wiring diagram placed under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the grey red cable of the injector is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation ELE SYS 148 DORSODURO FACTORY ABS Electrical system The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation NAVIGATOR ELECTRICAL ERRORS Front cylinder injector P0201 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 50 of the ENGINE con nector If shorted to negative no voltage has been detected If the circuit is open an interruption has been detected Troubleshooting shorted to positive disconnect the injector connector set key to ON activate the component with Navigator and check the voltage on the grey green cable on the filter box small con nector towards the Marelli control unit if there is voltage restore the cable harness between the filt
161. e value 502 mV 492 mV Voltage stored in the control unit corresponding to the throttle mechanical minimum position NAVIGATOR STATUSES Throttle Self learning Example value carried out not carried out Indicates whether or not the self acquisition process has been carried out through the diagnosis in strument NAVIGATOR ACTIVATION NAVIGATOR ELECTRICAL ERRORS Potentiometer 1 sensor front throttle position P0120 Example value short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN A6 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN A6 of the throttle control unit Troubleshooting e shorted to positive check the value shown by the parameter of the front throttle Potentiom eter 1 voltage disconnect the left connector and see the value displayed by Navigator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle body if the voltage drops to zero if the circuit is open shorted to negative check the throttle body connector and the throttle valve connector If not OK restore if everything is OK check circuit continuity between the two terminals If not OK restore the cable harness if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that
162. ean and flat Make sure all threads are in proper conditions e Check cylinder sliding surface for signs of friction and scratches Also check the seal sur faces for damages CAUTION IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT REPLACE THE CYLINDER AND THE PISTON Clean off lime scales on the cylinder cooling slots Measure the cylinder bore at a dis tance of 10 43 90 mm 0 39 1 69 3 54 in from the head coupling sur face the highest value should be considered to estimate wear limits Cylinder bore C 92 000 mm 3 6220 in C D1 or D2 max ENG 234 DORSODURO FACTORY ABS Engine Cylindricity tolerance 0 020 mm 0 00079 in Replace the cylinder the piston and the piston ring all together if not complying with specifications Checking the piston Measure the piston skirt diameter with a micrometer a 10 mm 0 39 in from the piston lower border Calculate the clearance between pis ton and cylinder as follows Piston cylinder clearance CZ C P Piston cylinder clearance 0 050 0 064 mm 0 00197 0 00252 in Limit 0 100 mm 0 00039 in Replace the cylinder the piston and the piston ring all together if not com plying with specifications PISTON RINGS Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves Measure the piston ring side clearance and replace the piston and the piston rings all togeth
163. ear throttle Potentiometer 1 voltage Example value 780 mV The value in the example refers to engine conditions with key set to ON Rear throttle Potentiometer 2 voltage Example value 3756 mV The value in the example refers to engine conditions with key set to ON Front throttle Potentiometer 1 2 degrees Rear throttle Potentiometer 1 2 degrees Example value 6 5 With key set to ON the throttle is kept in position by the springs approximately 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal to 0 5 When the gear is not engaged at approx 6000 rpm throttles open very little because the requested torque is too low approximately 5 7 ELE SYS 153 Electrical system DORSODURO FACTORY ABS Front rear cylinder throttle correction Example value 0 0 For example if there is a hole in the intake manifold the pressure read is different from the pressure estimated by the control unit and the system tries to reach an estimated situation by opening the throttle a little bit more therefore this parameter takes a value different from zero an acceptable value should be between 0 7 and 0 7 Front cylinder Limp home position Rear cylinder Limp home position Example value 800 mV 780 mV Voltage stored in the control unit corresponding to the throttle Limp home position Front throttle lower position Rear throttle lower position Exampl
164. ecting rods Connectors 171 coolant 348 358 Coolant 348 358 Crankcase 56 195 244 245 254 257 Crankshaft 56 244 253 255 257 Cylinder 55 216 217 222 231 234 238 242 253 D Diagnostics 279 332 Drive chain 14 315 E ECU 171 332 Electric fan 168 347 Electrical system 14 92 95 393 Engine oil 75 Engine temperature sensor 141 Exhaust 318 320 Exhaust manifold 320 F Filter box Fork 284 287 293 Front wheel 281 283 Fuel 274 384 Fuel pump 274 Fuses 122 G Gearbox selector 197 H Handlebar 284 Head cover 81 216 226 243 Headlight 366 Identification 12 Instrument panel Intake pressure sensor 136 L License plate holder 372 M Magneto flywheel 200 226 253 Maintenance 9 71 Maintenance Table Mudguard Oil filter 77 Oil pressure sensor 162 R Radiator 185 347 357 389 Rear wheel 307 309 315 Recommended products 60 Ride by wire 275 Run Stop switch 770 S Saddle Saddle mounting Shock absorbers 311 Side stand 166 Side stand sensor 166 Spark plug 72 Spark plugs Speed sensor 126 Stand 166 317 Starter motor 197 198 358 384 Throttle body 752 277 Transmission 13 Tyres 15 W Warning lights Water pump 348 Wiring diagram 111
165. el 2 3 50 Nm 2 58 Ibf ft Loctite 243 7 LH ball joint on gearbox control lever 1 10 Nm 7 37 Ibf ft Loctite 243 8 RH ball joint on gearbox control lever 1 10 Nm 7 37 Ibf ft Loctite 243 Fastener for positive cable on engine 1 10 Nm 7 37 Ibf ft TE screw fastening negative cable to M6x12 1 10 Nm 7 37 Ibf ft engine CHAR 32 DORSODURO FACTORY ABS Characteristics Air Temp Sensor Lights Rela 3 Main Switeh eS Rear Stop Switch Fan Rear ignition Right Switch 1 Recovery Relay njecton Resy 1 ME LJ Injection Relay 2 Right Switch 2 3 Resistence Box M _ Retain Relay Leen TE Order Relay Switch 2 1 AR Bo voltage Regulator Fan Relay 7 AIR BOK 2 E NL Front Ignition Coil Demand 1 master E Front Stop Switch ES Demand 2 slave Clutch Switch Position lamp jn 4 High Beam Relay Front Headlamp Antenna Right Front Let Front T urn indicator Turn Ind scator i Dashboard ELECTRICAL SYSTEM 1 pos Description Type Quantity Torque Notes Coil fixing screw 13 Nm 9 59 Ibf ft TE screw fastening regulator to M6x30 10 Nm 7 37 Ibf ft frame Secondary Fuses v E ECL Ground i am m Z Ecu E a m NE m Pick up i Side stand switch Gear Sensor Horn Temp Sensor
166. el grip The system restores the fluid taken from the calliper 8 9 in the section of the system between the brake pump 2 5 and the ABS inlet valve 10 12 BRAK SYS 328 DORSODURO FACTORY ABS Braking system D Pressure restored by opening the inlet valve 10 12 momentarily the pressure of the callipers 8 9 is increased until maximum deceleration is reached Then the system gives the control over the braking back to the rider E If the wheel does not reach complete grip the system continues operating as before until complete grip is obtained or until the vehicle stops An error can be detected if the duration of the pressure reduction phase exceeds the pre set time limit ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels locking in case of emergency braking increasing vehicle braking stability when compared to a traditional braking system Sometimes when the brake is operated the tyre locks with a consequent loss of grip which makes it difficult to control the vehicle A position sensor 3 on the tone wheel 2 forming an integral unit with the vehicle wheel reads the status of the vehicle wheel spotting any possible lock A control unit 1 signals this out and adjusts the pressure in the braking circuit accordingly NOTE WHEN THE ABS SYSTEM STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE
167. en detected at PIN 43 of the ENGINE connector Caution the lambda probe parameter is not the real value that is read a recovery value is displayed instead Troubleshooting Shorted to positive with key set to ON disconnect the sensor connector and measure PIN 1 voltage on the cable harness side grey cable if there is voltage 5 or 12 V restore the cable harness if there is not replace the lambda probe Lambda probe heating P0135 shorted to positive open circuit shorted to negative Error cause Shorted to positive excessive voltage has been detected at PIN 32 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 32 of the ENGINE connector Troubleshooting ELE SYS 146 DORSODURO FACTORY ABS Electrical system Shorted to positive disconnect the probe connector and check the sensor correct resistance replace the sensor if not OK if it is OK restore the cable harness e circuit is open shorted to negative check the continuity from probe connector PIN 3 and 4 towards the probe if not OK replace the probe if itis correct check the sensor connector and the Marelli control unit connector If not OK restore If OK and with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if not ok check the red black cable between the probe connector and the auxiliary injection relay No 40 in the wiring d
168. er box connector and the Marelli control unit If there is no voltage reconnect the connector and check if there is voltage at PIN if there is voltage restore the filter box cable harness If there is no voltage replace the sensor shorted to negative disconnect the injector connector set the key to ON and check if there is a ground connection on the grey green cable if there is voltage restore the cable harness between the filter box connector and the Marelli control unit if there is no voltage reconnect the connector and disconnect the injector connector and check if there is a ground connec tion on PIN if there is voltage restore the filter box cable harness If there is no voltage replace the injector the circuit is open check the component correct electrical characteristic if it is not correct replace the component if it is correct check the filter box small connector the connector on the component and the Marelli control unit connector If not OK restore if OK check cable continuity between ENGINE PIN 50 and component PIN and restore the cable harness Front cylinder injector P0202 See front injector Error cause If shorted to positive excessive voltage has been detected at PIN 34 of the ENGINE con nector If shorted to negative no voltage has been detected If the circuit is open an interruption has been detected Troubleshooting shorted to positive disconnect the injector connector set key to ON
169. er if not complying with specifications Piston ring side clearance Top ring 1st slot 0 030 0 065 mm 0 0012 0 0026 in Intermediate ring 2nd slot 0 020 0 055 mm 0 0008 0 0022 in Oil scraper ring 3rd slot 0 010 0 045 mm 0 0004 0 0018 in Fit the piston ring to the cylinder Level the installed piston ring with the piston crown ENG 235 Engine DORSODURO FACTORY ABS Measure piston ring port and replace it if not complying with specifications CAUTION IT IS NOT POSSIBLE TO MEASURE THE GAP OF THE OIL SCRAPER RING END IF CLEARANCE IS EXCESSIVE RE PLACE THE THREE PISTON RINGS Piston ring end gap Top ring 0 25 0 40 mm 0 0079 0 0157 in Intermediate ring 0 35 0 55 mm 0 0138 0 0216 in Oil scraper ring 0 20 0 70 mm 0 0079 0 0276 in PIN Clean off combustion residues from the piston crown and from the area above the top ring Check for cracks on the piston and for compression on the piston sliding surface seizing Replace the piston if required CAUTION SMALL STRIATIONS ON THE PISTON LINER ARE ADMISSIBLE Measure the pin outside diameter a and if not complying with specifica tions replace the pin Pin outside diameter 22 00 21 97 mm 0 8661 0 8650 in Limit 21 96 mm 0 8646 in Measure the pin housing diameter b and replace the piston if not complying with specifications Pin housing diameter b 22 010 22 015 mm 0 8665 0 8667
170. erations carry out a first tightening of the ring nut to the indicated tightening torque for the settlement of the steering package turn the steering completely from both sides for several times Loosen the ring nut completely carry out the final tightening of the ring nut to the indicated tightening torque Specific tooling 020884Y 46 mm wrench for steering ring nut STEERING RING NUT Description Type Suan Torque Notes Headstock ring nut pre tightening M25x1 30 Nm 22 13 Ib ft Steering package settlement Headstock ring nut tightening M25x1 12 Nm 8 85 Ib ft Fit the entire fork upper plate adjusting with short taps with a rubber hammer Tighten the nut to the specified torque Tighten the fixing screws of the upper plate to the prescribed tightening tor que STEERING UPPER PLATES pos Description Type Quantity Torque Notes Headstock nut M22x1 1 100 Nm 73 76 Ibf ft 3 Stainless steel TCC screw fastening M8x30 6 25 Nm 18 44 Ib ft stanchions to upper and lower yokes SUSP 301 Suspensions DORSODURO FACTORY ABS When refitting the U bolt position the two referen ces facing the front part of the vehicle OPTION 02 Steering upper plate with a headstock cut Unscrew and remove the U bolt four fixing screws Remove the U bolt Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out
171. ery Characteristic Battery 12V 10 Ah Battery installation NOTE THE FIRST TIME THE ENGINE IS STARTED AFTER RECONNECTING THE BATTERY LEADS WAIT 20 SECONDS BETWEEN THE MOMENT THE KEY IS SET TO KEY ON AND THE MOMENT THE STARTER BUTTON CAN BE PUSHED THE ENGINE WILL NOT START IF START UP IS ATTEMPTED BEFORE THE PRE SET 20 SEC ONDS ELAPSE ELE SYS 125 Electrical system DORSODURO FACTORY ABS Speed sensor VEHICLE FRONT SPEED SENSOR FUNCTION To indicate the vehicle speed by read ing the front wheel turning speed OPERATION OPERATING PRINCIPLE Magne toresistive sensor a square wave pulse is gener ated with voltage approx between 11 55 V and 11 25 V WIRING DIAGRAM Level in wiring diagram ABS REMOVAL LOCATION ON THE VEHICLE on the fork right stem next to the brake calliper support CONNECTOR LOCATION if available under the helmet compartment PINS PIN 1 Ground connection white PIN 2 Power supply voltage Output signal white brown NAVIGATOR Parameters Speed km h Vehicle speed ELECTRICAL ERRORS Speed sensor 5D90 electric malfunction Electrical fault in sensor or cable harness Troubleshooting Check the sensor connector and the ABS control unit connector If they are not OK restore the connectors If they are OK check continuity of the white brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector If there is no cont
172. esence of air is signalled by the sponginess of the brake control and poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid Remove the rear brake fluid reservoir cap e Quickly press and release the rear brake lever several times and then keep it fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before the lever reaches its end of stroke Repeat the operation until the fluid draining into the container is air bubble free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valv
173. est could show unreal errors because the voltage is too low Voltage is detected by the Marelli control unit Front throttle control circuit P0166 Example value short circuit to positive short circuit to negative open circuit overvoltage excessive internal temperature Error cause If shorted to positive excessive voltage has been detected at PIN C1 of the throttle control unit connector If shorted to negative no voltage has been detected If the circuit is open an interruption has been detected Troubleshooting shorted to positive disconnect the throttle body connector set key to ON and check voltage at PIN 3 if the voltage read is higher or equal to 5V there is a short circuit on the cable harness replace the throttle body if the voltage is null ELE SYS 156 DORSODURO FACTORY ABS Electrical system shorted to negative disconnect the throttle body connector set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection if it is there is a short circuit in the cable ground connection if it is not replace the throttle body open circuit overcurrent excessive inside temperature check the throttle body connector and the throttle control unit connector If not OK restore If everything is OK disconnect the throttle body connector PIN 3 and the throttle control unit connector C1 and check the circuit continuity between the two terminals if there is no continuity restore
174. ew fastening front side pan M6x16 4 6 Nm 4 42 Ibf ft els and duct to radiator 3 TBEI screw fastening ignition block M5x9 3 4 Nm 2 95 Ibf ft cover to spacer Front tank fastener spacer M6 2 10 Nm 7 37 Ibf ft a ABS Version FRONT WHEEL pos Description Type Quantity Torque Notes Wheel axle nut SSS UE 2 TE flanged screw fastening front disc M8x20 12 30 Nm 22 13 Ibf ft Loctite 243 CHAR 25 Characteristics DORSODURO FACTORY ABS FRONT BRAKE pos Description Type Quantity Torque Notes 1 Union with breather fixing pipe to M10x1 2 25 Nm 18 44 Ibf ft callipers 2 TEFL screw Fixing calliper to fork M10x1 25 4 50 Nm 36 88 Ibf ft stems Fastener for brake pipe on steering M6x25 1 10 Nm 7 37 Ibf ft base CHAR 26 DORSODURO FACTORY ABS Central part A FRONT CHASSIS pos Description Type 1 TCEI screw fastening shock absorb M10x30 er counterplate to RH frame bracket 2 TC TORX screw fastening trellis M12x53 frame to frame side panels 3 Screw fastening chain roller bracket M8x35 to LH plate 4 Screw fastening chain roller to chain M8x45 roller bracket 5 Screw fastening chain roller bracket M8x20 to LH plate Quantity 1 4 1 Torque 50 Nm 36 88 Ibf ft 80 Nm 59 Ibf ft 25 Nm 18 44 Ibf ft 25 Nm 18 44 Ibf ft 25 Nm 18 44 Ibf ft Characteristics Notes Loctite 243 Loctite 243 Loctite 24
175. ews fasten onto fork hubs 8 40 4 25 18 4469 E 30 Nm 22 13 Ib ft Loctite 242 Cap 20 Nm 14 75 Ib ft CHAR 17 Characteristics DORSODURO FACTORY ABS pos Description Type Quantity Torque Notes 4 Nut on pumping member pin 2 20 Nm 14 75 lb ft if C3 LE OPTION 01 Steering upper plate without a headstock cut STEERING OPTION 1 pos Description Type Quantity Torque Notes 1 Headstock ring nut pre tightening M25x1 1 30 Nm 22 13 Ib ft Steering package settlement 1 Headstock ring nut tightening M25x1 1 12 Nm 8 85 Ib ft 2 Headstock cap M22x1 1 100 Nm 73 75 Ib ft 3 Stainless steel TCC screw fastening M8x30 6 25 Nm 18 44 Ib ft stanchions to upper and lower yokes 4 TCEI screw fastening U bolt onto M10x60 2 50 Nm 36 88 Ib ft fork yoke OPTION 02 Steering upper plate with a headstock cut CHAR 18 DORSODURO FACTORY ABS Characteristics STEERING pos Description Type Quantity Torque Notes 1 Headstock ring nut pre tightening M25x1 1 30 Nm 22 13 Ib ft Steering package settlement 1 Headstock ring nut tightening M25x1 1 12 Nm 8 85 Ib ft 2 Headstock nut pre tightening M22x1 1 10 Nm 7 37 lb ft Loctite 243 2 Headstock nut M22x1 1 25 Nm 18 44 Ib ft Loctite 243 3 Stainless steel TCC screw fastening M8x30 6 25 Nm 18 44 Ib ft stanchions to upper and lower yokes 4 TCEI screw fastening U bolt onto M10x60 2
176. fect in the intake and pressure reading systems Pressure too low at front cylinder manifold error P0217 signal not valid A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Pressure too low at rear cylinder manifold error P0218 signal not valid Error cause ELE SYS 140 DORSODURO FACTORY ABS Electrical system A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Engine temperature sensor ENGINE TEMPERATURE SENSOR Function tells the engine temperature to the control unit so as to optimise its operation Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in electrical circuit sensors Location on the vehicle on t
177. forward and re lease the gearing chain from the sprocket Unscrew and remove the nut on the wheel axle Collect the thrust washer and the right chain tensioner slider Working on the right side hit the wheel axle lightly so as to take out the head from its housing Working on the left side slide off the wheel axle together with the chain guide slider Remove the wheel by freeing the disc from the brake calliper Collect the spacer from the rear wheel right side DORSODURO FACTORY ABS Suspensions Working from the left side unscrew and remove the five nuts and remove the sprocket and the bolts Unscrew and remove the five screws and remove the anti vibration buffer holder Check the flexible couplings according to the routine maintenance table See also Adjusting Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters SUSP 309 Suspensions DORSODURO FACTORY ABS Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE Check the radial and axial clearance Axial clearance a minimum axial clearance
178. fuel tank right side first relay starting from the rear side START UP RELAY Location on the wiring diagram 34 Location on the vehicle under the fuel tank left side second relay starting from the front RETENTION RELAY Location on the wiring diagram 37 Location on the vehicle under the fuel tank right side second relay starting from the front CONTROL RELAY ELE SYS 94 DORSODURO FACTORY ABS Electrical system Location on the wiring diagram 38 Location on the vehicle under the fuel tank right side third relay starting from the front MAIN INJECTION RELAY Location on the wiring diagram 39 Location on the vehicle under the fuel tank left side third relay starting from the front AUXILIARY INJECTION RELAY Location on the wiring diagram 40 Location on the vehicle under the fuel tank right side second relay starting from the front FAN CONTROL RELAY Location on the wiring diagram 41 Location on the vehicle under the fuel tank left side first relay starting from the front HIGH BEAM LIGHTS RELAY Location on the wiring diagram 64 Location on the vehicle under the fuel tank right side first relay starting from the front RECOVERY LOGIC RELAY URGENT SERVICE Location on the wiring diagram 65 Location on the vehicle behind the instrument panel Electrical system installation INTRODUCTION Scope and applicability The position of the cable h
179. fully CHAR 9 Characteristics DORSODURO FACTORY ABS BEFORE DISASSEMBLING COMPONENTS Before dismantling components remove dirt mud dust and foreign bodies from the vehicle Use the special tools designed for this bike as required COMPONENTS REMOVAL Do not loosen and or tighten screws and nuts using pliers or any other tools than the specific wrench Mark positions on all connection joints pipes cables etc before separating them and identify them with distinctive symbols Each component needs to be clearly marked to enable identification during reassembly Clean and wash the dismantled components carefully using low flammability detergent Keep mated parts together since they have adjusted to each other due to normal wear Some components must be used together or replaced completely Keep away from heat sources REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY WITHOUT JAMMING AND OR NOISE OTHERWISE THEY NEED TO BE REPLACED Only use ORIGINAL Aprilia SPARE PARTS e Comply with lubricant and consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers sealin
180. g rings circlips O rings OR cotter pins and screws with new parts if the thread is damaged When assembling the bearings make sure to lubricate them well Check that each component is assembled correctly After a repair or routine maintenance carry out pre ride checks and test the vehicle on private grounds or in an area with low traffic Clean all mating surfaces oil seal rims and gaskets before refitting Smear a thin layer of lithium based grease on the oil seal rims Reassemble oil seals and bearings with the brand or batch number facing outward visible side ELECTRICAL CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness Press the relative safety clips if applicable Grip the two connectors and disconnect them by pulling them in opposite directions CHAR 10 DORSODURO FACTORY ABS Characteristics If any signs of dirt rust moisture etc are noted clean the inside of the connector carefully with a jet of compressed air Ensure that the cables are correctly fastened to the internal connector terminals Then connect the two connectors ensuring that they couple correctly if fitted with clips you will hear them click into place CAUTION DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES NOTE THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION CONNECT THE
181. ge 2 and wear If necessary replace the parts PC M PF T SS a L2 fed EC KS 4 1 Sed Pa A 00 S 4 ar Wc a Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation If neces sary replace the bell Checking the springs M Check the springs for damage and if necessary replace the them all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Clutch spring length when unloaded 46 6 mm 1 83 in ENG 212 DORSODURO FACTORY ABS Engine Assembling the clutch e Fit the shim washer Fit the needle bearing and the spacer Fit the clutch housing Make sure that the oil pump control drive gear of the clutch housing engag es correctly with the oil pump driven gear Place the washer correctly between the clutch housing and the hub ENG 213 Engine DORSODURO FACTORY ABS Position the clutch hub Fit the clutch cover Check that the measurement has not changed compared with the one car ried out upon removal tighten the clutch nut afterwards If it has changed rotate the crankshaft so that the oil pump control drive gear engages cor rectly with the oil pump driven gear on the clutch bell e Fit the washer and a new clutch hub nut Tighten the clutch hub nut using the specific tool Specific tooling
182. ght running light 12V 6W H6 Low beam light 12V 50W H4 High beam light 12V 60W H4 ELE SYS 121 Electrical system DORSODURO FACTORY ABS Taillight Characteristic Rear daylight running light stop light LED Fuses AUXILIARY FUSES A Coil Light logic relay Recovery logic relay Stop Horn Tail lights License plate light 10 B Low beam high beam lights 154A C Live positive lead to EFG 1x control unit and to instrument panel Instrument panel diagnosis 10 A D Instrument battery positive and EFG 1x control unit 15 A E Permanent positive ECU power supply 3A F Oxygen sensor heater Coils Start up logic Fan and injection relay Fuel pump Purge valve Injectors ECU Start up logic 20 G Spare fuses 10 15 20 A MAIN FUSES H Spare fuses 30 A Battery charging fan relay live positive 30 A Control unit MARELLI CONTROL UNIT Function It controls the Ride by wire system the injection ignition the system safety checks and the self di agnosis function Location left side next to the engine ELE SYS 122 DORSODURO FACTORY ABS Electrical system Connector location ENGINE connector upper connector with control unit on the vehicle a letter E is stamped on the control unit to the right of the connector VEHICLE connector lower connector with control unit on the vehicle a letter V is stamped on the control unit to the right
183. he ENGINE connector of the Marelli control unit NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check through Navigator if the temperature indicated is the ELE SYS 142 DORSODURO FACTORY ABS Electrical system same as the engine temperature Check also that the sensor electrical characteristics are ob served replace the sensor if not OK if it is OK check the sensor connector and the Marelli control unit connector Air temperature sensor INTAKE AIR TEMPERATURE SENSOR Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti mise the petrol quantity necessary for correct com bustion Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in electrical circuit diagram Temperature sensors Location e on the vehicle on filter box e connector sensor near the probes Electrical characteristics Resistance at 0 32 5 5 Resistance at 25 10 0 5 Pin out 1 0 5 V signal PIN 1 2 Ground connection PIN 2 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Air temperature Example value 26 C In
184. he front cylinder the internal side facing the rear cylinder connector on the sensor Electrical characteristics Resistance at 25 2 05 100 Ohm Resistance at 60 575 Ohm 15 Ohm Resistance at 90 230 Ohm 5 Ohm M 0 5 D9 N 0 5 38 Pin out 1 Yellow brown 0 5 V signal PIN B1 2 Brown PIN B2 ground connection G M 0 5 35 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Engine temperature ELE SYS 141 Electrical system DORSODURO FACTORY ABS example value 75 C In case of recovery this value is set by the control unit Engine Temp before Recovery example value 40 C Value drawn from the signal read without taking into account any recovery the value in the example refers to an open circuit NAVIGATOR ELECTRICAL ERRORS engine temperature sensor P0115 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 45 of the ENGINE connector If shorted to negative voltage equal to zero has been detected at PIN 45 of the ENGINE connector If the circuit is open shorted to positive check the sensor connector and the Marelli control unit connector If they are OK c
185. heck sensor continuity replace the sensor if not OK if it is OK check the continuity between the ENGINE connector PIN 45 and the sensor PIN 1 restore cable harness if there is not continuity if itis OK reconnect the control unit connector and with key set to key ON check the continuity between the sensor connector PIN 2 and the vehicle ground connection if it is correct it means that the error cause is that the cable is short circuit to positive and it is necessary to restore the cable harness between the EN GINE PIN 45 and the sensor PIN 1 if there is no continuity with the ground connection check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If OK check continuity between the ENGINE connector PIN 35 and the sen sor connector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced Troubleshooting If shorted to negative check sensor correct resistance if resistance is null replace the sen Sor if resistance is correct it means that the cable has ground connection restore the cable harness NAVIGATOR LOGIC ERRORS engine temperature sensor P0116 signal not valid Error cause An excessive temperature variation has been detected for example the cause may be contact resistance between the terminals Troubleshooting e Check the sensor connector and t
186. here is no voltage check that PINS A7 and B7 are insulated from ground connection if they are not insulated from the ground connec tion replace the cable harness If they are insulated replace the throttle control unit or the Marelli control unit NAVIGATOR NOTES ELE SYS 124 DORSODURO FACTORY ABS Electrical system After installing the control unit and setting the key to ON wait for 3 seconds time during which the control unit detects the throttle valve position Connect to Navigator and check that the status for Throttle self learning is carried out and the status for Handle self learning is not carried out this last status entails Urgent service being displayed on the instrument panel If Throttle Self learning shows Not carried out go to stage 1 If it shows Carried out go to stage 2 Stage 1 current errors have probably been detected by the control unit solve these malfunctions and check the Throttle Self learning status again Throttle Self learning can also be checked from the Pa rameter adjustment screwdriver and hammer screen page Stage 2 Carry out the Handle Self learning from the Parameter adjustment screwdriver and hammer screen page and check that Handle Self learning status is Carried out If it is not correct or the voltage detected on the throttle is out of scale check with Navigator or if current errors are probably detected by the control unit solve these malfunctions and repeat the procedure Batt
187. his error even in the ATT status Troubleshooting Check that the throttle body is clean and that there is no ice or condensation in the intake duct If they are replace the throttle body Front throttle first self learning NOT performed P0165 test not carried out Error cause The first throttle self acquisition process has not been successful or has not been carried out The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Delete errors hindering throttle self learning Front throttle position error P0167 misalignment between control and activation Error cause ELE SYS 160 DORSODURO FACTORY ABS Electrical system The throttle mechanical control be damaged Troubleshooting Replace the throttle body Rear throttle Limp Home self acquisition P0180 test failed Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Rear throttle mechanical spring self acquisition P0181 test failed Error cause Return time of the throttle kept in position by the springs not within the expected limits the causes can be a deterioration of the performance of the springs or excessive throttle friction at e
188. hrottle Limp Home self acquisition P0160 test failed ELE SYS 159 Electrical system DORSODURO FACTORY ABS Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Front throttle mechanical springs self acquisition P0161 test failed Error cause Return time of the throttle kept in position by the springs not within the expected limits the causes can be a deterioration of the performance of the springs or excessive throttle friction at each key ON Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Front throttle minimum mechanical position self acquisition P0162 test failed Error cause Position of the throttle stop not within the expected range at each key ON Troubleshooting Check if the throttle body and the intake duct are clean If they are replace the throttle body Detection of front throttle valve Recovery conditions air T water T P0163 possible presence of ice Error cause A correct throttle rotation cannot be detected given low ambient and engine temperatures some ice may have formed in the duct at each key ON The instrument panel does not indicate the presence of t
189. htening Camshaft gear fastener nut tighten ing Timing drive gear fastener screw TIMING SYSTEM Type M15x1 M15x1 M24x1 5 Quantity 4 4 2 Torque 30 Nm 22 13 Ibf ft 90 Nm 66 38 Ibf ft 40 Nm 29 50 lof ft Engine Notes 3M SCOTCH GRIP 2353 ENG 223 Engine DORSODURO FACTORY ABS pos Description Type Quantity Torque Notes 3 Special screw for fastening mobile M8 4 19 Nm 14 01 Ibf ft Loctite 242 fixed shoes 4 Cam tower head fastener screws M6 16 4 90 6 86 Nm 3 61 pre tightening 5 06 Ibf ft 4 Cam tower head fastener screws M6 16 9 81 12 75 Nm 7 24 tightening 9 40 Ibf ft 4 Viti fissaggio castelletto testa ser Torx 16 12 14 Nm 8 85 10 32 raggio lbf ft 5 Camshaft retainer plate fastener torx M3 8 3 Nm 2 21 Ibf ft Loctite 270 screw Removing the chain tensioner Unscrew and remove the screw and collect the washer and the internal spring e Unscrew and remove the two screws Remove the chain tensioner and col lect the gasket Chain removal Remove the chain tensioner Remove the main pinion Remove the movable chain slider and release the fixed chain slider from the clamp e Unscrew and remove the pin of the tim ing chain intermediate gear paying at tention not to damage the O ring e Collect the washer ENG 224 DORSODURO FACTORY ABS Engine Remove the timing
190. iagram located under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables If there are also coil and injector errors check the relay and its excitation and power line if there is voltage at PIN 4 check the grey blue cable ground insulation PIN 3 if not OK restore the cable harness If it is OK check the continuity of the grey blue cable between the sensor connector PIN 3 and the ENGINE PIN 32 and restore the cable harness NAVIGATOR LOGIC ERRORS Lambda probe P0134 voltage without variation Error cause An abnormal behaviour of the voltage at PIN 43 of the ENGINE connector has been detec ted the voltage that should vary over time keeps a constant value Troubleshooting Check circuit continuity from probe connector PIN 1 and PIN 2 toward the probe replace the lambda probe if there is no continuity if there is continuity check the sensor connector and the Marelli control unit connector If not OK restore If OK check continuity between the ENGINE connector PIN 43 and PIN 60 and restore the cable harness CAUTION IN CASE THE Lambda sensor correction PARAMETER WITH ENGINE AT IDLE AND H20 T gt 90 C WHICH IS NOT WITHIN THE 0 9 1 1 RANGE WITHOUT ERRORS CHECK IF lt 0 9 THE PROBE READS LEAN COMBUSTION CONDITIONS AND THE CONTROL UNIT INCREASES INJECTION TIME CAUSES CHECK FOR INCORRECT AIR INTAKE LITTLE PET ROL
191. ide cover 3 Screw fastening Pump Cover M6 2 13 Nm 9 59 Ibf ft Clutch Cover clutch side crankcase half 4 Nut fastening pump drive input gear M6 1 12 Nm 8 85 Ibf ft Loctite 244 on shaft 5 Water pump rotor 1 4 50 Nm 3 32 Ibf ft OPTION 02 WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 11 13 Nm 9 59 Ibf ft 2 Fastener screw for Pump Cover M6 3 13 Nm 9 59 Ibf ft Clutch side cover 3 Screw fastening Pump Cover M6 2 13 Nm 9 59 Ibf ft Clutch Cover clutch side crankcase half 4 Nut fastening water pump drive gear M6 1 12 Nm 8 85 Ibf ft sprocket 5 Water pump rotor 1 4 50 Nm 3 32 Ibf ft 6 Screw fastening chain tensioner slid M6 1 8 10 Nm 5 90 7 38 Ibf er to water pump ft 7 Water pump support fixing screw M6 3 12 Nm 8 85 Ibf ft 8 Water pump support plug M6x10 1 6 5 Nm 4 79 Ibf ft 3M SCOTCH GRIP 2353 CHAR 52 DORSODURO FACTORY ABS Characteristics pos Description Spark plug Freewheel Ring fastener screw Screw fixing rotor Crankshaft 12 mm 0 47 in Screw fixing rotor Crankshaft 14 mm 0 55 in Screw fastening Stator Flywheel Cover Screw fastening pick up Flywheel cover Flywheel cover fastener screw Screw fastening starter motor brack et to crankcase Crankshaft access cap Retainer plate fastener screw Screw fastening bracket to starter motor Pick up cable retainer screw IGNITION Typ
192. igator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open shorted to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable ground insulation from the throttle grip sensor connector or the control unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the switch key set to ON check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is continuity replace the control unit if not restore the wiring Right side Throttle Grip Position sensor track C P0152 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 30 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 30 of the ENGINE connector Troubleshooting ELE SYS 133 Electrical system DORSODURO FACTORY ABS e shorted to positive check the value shown by the parameter of the right Throttle Grip position Sensor tra
193. il to drain out com pletely Replace the sealing washer of the drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Screw and tighten the drainage plug 2 DORSODURO FACTORY ABS Maintenance Locking torques N m Oil drainage plug M16x1 5 19 Nm 14 01 Ibf ft Replace the oil filter Fill up to the right engine oil level by adding recommended engine oil See also Engine oil filter Check Engine oil filter Drain the engine oil Remove the oil filter Fit a new engine oil filter Add engine oil up to the correct level CAUTION NEVER REUSE AN OLD FILTER See also Replacement Air filter e Remove the fuel tank Disconnect the air temperature sensor e Undo and remove the nine screws MAIN 77 Maintenance Remove the clamp and slide off the blow by tube e Remove the filter box cover Working on both ducts turn the upper part of the intake ducts anticlockwise and remove it Remove the filtering element COVER THE INTAKE DUCTS WITH A CLEAN CLOTH SO THAT FOREIGN BODIES DO NOT GET INTO THE INLET DUCTS UPON REFITTING AND BEFORE PLACING THE FILTER BOX COVER MAKE SURE NEITHER THE CLOTH NOR ANY OTHER OBJECT HAS BEEN LEFT INSIDE THE FILTER BOX MAKE SURE THE FILTERING ELEMENT IS CORRECTLY PLACED SO THAT UNFILTERED AIR DOES NOT FLOW IN DO NOT FORGET THAT EARLY WEAR OF THE PISTON RINGS AND THE CYLINDER CAN BE CAUSED BY A MAL
194. in Calculate the clearance between and pin hole and if not complying with specifications replace both pin and piston Pin piston clearance C b a ENG 236 DORSODURO FACTORY ABS Engine 0 010 0 045 mm 0 0004 0 0018 in Limit 0 060 mm 0 0024 in CAUTION AD OGNI TIPO DI CILINDRO IN ALLUMINIO O IN GHISA DEVE ESSERE ACCOPPIATO L AP POSITO PISTONE CYLINDER PISTON COUPLING Specification Desc Quantity Piston cylinder coupling Type A Cylinder 91 990 91 977 mm 3 6216 3 6219 in Piston 91 933 91 940 mm 3 6217 3 6197 in Piston cylinder coupling Type B Cylinder 91 997 92 004 mm 3 6219 3 6222 in Piston 91 940 91 947 mm 3 6197 3 6199 in Piston cylinder coupling Type C Cylinder 92 004 92 011 mm 3 6222 3 6225 in Piston 91 947 91 954 mm 3 6199 3 6202 in Piston cylinder coupling Type D Cylinder 92 011 92 018 mm 3 6225 3 6227 in Piston 91 954 91 961 mm 3 6202 3 6205 in Fitting clearance 0 050 0 064 mm 0 00197 0 00252 in if i IN Sui pistoni accoppiabili con i cilindri in ghisa ri portata l indicazione GH Fitting the piston An arrow stamped on the piston crown indicates the exhaust side When refitting the piston rings on the piston the arrow stamped inside the piston must be turned towards the operator The piston rings are different and must be installed with the N marking at the top ENG
195. inuity restore them If there is PIN 2 of the sensor on the cable harness side with the sensor disconnected and key set to ON must have 12V voltage approximately if there is no voltage check PIN 2 for continuity with the vehicle ground connection if itis grounded restore the cable harness If OK replace the control unit If PIN 2 has approx 12 V check the continuity of the white cable between PIN 1 of the sensor on the cable harness side and PIN 13 of the ABS control unit connector If there is no continuity restore the cable harness If there is replace the logic errors sensor LOGIC ERRORS Speed sensor 5D91 the signal works irregularly faulty sensor or signal interference ELE SYS 126 DORSODURO FACTORY ABS Electrical system Troubleshooting Check speed sensor retainer If it is not OK restore it If it is OK check if the tone wheel is dirty deformed or wrongly fixed If any of this happens replace the tone wheel Otherwise replace the speed sensor 5D92 the signal decreases periodically Possible tone wheel fault due to deformations or dirt pos sible alterations on the wheel bearing surface In very rare cases abnormal tone wheel vibrations Troubleshooting Check if the tone wheel is dirty deformed or wrongly fixed If the tone wheel is not OK replace it If it is OK check for possible faults in the wheel bearings and if it is not OK replace the bearings 5D93 missing signal or speed measured too low in relation
196. ion advance etc PARAMETERS Characteristic Value example Unit of Notes measure ment Front wheel speed O 3 km h Withstopped wheel Km h is displayed Rear wheel speed vn With stopped wheel 0 Km h is displayed Battery voltage 11 9 V BRAK SYS 333 Braking system DORSODURO FACTORY ABS ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit ACTIVATION Characteristic Value example Unit of Notes measure ment Front brake bleeding procedure Useful in case of lever sponginess although the bleeding has been done as in a regular braking system Rear brake bleeding procedure Useful in case of lever sponginess although the bleeding has been done as in a regular braking system ABS warning light During the test the warning light stays on Ambient parameter error reading 1 The ambient parameters are 4 Number of error detections Operation cycles from the last detec tion Battery voltage Speed Ambient parameter error reading 2 Number of error detections number of times the error has been detected by the control unit Ambient parameter error reading 3 for example if it indicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Ambient parameter error reading 4 Operation cycles from the last reading a
197. k E E i 3 T 2 US Er LIA M d Eam E ELE SYS 97 Electrical system DORSODURO FACTORY ABS TABLE D Lay the cable as shown and fasten it with a 2 5x160 clamp Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION TABLE A MAIN CABLE HARNESS LAYING View of main cable harness laying without airbox ELE SYS 98 DORSODURO FACTORY ABS Electrical system TABLE B CABLE HARNESS FOR RELAY UNIT The shortest cables must be connected to the three closest relays TABLE C To lay the auxiliary fuses box under the airbox slide off the protection cap reinsert it observing the correct poles 1 Side stand switch 2 Neutral switch 3 Horn 4 Control unit connectors TABLE D The generator output cable must be laid behind the thermostatic valve under the airbox ELE SYS 99 Electrical system DORSODURO FACTORY ABS TABLE E 5 Cable guide already fitted on engine 6 Rubber cap 4 5x180 0 18x7 08 Clamps TABLE G Plastic cable guide holding the auxiliary fuses branch and the cylinder coil cable 1 horizontal ELE SYS 100 DORSODURO FACTORY ABS Electrical system TABLE H 4 5x290 0 18x11 42 Clamp TABLE
198. left connector and see the value displayed by Navigator if ELE SYS 132 DORSODURO FACTORY ABS Electrical system the voltage does not vary there is a short circuit in the cable wiring replace the throttle grip sensor if the voltage drops to zero if the circuit is open shorted to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable ground insulation from the throttle grip sensor connector or the control unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the key set to ON check that there is power supply for the potentiometer PIN A and that PIN C is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is continuity replace the control unit if not restore the wiring Left side Throttle Grip Position sensor track B P0151 short circuit to positive open circuit short circuit to negative Error cause Voltage that is excessive equal to zero has been detected at PIN 40 of the VEHICLE connector Troubleshooting short circuit to positive check the value shown by the parameter of the left Throttle Grip position Sensor track B disconnect the left connector and see the value displayed by Nav
199. les opening and closing actuate on a scroll mounted on a shaft and which is sent back to its home position by a return spring On the shaft covers there are 2 double track potentiometers 4 control tracks by means of which the torque demand is read and checked Marelli 5DM electronic control unit Besides the regular control functions of the injection system it supervises the throttle bodies Through the throttle grip position sensor it reads the torque demand and through the THROTTLE MAP it decides the throttle opening and sends the command to the throttle valve control unit It checks the correct operation of each component Self diagnosis of the system Safety and carries out the emergency procedure Recovery EFI throttle control unit The control unit receives the target throttle opening to be carried out and it actuates on the control acting on the throttle body motors It checks through the throttle position sensor signal that the throttle bodies have reached the target position It communicates the position reached to the Marelli control unit It does not actuate on Safety strategies Throttle Body The two throttle bodies are made up of Throttle valve with 2 return springs for the controlled minimum opening position DC electrical motor Tinned double throttle position sensors with magnetic control contactless The throttle bodies do not require any maintenance and cannot be overhauled In case of electric or mech
200. license plate mounting to mounting Fastener for license plate mounting frame assembly to gusset plate saddle lock Screw fastening license plate mount ing cover to license plate mounting M6 REAR BODYWORK 3 Type M5x9 Quantity 3 4 Torque 6 Nm 4 42 Ibf ft 10 Nm 7 37 Ibf ft 0 8 Nm 0 59 Ibf ft Notes BODYW 364 DORSODURO FACTORY ABS pos Description Upper LH TCEI screw fastening sad dle mounting to frame Upper RH TCEI screw fastening sad dle mounting to frame Lower TCEI screw fastening Saddle mounting to frame TCEI screw fastening passenger grab handles to frame Type M8x55 M8x60 M8x40 M8x80 SADDLE MOUNTING Quantity 1 1 2 Torque 25 Nm 18 44 Ibf ft 25 Nm 18 44 Ibf ft 25 Nm 18 44 Ibf ft 30 Nm 22 13 Ibf ft Bodywork Notes BODYW 365 Bodywork DORSODURO FACTORY ABS Headlight assy HEADLAMP pos Description Type Quantity Torque Notes 1 TE screw fastening headlamp to M6x16 2 10 Nm 7 37 Ibf ft headlamp mounting and mudguard to steering base 2 Fastener for front turn indicators M5 2 3 Nm 2 21 Ibf ft 3 TCEI screw fastening headlamp M6 3 10 Nm 7 37 Ibf ft mounting to fork yoke Operating from both sides unscrew and remove the front frame fixing screw and collect the nut BODYW 366 DORSODURO FACTORY ABS Remove the instrument panel Working from
201. lide off the tail fairing backwards BODYW 390 INDEX OF TOPICS DORSODURO FACTORY ABS Pre delivery Carry out the listed checks before delivering the motorcycle WARNING HANDLE FUEL WITH CARE Aesthetic inspection Paintwork Fitting of Plastic Parts Scratches Dirt Tightening torques inspection Safety fasteners front and rear Suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine chassis retainers steering assembly Plastic parts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Electric starter Engine stop via emergency stop switch and side stand Helmet compartment electrical opening switch if present PRE DE 393 Pre delivery DORSODURO FACTORY ABS Through the diagnosis tool check that the last mapping version is present in the control unit s and if required program the control unit s again consult the technical service website to know about available upgrades and details regarding the operation CAUTION N TO ENSURE MAXIMUM PERFORMANCE TH
202. light input 29 BLACK BODY 30 BLACK BODY Ground for sensors 31 BLACK BODY Battery 32 BLACK BODY Rear left turn indicator activation 33 BLACK BODY Rear right turn indicator activation 34 BLACK BODY Aerial 1 35 BLACK BODY Light relay activation 36 BLACK BODY 37 BLACK BODY 38 BLACK BODY General ground 39 BLACK BODY General ground 40 BLACK BODY General ground Can line CAN line Function ols 31 1 3 o oo ooon a O D x ilO ma Oo Ob O G2 OF amp Desc Quantity PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 PIN 27 PIN 28 PIN 29 PIN 30 PIN 31 PIN 32 PIN 33 PIN 34 PIN 35 PIN 36 PIN 37 PIN 38 PIN 39 PIN 40 Electrical system ELE SYS 175 Electrical system DORSODURO FACTORY ABS It allows communication between the Marelli injection control unit the throttle control unit and the in strument panel Level in electrical circuit diagram CAN line Pin out see wiring diagram NAVIGATOR ELECTRICAL ERRORS U1602 CAN line without signals Bus Off Error cause No communication on CAN line PIN 20 and or PIN 51 VEHICLE problem on the whole network for example battery cut off or short circuited or shorted to ground Troubleshooting Check the Marelli control
203. m M Sensor inverted closed circuit con tinuity Pin out 1 Ground connection 2 Voltage 5V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Fall sensor ELE SYS 167 Electrical system DORSODURO FACTORY ABS Example value Normal Tip over Indication on Navigator always Normal even when the sensor is inverted disconnect the connector and with sensor inverted check if there is continuity between the two PINS of the sensor if there is no continuity replace the sensor if there is check the connector If not OK restore the cable harness if OK check continuity to ground of PIN 1 if there is no continuity restore the cable harness if there is with key set to ON check if there is 5V voltage at PIN 2 If there is not check the Marelli control unit connector ENGINE connector PIN 8 Indication on Navigator always Tip over disconnect the connector and check if there is continuity between the two PINS when the sensor is in vertical position if there is continuity replace the sensor if there is not it means that with key set to ON there is no 5V voltage at PIN 2 restore the cable harness whose pink white cable will be shorted to ground Electric fan circuit ELECTRIC FAN CIRCUIT Function Radiator fan and coolant Operation
204. mmer puller Remove the fixed bushing 1 the movable bushing 2 the ring 3 and the oil seal 4 from the stem SUSP 290 DORSODURO FACTORY ABS Suspensions Remove the lock seeger ring of the spring guide Remove the spring guide Using a hook spanner lock the pump ing member pin Remove the stem bottom screw Specific tooling 020889Y Pumping member ring nut locking spanner Remove the pumping member pin Checking the components Stem Check the sliding surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit SUSP 291 Suspensions DORSODURO FACTORY ABS 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in good conditions Check that the following components are in good conditions upper bushing lower bushing piston If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE SUSP 292
205. n Operating principle The two throttle cables opening and closing actuate on a scroll mounted on a shaft which is sent back to its home position by a return spring On the shaft covers there are 2 double track potentiometers 4 control tracks by means of which the torque demand is read and checked The 4 potentiometers are tinned and magnetically controlled contactless they cannot be overhauled nor replaced Level in electrical circuit diagram Throttle grip position sensor Location e on the vehicle under the fuel tank e connector direct to the Marelli control unit Electrical characteristics Not detected by a multimeter as they are contactless read voltage on the 4 tracks through Navigator CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER CAUTION THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED MARK OR CHECK THE CONNECTOR MARK ING BEFORE REMOVING THEM BLUE STAMP BLUE BAND THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED TO THE LEFT THE CONNECTOR AND THE WHITE BAND SHOULD BE PLACED TO THE RIGHT Az 0 5 33 M N 0 5 D10 Ar R 0 5 D7 _ Vi 0 5 35 M N 0 5 D10 Ar R 0 5 D7 NAVIGATOR PARAMETERS ELE SYS 131 Electrical system DORSODURO FACTORY ABS Left side throttle grip po
206. n out 1 Fuel system 2 Ground connection 3 Output signal REAR CYLINDER R Bi 0 5 1 ELE SYS 136 DORSODURO FACTORY ABS Electrical system NAVIGATOR PARAMETERS Front Cylinder Intake Pressure example value 1003 mbar Pressure read by the front sensor Rear Cylinder Intake Pressure example value 1004 mbar Pressure read by the rear sensor Front Cylinder estimated Intake Pressure example value 1003 mbar Pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure example value 1004 mbar Pressure estimated by the control unit according to the throttle position NAVIGATOR ELECTRICAL ERRORS Front cylinder air pressure sensor P0105 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 34 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 34 of the VEHICLE connecior Troubleshooting If short circuit to positive see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx 1200 mbar disconnect the large connector from the filter box if the value does not vary it means that the cable is shorted between the filter box connector and the control unit connector restore the cable harness If the value varies reconnect the filter
207. nal not within the expected value drawn according to the values of the intake pressure Troubleshooting Check the parameter of the Potentiometer 1 Front throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 1 Rear throttle voltage Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 1 and the throttle control unit PIN 6A is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body Potentiometer 2 sensor front throttle position P0123 signal not valid Error cause Signal not within the expected value drawn according to the values of the intake pressure Troubleshooting Check the parameter of the Potentiometer 1 Front throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 2 Rear throttle voltage Check the throttle body connector as well as the throttle valve control unit connector Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5A is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body Front throttle valve position sensors P0124 illogical signal Error cause Potentiometer 1 and potentiometer 2 do not
208. nd check continuity between the ENGINE connector PIN 15 and the sensor connector PIN 1 If not OK restore the cable harness if it is OK replace the control unit if there is 5V voltage at PIN 1 and with key set to ON check the continuity to ground of the sensor connector PIN 3 if not OK restore the cable harness if OK replace the sensor NAVIGATOR LOGIC ERRORS ELE SYS 138 DORSODURO FACTORY ABS Electrical system front cylinder air pressure sensor P0107 signal not valid Error cause According to the engine operation data rom throttle etc an average value for the intake pressure is estimated if the value read deviates by a given percentage this error is activa ted The most frequent causes can be abnormal resistance in the sensor circuit for example rusted terminals or sensor with poor performance Troubleshooting Check the filter box large connector the Marelli control unit connector and the sensor con nector if not OK restore If everything is OK check that cable resistance between VEHICLE connector PIN 34 and sensor connector PIN 3 is a few tenths of an Ohm If it is above that value restore cable harness Replace the sensor if it is correct rear cylinder air pressure sensor P0108 signal not valid Error cause According to the engine operation data rom throttle etc an average value for the intake pressure is estimated if the value read deviates by a given percentage this error i
209. nd check if there is continuity between the ground connection and the PIN towards the sensor with gear engaged if there is continuity replace the sensor If it is insulated from the ground connection it means that the green black cable from sensor PIN 1 to ENGINE connector PIN 16 is shorted to ground restore the cable harness Clutch lever sensor CLUTCH LEVER SENSOR Function It tells the clutch lever position to the control unit Operation Operating principle If there is gear engaged but the clutch is pulled i e circuit closed to ground vehicle start up is not enabled Level in electrical circuit diagram Start up enabling switches Location e on the vehicle under clutch lever connector behind the instrument panel Electrical characteristics Clutch pulled closed circuit continuity Clutch released open circuit infinite resistance Pin out 1 Voltage 12V 2 Ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR STATUSES Clutch Example value ndefinite released pulled The statuses regularly viewed are Released Pulled Troubleshooting ELE SYS 165 Electrical system DORSODURO FACTORY ABS Indication on Navigator always released check the correct position of the cable terminals on the conne
210. nector 16 Engine connector 21 Engine connector 5 Engine connector 22 Engine connector 6 Engine connector 15 Engine connector 13 Engine connector 35 Vehicle connector 46 Engine connector 36 Vehicle connector 51 Vehicle connector 20 Engine connector 24 DORSODURO FACTORY ABS Electrical system THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNEC TOR 222222 27 2 SP ECU E Bi ZEE en A B V 0 75 D4 Az V 0 75 24 B V 0 75 D4 R 0 5 9 Az Ar 0 75 17 G B 0 5 13 Gr B 0 75 43 Gr V 0 75 30 V Bi 0 5 43 Vi N D 5 25 ESTE TED al i lf ETE Ho Bi D 5 48 G BI 0 5 13 NOSE 0 Gr ETI B V 0 75 D4 LAURO DI GUROJS30 G MOS3B 80075 04 ee G Ro 0 5 29 V N 0 75 36 bs be fs fe rne rn e e EEE s NOTE THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNEC TOR ZA E EET Ag LLL 722 ECU G HEY 777 oT R B 05 10 Ar G 0 5 31 Ar 0 5 D15 Az Bi 0 5 31 G Gr 0 5 19 M Vi 0 5 D22 G N 0 5 54 Bi N 0 5 D14 R N 0 5 D6 Gr Bi 0 5 42 G Vi 0 5 27 PEASE Ee MEMBERS NO v n 24 35 2 a JE 2 TEST ARERR Bi B 0 5 46 R N 0 5 D6 REDE Spee M V 0 5 14 Ro N 0 5 D21
211. ng tool ENG 248 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Engine The tone wheel is fixed with Loctite threadlock and must therefore be heated with a special hot air gun taking particular care not to heat ex cessively Remove the speed sensor tooth with the special tool When refitting fix the tone wheel with strong Loctite threadlock Specific tooling 020715Y Tone wheel removal Unscrew and remove the selector drum fastener screw e Remove the selector drum ENG 249 Engine DORSODURO FACTORY ABS Remove the pinion e Remove the clutch control rod Working on the left hand side unscrew and remove the nine M8 crankcase fastener screws Working on the left hand side unscrew and remove the nine M6 crankcase fastener screws ENG 250 DORSODURO FACTORY ABS Engine Remove the fuel vapour breather pipe mounting plate CAUTION DURING REASSEMBLY REMEMBER TO FIT THE FUEL VAPOUR BREATHER PIPE MOUNTING PLATE NEAR THE PINION Rotate the engine and the engine mounting into a horizontal position e Unscrew and remove the pin then re tighten by one turn to give the crank case halves clearance and verify tight ness CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE EN GINE AND ENGINE MOUNTING ARE STABLE AND EN SURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE Remove the two screws fastening the mounting
212. nifold ELE SYS 139 Electrical system DORSODURO FACTORY ABS Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Estimation error for front cylinder intake manifold pressure P0215 pressure too high pressure too low Error cause A substantial difference between the estimated pressure and the measured pressure has been detected for example the pipe between sensor and throttle body is fully detached clogged or squashed Troubleshooting e Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean there is an evident defect in the intake and pressure reading systems Estimation error for rear cylinder intake manifold pressure P0216 pressure too high pressure too low Error cause A substantial difference between the estimated pressure and the measured pressure has been detected for example the pipe between sensor and throttle body is fully detached clogged or squashed Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean there is an evident de
213. nsor rear throttle position P0125 Example value short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN B6 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN B6 of the throttle control unit Troubleshooting shorted to positive check the value shown by the parameter of the Rear throttle Potenti ometer 1 voltage disconnect the left connector and see the value displayed by Navigator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle body if the voltage drops to zero if the circuit is open shorted to negative check the throttle body connector and the throttle valve connector If not OK restore if everything is OK check circuit continuity between the two terminals If not OK restore the cable harness if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body Potentiometer 2 sensor rear throttle position P0127 Example value short circuit to positive open circuit short circuit to negative Error cause ELE SYS 155 Electrical system DORSODURO FACTORY ABS If shorted to positive excessive
214. of your warranty For further information regarding Warranty procedures and Scheduled Maintenance please refer to the Warranty Booklet NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Check and clean and adjust or replace if necessary every 1 000 Km 621 37 mi 2 Replace every 2 years 3 Replace every 4 years 5 Check every month 4 At each engine start 6 Check each time the rear tyre is replaced 7 Replace at whichever of the following occurs first 40 000 km 24 854 mi or 48 months ROUTINE MAINTENANCE TABLE km x 1 000 1 5 10 15 25 30 35 Rear shock absorber Spark plug Drive chain 2 Transmission cables and controls Steering bearings and steering clearance Wheel bearings Control unit diagnosis Brake discs Air filter Engine oil filter R Fork General vehicle operation Valve clearance Cooling system Braking systems Light circuit gt gt amp 8 MAIN 71 Maintenance DOR
215. ometer to check the sizes a and b of the camshaft lobes Camshaft lobes sizes Inlet a 36 28 36 32 mm 1 4283 1 4299 in Limit 36 15 mm 1 4232 in e b 28 mm 1 1023 in Outlet ENG 220 DORSODURO FACTORY ABS DORSODURO FACTORY ABS 35 13 35 17 mm 1 3831 1 3846 in Limit 35 00 mm 1 3779 in b 28 mm 1 1023 in Fasten the camshaft in horizontal po sition as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the component Camshaft eccentricity maximum limit 0 040 mm 0 0016 in Valve check CAUTION Engine REPLACE THE VALVES ONE AT A TIME DO NOT MIX THE COMPONENTS EACH VALVE MUST BE INSERTED INTO ITS SEAT WHICH IS MARKED PRIOR TO REMOVAL CAUTION THE SEAT 1 ON THE VALVE HEAD CANNOT BE REGROUND IF REQUIRED REPLACE THE VALVE GRINDING WITH ABRASIVE PASTE IS ALLOWED VALVE STEM END REGRINDING IS NOT AL LOWED Clean off any combustion residues from the valves Check the seat 1 on the valve head with a ruler flush The surface of the seat must not be concave re place the valve if necessary Check the clearance between the stem and the valve guide inlet 0 013 0 040 mm 0 00051 0 00157 in limit 0 080 mm 0 00315 in outlet 0 025 0 052 mm 0 00098 0 00205 in limit 0 100 mm 0 00394 in ENG 221 Engine DORSODURO FACTORY ABS Check the valve eccentricity v
216. on tank cap Refit the front protection and tighten the screw Fit the right side fairing Water pump OPTION 01 COOL SYS 348 DORSODURO FACTORY ABS Cooling system WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 13 13 Nm 9 59 Ibf ft 2 Fastener screw for Pump Cover M6 3 13 Nm 9 59 Ibf ft Clutch side cover 3 Screw fastening Pump Cover M6 2 13 Nm 9 59 Ibf ft Clutch Cover clutch side crankcase half 4 Nut fastening pump drive input gear M6 1 12 Nm 8 85 Ibf ft Loctite 244 on shaft 5 Water pump rotor 1 4 50 Nm 3 32 Ibf ft OPTION 02 COOL SYS 349 Cooling system DORSODURO FACTORY ABS WATER PUMP pos Description Type Quantity Torque Notes 1 Clutch side cover fastener screw M6 11 13 Nm 9 59 Ibf ft 2 Fastener screw for Pump Cover M6 3 13 Nm 9 59 Ibf ft Clutch side cover 3 Screw fastening Pump Cover M6 2 13 Nm 9 59 Ibf ft Clutch Cover clutch side crankcase half 4 Nut fastening water pump drive gear M6 1 12 Nm 8 85 Ibf ft sprocket 5 Water pump rotor 1 4 50 Nm 3 32 Ibf ft 6 Screw fastening chain tensioner slid M6 1 8 10 Nm 5 90 7 38 Ibf er to water pump ft 7 Water pump support fixing screw M6 3 12 Nm 8 85 Ibf ft 8 Water pump support plug M6x10 1 6 5 Nm 4 79 Ibf ft 3M SCOTCH GRIP 2353 Removal OPTION 01 COVER REMOVAL Drain off the cooling circuit comple
217. ook spanner and unscrew the nut collecting the safety washer Remove the water pump gear e Collect the shim washer ENG 266 DORSODURO FACTORY ABS Engine Undo and remove the two screws fixing the oil pump Remove the entire pump Inspection Undo and remove the two fixing SCrews Using a thickness gauge check clear ance between rotor and stator and re place the rotor stator unit if necessary clearance between rotor and stator 0 04 0 10 mm 0 0016 in 0 0039 in ENG 267 Engine DORSODURO FACTORY ABS e Slide off the shaft with the cover Collect the lock pin from the shaft Remove the oil pump rotor Remove the oil pump stator CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAM AGED NO EVIDENT ABRASIONS SCORES OR ANY OTH ER MARKS ENG 268 DORSODURO FACTORY ABS Engine Installing NOTE PAY ATTENTION TO ALIGN THE REFERENCES ON STA TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE IF REQUIRED REPLACE THE STATOR ROTOR UNIT OLD GENERATION PUMP INSTALLATION Fit the oil pump in its seat Tighten both oil pump fixing screws ENG 269 Engine e Fit the shim washer Fit the oil pump gear and fasten it through appropriate screw with corre sponding washer By means of a commercial hook span ner lock the pump and tighten the screw to the prescribed torque NEW GENERATIO
218. orarily fit the piston to the cylin i gt der without base or head gasket Remove the clamp from the sealing ring locking tool Remove the special tool for locking the connecting rod Fit a dial gauge on the specific tool Set the dial gauge to zero on a refer ence surface with a medium preload e g 5 mm 0 2 in Keeping the zero setting fit the tool on the cylinder and lock it with two nuts 10 Nm 7 38 Ib ft as shown in the figure Specific tooling ENG 241 Engine 020714Y Dial gauge mounting Rotate the crankshaft up to the TDC the reversal point of the dial gauge ro tation Lock the crankshaft at TDC using the specific tool e Calculate the difference between the two measurements using the chart be low identify the thickness of the cylin der base gasket to be used upon refitting By correctly identifying the cyl inder base gasket thickness an ade quate compression ratio can be main tained Remove the specific tool and the cyl inder Specific tooling 020720Y Timing tool DORSODURO FACTORY ABS BASE GASKET Specification Measured protrusion 0 10 0 0 mm 0 0039 0 0000 in Measured protrusion 0 05 0 10 mm 0 0020 0 0039 in Measured protrusion 0 15 0 30 mm 0 0059 0 0118 in Installing the cylinder head e Place the fixed chain tensioner slider on the cylinder timing chain compart ment opposite to the chain tensioner ENG 242
219. oting shorted to positive disconnect the throttle body connector set key to ON and check voltage at PIN 3 if the voltage read is higher or equal to 5V there is a short circuit on the cable harness replace the throttle body if the voltage is null shorted to negative disconnect the throttle body connector set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection if it is there is a short circuit in the cable ground connection if it is not replace the throttle body ELE SYS 157 Electrical system DORSODURO FACTORY ABS e open circuit overcurrent excessive inside temperature check the throttle body connector and the throttle control unit connector If not OK restore If everything is OK disconnect the throttle body connector PIN 3 and the throttle control unit connector C8 and check the circuit continuity between the two terminals if there is no continuity restore the cable har ness If there is continuity with the throttle body connector connected check that the resistance from the throttle control unit connector between PIN A8 and C8 is within 1 and 2 5 Ohm if it is not replace the throttle body if it is check that the throttle body is not mechanically blocked if blocked solve the problem and replace the body if it is not replace the throttle control unit NAVIGATOR LOGIC ERRORS Potentiometer 1 sensor front throttle position P0121 signal not valid Error cause e Sig
220. ottle valve value is 0 5 or above e the difference of throttle valve correction values between the front and rear cylinders should not exceed 0 6 See also Air filter Fuel tank FUEL TANK pos Description Type Quantity Torque Notes 1 TCEl screw fastening filler cap flange 5 16 3 Nm 2 21 Ibf ft INN 2 Rear TE screw fastening tank M6x90 10 Nm 7 37 Ibf ft CAUTION DURING FUEL TANK LIFTING AND REPOSITIONING BE CAREFUL SO AS NOT TO CRUSH BEND OR SLIDE OFF TANK BREATHERS FROM THE CORRESPONDING TUBE GUIDES LIFTING THE FUEL TANK Remove the saddle Remove both side fairings BODYW 384 DORSODURO FACTORY ABS Bodywork e Undo and remove the two tank front SCrews See also Side body panels TANK REMOVAL Undo and remove the rear screw Remove the rubber ring on the ignition lock Pay attention not to damage the immo bilizer aerial BODYW 385 Bodywork Draw the tank backward as much as you can in order to avoid interferences in the front part when lifting the tank CAUTION PAY ATTENTION WHEN LIFTING THE TANK SINCE IF BREATHER PIPES ARE NOT ACCOMPANIED THEY MAY TEAR Insert a pin in the rear fixing screw hole so that you can lift the tank and be able to disconnect the breather pipes Disconnect the fuel pipe OPTION 01 BODYW 386 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Bodywork If there is a Y joint disconnect the
221. over in order to re move the front head camshafts Mark the head camshafts the corresponding sprocket wheels and cam caps in order not to in terchange them upon refitting Undo and remove the eight cam cap screws working in a diagonal se quence and in stages Remove the cam cap carefully so as not to go through it and damage the seats of the calibrated dowels Remove the camshafts with the gears ENG 218 DORSODURO FACTORY ABS Engine Removing the valves When removing the valve mark the components according to the position and the cylinder they belong to in order to refit the components to their correct positions Remove the bucket tappets and the adjustment shims using a magnet Compress the valve springs with the specific wrench and with the spring compressing tool Specific tooling AP8140179 Valve spring compressor 020721Y Adaptor for valve removal Remove the cotters using a magnet ENG 219 Engine Release the valve springs Remove the valve spring fittings and the springs Remove the valves Checking the overhead camshaft Check that the camshaft toothed wheel works properly if it is damaged or does not move smoothly replace both the timing chain and the camshaft toothed wheel CAMSHAFT LOBES Check that they do not show blue col ouring pitting or scratches otherwise replace the camshaft and the relevant toothed wheel Use a micr
222. ractor for bushings manometer for fuel oil compression ro ff e mh m Ph X 2d A X V Tool panel Generic adhesive film for panel apn lia Hooks for panel I zc ue i Panel graphics Protection for fitting operations DORSODURO FACTORY ABS Special tools Stores code Description AP8140189 Oil seal fitting tool for 43 mm 1 69 in orifices form ff a nn 7 Eom ite 3 ee a 8140146 Weight fe N eat NW JT pe S ud 020889Y Pumping member ring nut locking span ner 020888Y Pliers for pre fill pipe 020884Y 46 mm wrench for steering ring nut 020890Y Pumping member stanchion support rod S TOOLS 69 INDEX OF TOPICS DORSODURO FACTORY ABS Maintenance Maintenance chart Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance To this end Aprilia offers a set of checks and maintenance services at the owner s expense that are summarised in the table shown on the following page Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub Dealer without waiting until the next scheduled service to solve it All scheduled services must be carried out at the specified intervals and mileage as soon as the pre determined mileage is reached Carrying out scheduled services on time is essential for the validity
223. re communicated to all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle NOTE Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely observe these instructions will result in serious risk of personal injury Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment A Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee INDEX OF TOPICS CHAR 7 E ze 2 HBE 7 7 t5 4 o o S TOOLS MAIN gt Z m Z gt Z m TROUBL TROUBLESHOOTING ELE SYS ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENG VE ENG U m 20 o c U U r lt P SUPP SUSP CHAS CHASSIS BR
224. re connected raises Remove the oil seal OPTION 02 COVER REMOVAL Drain off the cooling circuit completely e Unscrew and remove the five water pump cover fixing screws COOL SYS 352 DORSODURO FACTORY ABS Cooling system Release the clamp Remove the water pump cover PUMP ROTOR REMOVAL Remove the water pump cover H20 Unscrew and remove the impeller pay ing attention to the left handed thread ing of the pin COMPLETE H20 PUMP REMOVAL Remove the clutch cover e Unscrew and remove the three H2O pump fixing screws Remove the H2O pump and slide off the drive chain NOTE REPLACE THE O RINGS ON REASSEMBLY Installing CAUTION COOL SYS 353 Cooling system DORSODURO FACTORY ABS PAY ATTENTION TO THE TYPE OF PUMP FITTED DURING FITTING THERE ARE TWO TYPES WITH 1 AND WITHOUT O RING 2 THEY CANNOT BE INTERCHANGED BETWEEN THEM IT IS POSSIBLE TO CHECK THE PRESENCE OF O RING ON THE CARTER OR DIRECTLY ON THE PUMP THE SEAT MUST BE AS SHOWN IN THE FIGURE FURTHERMORE THE CARTERS STAMPED WITH NUMBER 28127 AND FOLLOWING ARE ALL WITH O RING SEAT OPTION 01 COOL SYS 354 DORSODURO FACTORY ABS Cooling system REFITTING Insert a new oil seal using the appro priate tool to a depth of 2 mm 0 079 in determined by the tool relative to the upper part of the crankcase at the end of the flanged part of the seat orifice CAUTION AFTER INSTALLING THE OIL
225. refer to the operations described in the chapter If the previous checks are OK the causes might be e C ABS control unit malfunction D Instrument panel malfunction NOTE to check the wheel speed sensor using the NAVIGATOR follow the instructions given in chapter ELECTRICAL SYSTEM CHECKS AND TESTS SPEED SENSOR Use of diagnostics instrument for ABS system ECU INFO screen page This screen page shows general data regarding the control unit for example software type map ping control unit programming date INFO ECU SCREEN PAGE Characteristic Value example Unit of Notes measure ment Vehicle manufacturing date Frame number n O Software version Vehicle code Mana Shiver Dorso The vehicle code stored in the control unit is read duro Scarabeo Vehicle identification according to Mana Shiver Dorso The vehicle type Mana Shiver Dorsoduro is de the status of Pin 2 and 15 of the ABS duro Scarabeo fined according to the connection found for PIN 2 control unit connector and PIN 15 of the ABS control unit connector see the following table BRAK SYS 332 DORSODURO FACTORY ABS Braking system NOTE the X in the table identifies the con nector pin is grounded PIN2 PIN15 X X X X Dorsoduro PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the control unit injection time ignit
226. rn or damaged bearings Replace the rim if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 2 mm 0 0079 in Handlebar HANDLEBAR pos Description Type Quantity Torque Notes 1 TCEI screw fastening counterweight M6x50 2 10 Nm 7 37 Ibf ft to handlebar end 2 Stainless steel TCC screw fastening M8x25 4 25 Nm 18 44 Ibf ft upper U bolt to lower clamp 3 Screws fastening light switch assem 242 1 5 Nm 1 11 Ibf ft E bly Front fork SUSP 284 Suspensions DORSODURO FACTORY ABS Diagram pem Bin ji 0 z M fo i CENE FRONT FORK Notes pos Description Type Quantity Torque Screws fasten onto fork hubs M6x40 4 12 Nm 8 85 Ib ft 2 Screw Pumping member pin fixing 2 30 Nm 22 13 Ib ft to the stem base Upper cover 2 20 Nm 14 75 Ib ft 2 20 Nm 14 75 Ib ft Upper cover locking nut Sp SUSP 285 Suspensions DORSODURO FACTORY ABS OPTION 01 Steering upper plate without a headstock cut pos Description Headstock ring nut pre tightening Headstock ring nut tightening Headstock cap Stainless steel TCC screw fastening stanchions to upper and lower yokes TCEI screw fastening U bolt onto fork yoke Type M25x1 M25x1 M22x1 M8x30 M10x60 STEERING OPTION
227. ry Clamp between front rear M6 2 7 Nm 5 16 Ibf ft manifolds and central manifold 3 Silencer Clamp between central M6 1 7 Nm 5 16 Ibf ft manifold and silencer 4 Self tapping TE screw fastening si M8x20 2 25 Nm 18 44 Ibf ft lencer mounting bracket to saddle mounting 5 Self tapping TE screw fastening front M8x35 2 35 Nm 25 81 Ibf ft silencer fixture to silencer mounting bracket CHAS 318 DORSODURO FACTORY ABS Chassis Removing the tail pipe Loosen the clamp between the ex haust end and the manifold Remove the saddle Undo and remove the two upper screws and collect the washers Remove the exhaust end backwards by sliding off the two brackets from the rubber rings in the upper section and the bracket from the chassis retainer in the lower part CHAS 319 Chassis DORSODURO FACTORY ABS Removing the manifold tail pipe Remove the front exhaust manifold Disconnect the lambda probe Loosen the exhaust manifold and the exhaust end clamps from the rear cyl inder Hemove the manifold terminal coupling See also Removing the exhaust manifold Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine
228. s activa ted The most frequent causes can be abnormal resistance in the sensor circuit for example rusted terminals or sensor with poor performance Troubleshooting Check the filter box large connector the Marelli control unit connector and the sensor con nector if not OK restore If everything is OK check that resistance between VEHICLE connector PIN 5 and sensor connector PIN 3 is a few tenths of an Ohm If it is above that value restore cable harness Replace the sensor if it is correct Error for unexpected intake air in the front cylinder manifold P0210 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is higher than the estimated one for example cut or wrongly connected pipe between sensor and throttle body or a hole in the intake manifold Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Error for unexpected intake air in the rear cylinder manifold P0211 signal not valid Error cause A small difference between the estimated pressure and the measured pressure has been detected the measured pressure is higher than the estimated one for example cut or wrongly connected pipe between sensor and throttle body or a hole in the intake ma
229. s of operation However even though the malfunction is no longer present and the control unit considers the error no longer current but mem orised MEM error indication on Navigator the instrument panel may keep showing there is an error present Diagnosis An access code is required to enter this menu which controls the diagnosis function ENTER SERVICE CODE This is a 5 digit code fixed for each vehicle For these vehicles the code is 98789 If the code is incorrect the following message is displayed INCORRECT CODE and the instrument panel goes back to the main menu Otherwise the following menu is displayed Exit ECU diagnosis INSTRUMENT PANEL ERRORS ELE SYS 115 Electrical system DORSODURO FACTORY ABS Error Clearing e VEHICLE SERVICING RESET Update e CHANGE KEYS e KM MILES ERRORI ECU In this mode a chart is displayed showing potential ACTIVE errors in the control unit IT IS NECESSARY TO REFER TO THE ERROR 0 M ECU INDICATIONS GIVEN BY NAVIGATOR FOR ECU 13 be THIS VEHICLE ECU 14 ECU 15 O ECU 16 The instrument panel does not keep all previous errors stored its memory INSTRUMENT PANEL ERRORS In this mode a chart is displayed showing potential ScTive MEMO errors in the immobilizer and the sensors connec DSB U 1 ted to it DSB y DSB 09 PH A DSB LIH P5 DSB OS DSB Ub D Instrument panel errors In this mode
230. shaft e Place the left side crankcase half on the engine support adequately e Place the crankshaft on the seat of the crankcase half with caution Refitting the crankcase halves Fit the strum box if previously re moved Tighten the two strum box fixing SCrews c d 4 t Low as S a E gt 4 S IT Hie Turn the engine support into horizontal position Place the left crankcase half on the engine support fitting it on the engine support pins CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE ENGINE AND ENGINE MOUNTING ARE STA BLE AND ENSURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE ENG 257 Engine DORSODURO FACTORY ABS Fit the complete transmission gears unit Apply black sealing paste Threebond on the left crankcase half CAUTION BE CAREFUL NOT TO APPLY THREEBOND IN EXCESS AS IT MAY BLOCK OIL DUCTS THROUGH THE CRANKCASE HALVES Place the right crankcase half with the aid of a rubber hammer Tighten the two fixing pins Rotate the engine and the engine support into vertical position ENG 258 DORSODURO FACTORY ABS Engine Working on the left side place the nine M6 screws fixing the crankcase Working on the left side place the nine M8 screws fixing the crankcase Tighten all the crankcase fixing screws both M6 and M8 type e Slide in the clutch control rod Plac
231. show a logical value the sum of the two voltages should be constant The cause may be a malfunction in one of the two sensors or an ab normal resistance in one of the two circuits Troubleshooting ELE SYS 158 DORSODURO FACTORY ABS Electrical system Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 1 and the throttle control unit PIN 6A is a few tenths of an Ohm Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5A is a few tenths of an Ohm If one of the two is different restore the cable harness If correct replace the complete throttle body Potentiometer 1 sensor rear throttle position P0126 signal not valid Error cause e Signal not within the expected value drawn according to the values of the intake pressure Troubleshooting e Check the parameter of the Potentiometer 1 Rear throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 1 Front throttle voltage Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 1 and the throttle control unit PIN 6B is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body Potentiometer 2 sensor rear thro
232. side insert the three bolts with their washers Working on the right side place the spacers on the three bolts between the engine block and the chassis CAUTION THE SPACERS HAVE DIFFERENT SIZES REFIT THEM IN THE SAME WAY THEY WERE BEFORE BEING REMOVED ENG VE 187 Engine from vehicle DORSODURO FACTORY ABS Working from the left side tighten the three nuts Release the engine from the belt and the hoist Refit the pinion and restore the gearing chain clearance Reconnect the electric connections and clamp the cable harnesses Carry out the vehicle preparation oper ations but in reverse order restore the correct level of all fluids and carry out the adjustments that may be required ENG VE 188 DORSODURO FACTORY ABS Engine from vehicle See also Vehicle preparation Adjusting ENG VE 189 INDEX OF TOPICS DORSODURO FACTORY ABS Engine Gearbox Diagram Key Complete gear shaft and spring Selector lock Selector sprocket wheel M5x16 Screw Sprocket wheel pawl Spring Pin for spring Complete transmission gear shaft Forks 10 Fork shaft 11 Gear selector 12 Fork shaft 13 Fork 14 Gear selector drum 15 M8x1 25 threaded pin 16 Selector locking plate er CX gt oe w ENG 191 Engine 17 Complete main gear shaft 18 TE flanged screw M6x15 19 Complete index lever 20 Spring 21 Nut 22 Threaded pin Gearbox shafts Gearbox shafts
233. sition are not worn or damaged Check all ball bearings for clearance smoothness and potential distortions CAUTION LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING If the internal ring does not rotate smoothly and silently or if there is some noise while it turns it means that the bearing is faulty and must be replaced OIL FILTER AND OIL DELIVERY PIPE CHECK Check the oil filter for damage If necessary replace the part Clean the oil net with petrol and inspect the net links for potential damage CHECK THE ENGINE OIL FILTER O RING ENG 254 DORSODURO FACTORY ABS Engine LUBRICATION CHECK Working on both crankcase halves re move and thoroughly clean the nozzle that lubricates the piston crown REPLACE THE SPRAY NOZZLE O RING IF NECESSARY Replace the O ring on the oil passage duct Before refitting UPON REFITTING THE CRANKSHAFT GREASE THE SHAFT BUSHING CONNECTING ROD COUPLING Inspecting the crankshaft components Crankshaft axial clearance check The shaft axial clearance on the crank case should be checked with a com parator mounted on the specific com parator support The clearance should be between 0 1 0 4 mm 0 0039 0 0157 in If the clearance is beyond tolerance check the reference surfaces Specific tooling 020714Y Dial gauge mounting Main bearing journal ENG 255 Engine DORSODURO FACTORY ABS Removal Mark the position of th
234. sition sensor track A example value 1107 mV Voltage value of the left potentiometer track A Left side throttle grip position sensor track B example value 1107 mV Voltage value times 2 of the left potentiometer track B Right side throttle grip position sensor track C 3560 mV Voltage value of the left potentiometer track C Right side throttle grip position sensor track D 3555 mV Voltage value times 2 of the left potentiometer track D Throttle grip position sensor 1107 mV Voltage corresponding to the potentiometer track A Throttle grip opening percentage 0 With a released throttle grip the value read should be 0 whereas 100 should be read with throttle grip fully twisted NAVIGATOR STATUSES Throttle grip Example value Slightly twisted_choked_fully twisted Handle self learning Example value carried out not carried out NAVIGATOR PARAMETER ADJUSTMENT Handle self learning NAVIGATOR ELECTRICAL ERRORS Left side throttle grip position sensor track A P0150 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 42 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 42 of the VEHICLE connector Troubleshooting shorted to positive check the value shown by the parameter of the left Throttle Grip Position Sensor track A disconnect the
235. sure rider only 2 3 bar 230 kPa 33 36 PSI rider passenger 2 4 bar 240 kPa 34 81 PSI Rear tyre 180 55 ZR17 Rear tyre pressure rider only 2 5 bar 250 kPa 36 26 PSI rider passenger 2 7 bar 270 kPa 39 16 PSI CHAR 15 Characteristics DORSODURO FACTORY ABS Supply FUEL SYSTEM Specification Desc Quantity Type Electronic injection Multipoint Throttle valve diameter 52 mm 2 05 in Fuel Premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM Tightening Torques Chassis Front side from rear cylinder _ Od from des cylinder CooLiNG SYSTEM pos Description Type Quantity Torque Notes 1 Fan fastener screw 3 3 Nm 2 21 Ibf ft 2 Flanged TE screw fixing LH side ra M6x25 2 10 Nm 7 37 Ibf ft diator to trellis frame and radiator bracket to engine CHAR 16 DORSODURO FACTORY ABS Characteristics i 7 2 0 i Ti ie Lr h mes i ir z h v a pe ATE 1 ic a Lo hes i e FRONT FORK SHOWA pos Description Type Quantity Torque Notes 1 Screws fasten onto fork hubs M8x40 4 25 Nm 18 44 Ib ft m In TH li n j i A aa a H I iul T IM rene 1 Fa NO OE 1 2 4 wm C EN E p i E p FRONT FORK SACHS Description Type Quantity Torque Notes a Scr
236. tank breather pipe and when refitting it place it according to the new standard following the refitting procedure OPTION 02 Disconnect the breather pipes from the tank Release the cable harness from the clamps Disconnect the fuel pump connector e Remove the tank CAUTION UPON REFITTING THE TANK FOLLOW THE SAME STEPS BUT IN REVERSE ORDER CONNECT AGAIN THE FUEL PIPES AND THE FUEL PUMP CONNECTOR REMEMBER TO SLIDE OFF THE PIN PREVIOUSLY FITTED AND TO DRAW THE TANK BACKWARD AS MUCH AS POSSIBLE IN ORDER TO FIT IT PROPERLY BODYW 387 Bodywork DORSODURO FACTORY ABS Instrument cluster support Working on both sides loosen the nuts and screws and remove them e Disconnect the connectors of arrow in dicators headlamps ignition switch assembly and relay Remove the three screws that fix the instrument panel Slide off the instrument panel from its support BODYW 388 DORSODURO FACTORY ABS Bodywork Disconnect the instrument panel con nector Remove the instrument panel Radiator cover Working from both sides unscrew remove the screw e Remove the radiator cover BODYW 389 Bodywork DORSODURO FACTORY ABS Tail guard Remove the saddle Remove the rear passenger grab han dle if present Working from both sides unscrew remove the external screw Unscrew remove the three screws M S
237. te 243 2 Headstock nut M22x1 1 25 Nm 18 44 Ib ft Loctite 243 3 Stainless steel TCC screw fastening M8x30 6 25 Nm 18 44 Ib ft stanchions to upper and lower yokes 4 TCEI screw fastening U bolt onto M10x60 2 50 Nm 36 88 Ib ft fork yoke 5 Steering upper plate clamp closing M8x30 1 25 Nm 18 44 Ib ft Loctite 243 screw Adjusting play Place the vehicle so that the front wheel is off the ground Carry out a handlebar rotation test using a dynamometer at the hand grip external end The handlebar resistance to rotation must be of 400 150 g 0 88 0 33 Ib in both directions Adjust if clearance is detected OPTION 01 Steering upper plate without a headstock cut SUSP 299 Suspensions DORSODURO FACTORY ABS Unscrew and remove the U bolt four fixing screws Remove the U bolt Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out Unscrew and remove the top bolt on the headstock and retrieve the washer Operating from both sides loosen the screws fixing the stanchions to the up per plate Undo and remove the two screws fixing the instrument panel support to the fork upper plate Slide off the fork upper plate by moving it towards the instrument panel SUSP 300 DORSODURO FACTORY ABS Suspensions Get the suitable tool for the tightening of the ring nut Carry out the following op
238. tely e Undo and remove the five screws Remove the water pump cover PUMP ROTOR REMOVAL COOL SYS 350 DORSODURO FACTORY ABS Cooling system Remove the clutch side cover Lock the pump shaft with a universal wrench on the hexagonal insert on the shaft e Unscrew and remove the anticlock wise nut fixing the rotor e Remove the rotor Unscrew remove the rotor control gear fixing nut and act on the gear hex agonal insert Remove the rotor control gear From the cover inside to the outside remove the rotor control shaft with a punch and a rubber hammer Use a screwdriver to remove the upper part of the shaft and integrated seal as sembly as indicated CAUTION BEFORE TIGHTENING THE 3 SCREWS ENSURE THAT THE TOOL IS PERFECTLY CENTRED WITH THE SEAL AND THAT THE SCREWS ARE PERPENDICULAR TO THE SURFACE OF THE SEAL ITSELF TIGHTENING THE SCREWS INCORRECTLY MAY DAMAGE THE OIL SEAL UNDERNEATH THE WATER SEAL AND THE COVER IT SELF Fit the tool and use the specific punch to make 3 holes in the integrated seal Specific tooling 020661Y Water pump overall seal replacement kit COOL SYS 351 Cooling system DORSODURO FACTORY ABS Tighten the three screws Fit the upper part of the tool Fully tighten the pin with the bolt Preventing the bolt from turning tight en the nut to that the lower part of the tool onto which the shaft and integra ted seal a
239. tem is often detected the EFI warning light turns on permanently and the word ABS is shown on the display NA 850 Mana ABS the ABS warning light turns on permanently SL 750 SHIVER ABS DORSODURO 750 ABS If on the vehicle NA 850 Mana ABS temporary errors of other control units are detected the word ABS shown on the display is displayed instead of the word relative to the other control units where errors have been detected e g GEAR or SERVICE The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The diagnosis requires exceeding the 5 km h Each time the key is ON if at least one current or stored error of the ABS system is not detected the EFI warning light flashes and the word ABS is shown on the display NA 850 Mana ABS the ABS warning light flashes SL 750 Shiver ABS Dorsoduro 750 ABS When the 5 km h 3 11 mph are exceeded if errors are not detected BRAK SYS 330 DORSODURO FACTORY ABS Braking system the EFI warning light turns off and the word ABS on the display disappears NA 850 Mana ABS the ABS warning light turns off SL 750 Shiver ABS Dorsoduro 750 ABS if at least one malfunction is detected the EFI warning light turns permanently and the word ABS appears on the display 850 Mana ABS the ABS warning light turns on permanently SL 750 Shiver ABS Dorsoduro 750 ABS The ABS system is deactivated The sys
240. tem operates perfectly just as any other braking system without ABS The detection of malfunctions may require more or less time according to the type of failure Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no longer able to diagnose the error The ABS system is still inactive Example error code 5D93 requires some minutes before it is diagnosed during the given time A The EFI warning light keeps flashing with the word ABS on the display NA 850 Mana ABS B The ABS warning light keeps flashing SL 750 Shiver ABS Dorsoduro 750 ABS ABS FAULTS GUIDE TO THE DIAGNOSIS 1a NA 850 Mana ABS WARNING LIGHT ICON 1b Dorsoduro 750 SL 750 Shiver ABS WARN ING LIGHT LIT 2 CONNECT NAVIGATOR DOES NAVIGATOR COMMUNICATE NO go to 3 YES go to 4 3 PERFORM THESE CHECKS A Ground connection PIN 1 B 12V at PIN 18 12 at PIN 4 with key ON 4 ARE THERE ANY ERRORS YES go to 5 NO go to 6 5 CONSULT THE ERRORS TABLE 6 ABS WARNING LIGHT ACTIVATION ACTIVE YES go to 7 NO go to 8 7 CONTACT TECHNICAL SERVICE 8 CHECK BRAK SYS 331 Braking system DORSODURO FACTORY ABS A Cable continuity between PIN 8 of the ABS control unit connector and PIN 28 of the instrument panel B Check connectors
241. the locking catch is re leased e Yen 2 Observation of the terminals on the connector no rust marks or dirt should be present and it is important to check terminal correct positioning on the connector i e all terminals aligned at the same depth and terminal integrity i e that termi nals are not loose open bent etc For connec tors whose terminals are not visible e g Marelli control unit use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector CAUTION IN CASE OF TEMPORAL MALFUNCTIONING CARRY OUT ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED 3 Pulling the cables slightly from the back of the connector in order to check the correct position of terminals on the connector and of the cable on the terminal CONTINUITY check Check goal this control is to check that there are not any circuit interruptions nor excessive resistance for instance caused by rust on the two terminals being inspected Tester set the tester on the continuity symbol and place the tester probes on the two circuit ends the tester emits a sound signal only if there is continuity the tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm CAUTION THE CIRCUIT SHOULD NOT BE ENERGISED OTHERWISE THE TEST IS IRRELE VANT GROUND CONNECTION check
242. the sensor connector and the instrument panel connector PIN 17 if they are not OK restore If OK check continuity of the purple cable between the sensor connector and the instru ment panel connector PIN 17 if not OK restore the cable harness if OK replace the sensor Error DSB 08 Error cause An oil sensor fault is signalled when with engine running it is detected that the sensor circuit is closed There is an error when the general warning light turns on Troubleshooting Check if oil pressure is low with the specific gauge ELE SYS 163 Electrical system Electrical system DORSODURO FACTORY ABS Neutral sensor GEAR IN NEUTRAL SENSOR ed V N 0 75 35 it tells the gear position to the control unit if it is in neutral or in gear Operation Operating principle for gear in neutral the circuit is closed to ground connection then via CAN the control unit sends the signal to the instrument panel which turns on the neutral speed warning light Level in electrical circuit diagram Start up ena bling switches Location on the vehicle left side of the vehicle near flywheel cover connector upper part of the flywheel cover Electrical characteristics gear in neutral closed circuit continu ity gear engaged open circuit infinite re sistance Pin out 1 Voltage 12V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONC
243. there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body Potentiometer 2 sensor front throttle position P0122 ELE SYS 154 DORSODURO FACTORY ABS Electrical system Example value short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN A5 of the throttle control unit If the circuit is open shorted to negative voltage equal to zero has been detected at PIN A5 of the throttle control unit Troubleshooting shorted to positive check the value shown by the parameter of the front throttle Potentiom eter 2 voltage disconnect the left connector and see the value displayed by Navigator if the voltage does not vary there is a short circuit in the cable wiring replace the throttle body if the voltage drops to zero if the circuit is open shorted to negative check the throttle body connector and the throttle valve connector If not OK restore if everything is OK check circuit continuity between the two terminals If not OK restore the cable harness if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body Potentiometer 1 se
244. tions are dis played in case of lack of activation Rear coil The auxiliary injection relay No 40 in the wiring diagram placed under the fuel tank right side second relay starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the sky blue green of the coil is closed to ground for 2 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation NAVIGATOR ELECTRICAL ERRORS Lambda probe P0130 shorted to positive circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 17 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 17 of the ENGINE connector Troubleshooting ELE SYS 151 Electrical system DORSODURO FACTORY ABS shorted to positive disconnect the coil connector set the key to ON activate the coil with Navigator and check voltage at connector PIN 3 if there is voltage restore the cable har ness if voltage 0 replace the coil Open circuit shorted to negative check the coil connector and the Marelli control unit connector If not OK restore if everything is OK check cable continuity between the two cable terminals If there is no contin
245. tis not OK replace it If it is OK check that the tyre pressure is the correct one If it is not OK restore it if itis OK replace the speed Sensor Engine rpm sensor ENGINE SPEED SENSOR Cy Function It informs crankshaft position and speed to the Marelli control unit Operation Operating principle Inductive sensor sinusoidal type generated volt age two teeth are missing on the flywheel for the reference position Level in electrical circuit diagram engine spe ed sensor Location on the vehicle inside the flywheel cov er connector if available near the Mar elli control unit Electrical characteristics ELE SYS 129 Electrical system DORSODURO FACTORY ABS Resistance at ambient temperature 130 20 Ohm Pin out 1 Negative signal 2 Positive signal CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR PARAMETERS Engine rpm NAVIGATOR STATUSES Synchronised panel Example value Start up Lean Fault due to rich value Fault due to lean value If the probe connector is removed voltage almost equal to zero the status is Fault due to lean value Example value No under analysis standby Yes The parameter refers to the engine revs signal in case the signal has not been correctly identified yet
246. tite 243 ENG VE 179 Engine from vehicle DORSODURO FACTORY ABS CENTRE FRAME pos Description Type Quantity Torque Notes 1 TCEI screws fastening side panels to M12x282 3 80 Nm 59 Ibf ft engine 2 TCEI screw fastening lambda probe M4x10 2 3 Nm 2 3 Ibf ft plate to RH frame pre fit on RH side panel 3 SWP self tapping screw fastening M5x14 4 2 6 Nm 1 92 Ibf ft demand sensor mounting to demand sensor 4 Flanged TE screw fastening demand M6x20 3 10 Nm 7 37 Ibf ft sensor to frame ENG VE 180 DORSODURO FACTORY ABS 100 Engine from vehicle pos Description Flanged TE screw fastening pinion TCEI screw fastening Pin to gearbox lever and Gearbox Lever to knurled shaft LH lock nut for ball joint RH lock nut for ball joint Screw fastening engine bracket clutch side crankcase half Map sensor union brass Map sensor union steel LH ball joint on gearbox control lever RH ball joint on gearbox control lever Fastener for positive cable on engine TE screw fastening negative cable to engine Quantity ENGINE Type M10x1 25x25 1 M6x16 2 M6 1 M6 1 M6 2 2 2 1 1 1 M6x12 1 Torque 50 Nm 36 88 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 lbf ft 10 Nm 7 37 Ibf ft 12 Nm 8 85 Ibf ft 2 Nm 1 48 Ibf ft 3 50 Nm 2 58 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft 10 Nm 7 37 Ibf ft
247. to 19 M 18 WHEN THE KEY IS TURNED TO OFF CHECK CONTINUITY AND GROUND IN SULATION OF THE YELLOW PURPLE CABLE FROM THE RELAY TO PIN 62 VEHICLE CONNECTOR YES go to 22 NO go to 21 19 RESTORE THE CABLE HARNESS e 20 CHECK THERE IS GROUND INSULATION FOR THE BLUE CABLE OF THE PUMP CONNECTOR OK go to 24 NOT OK go to 23 21 RESTORE THE CABLE HARNESS END e 22 CHECK THE VEHICLE CONNECTOR OK go to 25 NOT OK go to 26 23 RESTORE THE CABLE HARNESS END e 24 CHECK THAT THE RESISTANCE OF THE PUMP IS APPROX 1 OHM IF THE RE SISTANCE IS INCORRECT REPLACE THE PUMP END 25 REPLACE THE CONTROL UNIT END e 26 RESTORE THE CABLE HARNESS END 27 DOES THE MOTOR TURN WHEN THE STARTER BUTTON IS PRESSED YES go to 29 NO go to 28 28 WHAT DOES THE START UP ENABLING SWITCH STATUS ON NAVIGATOR DE VICE STATUS ICON 0 1 SCREEN PAGE MEAN YES go to 43 NO go to 64 TROUBL 86 DORSODURO FACTORY ABS Troubleshooting M 29 CHECK FOR VOLTAGE ON THE BROWN WHITE WIRE OF STARTER MAINTE NANCE RELAY POLARISED 37 OK go to 30 NOT OK go to 31 s 30 WITH THE STARTER MAINTENANCE RELAY POLARISED 37 DISCONNECTED KEEP THE STARTER BUTTON PRESSED AND CHECK THAT A VOLTAGE OF APPROX 1 2V IS MEASURED ON THE YELLOW RED WIRES OK go to 32 NOT OK go to 33 31 CHECK FOR CONTINUITY ON THE BROWN WHITE CABLE OK go to 31a NOT OK go to 31b 31a WITH THE LIGHT LOGIC RELAY 7 DISCO
248. ttle position P0128 signal not valid Error cause Signal not within the expected value drawn according to the values of the intake pressure Troubleshooting Check the parameter of the Potentiometer 2 Rear throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 2 Front throttle voltage Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5B is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body Rear throttle position sensors P0129 illogical signal Error cause Potentiometer 1 and potentiometer 2 do not show a logical value the sum of the two voltages should be constant The cause may be a malfunction in one of the two sensors or an ab normal resistance in one of the two circuits Troubleshooting e Check the throttle body connector as well as the throttle control unit connector Check that cable resistance between the throttle body connector PIN 1 and the throttle control unit PIN 6B is a few tenths of an Ohm Check that cable resistance between the throttle body connector PIN 4 and the throttle control unit PIN 5B is a few tenths of an Ohm If one of the two is different restore the cable harness If correct replace the complete throttle body Front t
249. uity restore the cable harness if there is cable continuity with key set to ON check the cable ground insulation from coil connector or control unit connector If not OK restore the cable harness Rear coil P0352 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 19 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 19 of the ENGINE connector Troubleshooting Shorted to positive disconnect the coil connector set the key to ON activate the coil with Navigator and check voltage at connector PIN 3 if there is voltage restore the cable har ness if voltage 0 replace the coil If the circuit is open shorted to negative check the coil connector and the Marelli control unit connector If not OK restore if everything is OK check cable continuity between the two cable terminals If there is no continuity restore the cable harness if there is cable continuity with key set to ON check the cable ground insulation from coil connector or control unit connector If not OK restore the cable harness NAVIGATOR LOGIC ERRORS Throttle body THROTTLE BODY Function To inform the throttle control unit the position of the two throttle valves and to drive them both Operation Operating principle All the unit internal components potentiometer and electric motor
250. upper plate to the prescribed tightening tor que Finish the nut tightening to the indica ted tightening torque STEERING UPPER PLATE pos Description Type Quantity Torque Notes 2 Headstock nut pre tightening M22x1 1 10 Nm 7 37 lb ft Loctite 243 2 Headstock nut M22x1 1 25 Nm 18 44 Ib ft Loctite 243 3 Stainless steel TCC screw fastening M8x30 6 25 Nm 18 44 Ib ft stanchions to upper and lower yokes When refitting the U bolt position the two referen ces facing the front part of the vehicle SUSP 304 DORSODURO FACTORY ABS Assembling Grease the lower and upper bearing rollers Prefit the shim dust gaiter and lower bearing on the steering yoke as shown in the figure Recommended products AGIP MP GREASE Grease for bearings joints couplings and linkages As an alternative to the recommended product use top brand grease for roller bearings with an operating temperature range of 22 F to 284 F 30 C to 140 C drop point between 302 F to 446 F 150 C to 230 C high corrosion protection qualities and good water and rust resistance Install the upper bearing on the steer ing tube as shown in the figure with the conical part facing down After inserting the bearing must slide freely on the steering column till match ing with the steering bearing conic in the frame Ensure the bearing mating in its seat using a teflon buffer
251. voiding sudden or prolonged braking That is to permit the adequate adjustment of the pad friction material to the brake discs AFTER THE SPECIFIED MILEAGE TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE AFTER RUN IN TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURING YOURSELF OTHERS AND OR DAMAGING THE VEHICLE CHAR 11 Characteristics DORSODURO FACTORY ABS Vehicle identification Write down the chassis and engine number in the specific space in this booklet The chassis number is handy when purchasing spare parts CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME HOWEVER THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE IDENTIFICATION NUMBER VIN HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED This number consists of numbers and letters as in the example shown below ZD4SMBOOOYSXXXXXX KEY ZD4 WMI World manufacturer identifier code SM model BOO version variation 0 free digit Y year of manufacture S production plant S Scorz XXXXXX serial number 6 digits ENGINE NUMBER The engine number is printed on the base of the engine crankcase left hand side Engine No CHASSIS NUMBER The chassis number is stamped on the right side of the headstock Chassis No Dimensions and mass DIMENSIONS Specification Desc Quantity Max length 2210 mm 87 01 in Max
252. wingarm screws Remove the cable guides e Unscrew and remove the shock ab sorber lower screw and collect the nut e Fasten the shock absorber to the chas SIS With the specific box spanner screw and remove the locking ring nut CHAS 314 DORSODURO FACTORY ABS DORSODURO FACTORY ABS Chassis Working from the left side unscrew and remove the nut and collect the washer REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOW ERING AND TO KEEP IT UPRIGHT Working on the right side unscrew and UPON REMOVING THE REAR SWINGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN remove the swingarm bolt See also Removing the rear wheel Drive chain Adjusting The vehicle ts fitted with an endless chain without master link NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE To check clearance M Shut off the engine Rest the vehicle on its stand Engage neutral gear Check that the vertical oscillation at a point between the pinion and the sprocket on the lower branch of the chain is approx 25 30 mm 0 98 1 18 In CHAS 315 Chassis DORSODURO FACTORY ABS Move the vehicle forwar
253. y between the ENGINE connector PIN 35 and the sensor connector PIN 2 restore the cable harness if there is not continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If shorted to negative check sensor correct resistance if resistance 0 replace the sensor If resistance is correct it means that the cable has ground connection restore the cable harness NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check through Navigator if the temperature indicated is plausible in relation to the ambient temperature Check also that the sensor electrical charac teristics are observed replace the sensor if not OK if itis OK check the sensor connector and the Marelli control unit connector Lambda sensor LAMBDA PROBE Function In charge of telling the control unit whether the mixture is lean or rich Operation Operating principle The Marelli injection control unit reads and inter prets a voltage generated by the difference in oxy gen content between the exhaust fumes and the ELE SYS 144 DORSODURO FACTORY ABS Electrical system ambient It does not require an external supply source but in order to work properly it should 99 reach a high operating temperature that is why there is a heating circuit inside R N 0 75 D6 Gr B 0 75 35 V Bi 0

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