APRILIA SHIVER 900 Service Station Manual

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SERVICE STATION MANUAL

2Q000335

SHIVER 900

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Summary of Contents for APRILIA SHIVER 900

Page 1 SERVICE STATION MANUAL 2Q000335 SHIVER 900...
Page 2 Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
Page 3 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.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM CLU SYS LUTCH SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 SHIVER 900 Characteristics 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.
Page 8 SHIVER 900 Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10 SHIVER 900 Characteristics • Grip the two connectors and disconnect them by pulling them in opposite directions. • If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air.
Page 11 SHIVER 900 Characteristics MAINTENANCE PROGRAMME SECTION CARRIED OUT AT THE SPECIFIED MILEAGE INTER- VALS. 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.
Page 12 SHIVER 900 Characteristics Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Max. length 2130 mm (83.86 in) Max. width 810 mm (31.89 in) Max height (at handlebar) 1110 mm (43.70 in) Wheelbase 1465 mm (57.68 in) Kerb weight 218 Kg (481 lb)
Page 13 SHIVER 900 Characteristics Specification Desc./Quantity Fuel reserve 3 l (0.66 UK gal; 0.79 US gal) Engine oil 3.0 l (without oil filter change) (0.66 Uk gal; 0.79 US gal) 3.2 l (with oil filter change) (0.70 Uk gal; 0.85 US gal) Coolant 1.8 l (0.40 UK gal;...
Page 14 SHIVER 900 Characteristics Frame and suspensions FRAME Specification Desc./Quantity Type Die-cast aluminium plates and high-yield strength steel frame. Steering inclination angle (with extended suspensions) 26° Trail 114 mm (4.49 in) SUSPENSIONS Specification Desc./Quantity Front Telescopic upside-down hydraulic fork, stems diam 41 mm (1.61 in)
Page 15 SHIVER 900 Characteristics TYRES Specification Desc./Quantity Front 120/70 ZR17" (58W) Inflation pressure 1 passenger: 2.3 bar (230 KPa) (33.36 PSI) 2 passengers: 2.5 bar (250 KPa) (36.26 PSI) Rear 180/55 ZR17" (73W) Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI) 2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Page 16 SHIVER 900 Characteristics Front side EADLAMP Pos. Description Type Quantity Torque Notes Button head, hex. socket screws M6x15 10 Nm (7.38 lb ft) used to fasten the headlight bracket to the bottom yoke Button head, hex. socket screws M5x16 3 Nm (2.21 lb ft)
Page 17 SHIVER 900 Characteristics NSTRUMENTS Pos. Description Type Quantity Torque Notes Button head, hex. socket instrument M5x12 3 Nm (2.21 lb ft) panel adapter fastening screws Self-tapping, SWP screws used to 5x14 3 Nm (2.21 lb ft) fasten the instrument cluster and cover to the support plate Button head, hex.
Page 18 SHIVER 900 Characteristics ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Stainless steel, cyl. head Pozidriv M8x25 25 Nm (18.44 lb ft) screws used for fastening the upper U-bolt to the lower U-bolt Electronic accelerator control fasten- 4 Nm (2.95 lb ft)
Page 19 SHIVER 900 Characteristics LUTCH CONTROL Pos. Description Type Quantity Torque Notes Clutch pump U-bolt fastening screws 10 Nm (7.38 lb ft) Special screw for fastening the pipe 25 Nm (18.44 lb ft) to the clutch cylinder Special screw for fastening the pipe 25 Nm (18.44 lb ft)
Page 20 SHIVER 900 Characteristics TEERING Pos. Description Type Quantity Torque Notes Headstock ferrule (pre-tightening) 50 Nm (36.88 lb ft) Steering assembly settling Headstock ferrule (tightening) 15 Nm (11.06 lb ft) Flanged upper steering plate fasten- 25 Nm (18.44 lb ft) ing nut (stop) Flanged upper steering plate fasten- 25 Nm (18.44 lb ft)
Page 21 SHIVER 900 Characteristics RONT FORK Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M6x40 10 Nm (7.38 lb ft) closing the fork feet Button head, hex. socket screws M5x16 6 Nm (4.43 lb ft) used for fastening the sensor to the...
Page 22 SHIVER 900 Characteristics RONT MUDGUARD NGINE FAIRING Pos. Description Type Quantity Torque Notes Button head hex. socket screws M5x9 4 Nm (2.95 lb ft) Loct. 243 used to fasten the mudguard to the calliper mounting bracket Button head hex. socket screws for M6x20 10 Nm (7.38 lb ft)
Page 23: Table Of Contents
SHIVER 900 Characteristics RONT BRAKE CALLIPERS Pos. Description Type Quantity Torque Notes Flanged, hex. head screws for fas- M10x1.25 50 Nm (36.88 lb ft) tening the brake callipers to the fork stanchions Special screws for fastening the 25 Nm (18.44 lb ft)
Page 24 SHIVER 900 Characteristics RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Flanged, hex. head screws for fas- M6x20 10 Nm (7.38 lb ft) tening the voltage regulator to the frame Flanged SWP screws for fastening M5x20 2.5 Nm (1.84 lb ft)
Page 25 SHIVER 900 Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M6x12 10 Nm (7.38 lb ft) fastening the rider/passenger rubber footrests Cyl. head, hex. socket screws used M8x25 18 Nm (13.28 lb ft) Loct. 243...
Page 26 SHIVER 900 Characteristics TAND Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M8x30 25 Nm (18.44 lb ft) fastening the stand plate to the en- gine Screw for fastening the stand to the M10x1.25 10 Nm (7.38 lb ft)
Page 27 SHIVER 900 Characteristics OCKS Pos. Description Type Quantity Torque Notes Button head, hex. socket ignition lock M8x40 25 Nm (18.44 lb ft) fastening screw Ignition lock fastening shear head Manual screw Flanged, hex. head screws used to M6x25 10 Nm (7.38 lb ft) fasten the saddle lock to the saddle Cyl.
Page 28 SHIVER 900 Characteristics UEL TANK COVER Pos. Description Type Quantity Torque Notes Button head, hex. socket screws M6x12 10 Nm (7.38 lb ft) used to fasten the radiator guard to the radiator Button head, hex. socket block lid/ M5x9 10 Nm (7.38 lb ft) fuel tank cover fastening screws Button head, hex.
Page 29 SHIVER 900 Characteristics pos. Description Type Quantity Torque Notes Flanged, hex. head front fuel tank M6x30 6 Nm (4.43 lb ft) fastening screws Fuel pump fastening nuts 6 Nm (4.43 lb ft) CHAR - 29...
Page 30 SHIVER 900 Characteristics IR FILTER CASING Pos. Description Type Quantity Torque Notes Self-tapping, SWP air pressure sen- 5x20 2 Nm (1.48 lb ft) sor fastening screws Self-tapping air temperature sensor 2.9x12 2 Nm (1.48 lb ft) fastening screws SWP filter box lid fastening screws 5x20 2 Nm (1.48 lb ft)
Page 31 SHIVER 900 Characteristics IDE FAIRINGS Pos. Description Type Quantity Torque Notes Self-tapping, cyl. head slot drive 4.2x16 3 Nm (2.21 lb ft) screws used for fastening the grilles to the duct covers Self-tapping, cyl. head slot drive 4.2x16 3 Nm (2.21 lb ft)
Page 32 SHIVER 900 Characteristics OOLING SYSTEM Pos. Description Type Quantity Torque Notes Flanged, hex. head used for fasten- M6x20 10 Nm (7.38 lb ft) ing the trellis expansion tank Flanged, hex. head screw used for M6x25 10 Nm (7.38 lb ft) fastening the trellis radiator Button cyl.
Page 33 SHIVER 900 Characteristics BRAKING SYSTEM pos. Description Type Quantity Torque Notes Flanged, hex. head screw used for M6x25 10 Nm (7.38 lb ft) fastening the ABS control unit on the support Front fastening, flanged self-locking 10 Nm (7.38 lb ft) Flanged, hex.
Page 34 SHIVER 900 Characteristics ETROL VAPOUR RECOVERY SYSTEM Pos. Description Type Quantity Torque Notes Cyl. head, hex. socket screws used M6x25 4 Nm (2.95 lb ft) for fastening the pinion cover guard Back side CHAR - 34...
Page 35 SHIVER 900 Characteristics WINGARM Pos. Description Type Quantity Torque Notes Swingarm pivot bolt fastening nut 90 Nm (66.38 lb ft) Swingarm pivot bolt fastening nut 12 Nm (8.85 lb ft) swingarm bolt regulator bushing Swingarm pivot bolt fastening swing- 60 Nm (44.25 lb ft) arm bolt ferrule Button head, hex.
Page 36: M10X1.25
SHIVER 900 Characteristics EAR WHEEL Pos. Description Type Quantity Torque Notes Wheel axle nut M25x1.5 120 Nm (88.51 lb ft) Button head, hex. socket screw used M5x16 6 Nm (4.43 lb ft) for fastening the sensor to the brake calliper support DAX nut for fastening the crown gear M10x1.25...
Page 37: Nm (18.44 Lb Ft)
SHIVER 900 Characteristics EAR BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Cyl. head, hex. socket screw used for M6x16 10 Nm (7.38 lb ft) fastening the peg to the gearshift lev- Pin used to fasten the lever to the 25 Nm (18.44 lb ft)
Page 38 SHIVER 900 Characteristics EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Special brake pipe coupling fasten- M10x1 10 Nm (7.38 lb ft) ing screw Button head, hex. socket screws M5x9 4 Nm (2.95 lb ft) used for fastening the brake pipe pro-...
Page 39: Description Type Quantity
SHIVER 900 Characteristics EAR BODYWORK Pos. Description Type Quantity Torque Notes Button head, hex. socket screws M6x20 10 Nm (7.38 lb ft) used for fastening the covers to the terminal Self-tapping screws used for fasten- M5x19 4 Nm (2.95 lb ft)
Page 40: Torque Notes
SHIVER 900 Characteristics ILENCER Pos. Description Type Quantity Torque Notes Lambda probes 40 Nm (29.50 lb ft) Flanged, self-locking used for fasten- 12.5 Nm (9.22 lb ft) ing the exhaust flanges to the big ends Cyl. head, hex. socket screws used M4x6 3 Nm (2.21 lb ft)
Page 41 SHIVER 900 Characteristics EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Button head, hex. socket screw used M5x35 3 Nm (2.21 lb ft) for fastening the anti-rollover sensor Engine CHAR - 41...
Page 42 SHIVER 900 Characteristics EAD COVER Pos. Description Type Quantity Torque Notes Special head cover fastening screw 9 Nm (6.64 lb ft) IMING SYSTEM Pos. Description Type Quantity Torque Notes Cam shaft gear fastening nut M15x1 88 Nm (64.91 lb ft)
Page 43: Nm (18.44 Lb Ft)
SHIVER 900 Characteristics Pos. Description Type Quantity Torque Notes (axle cone and gear cone) Timing lay shaft fastening screw M24x1.5 88 Nm (64.91 lb ft) 3M SCOTCH GRIP 2353 Special mobile / fixed slider fastening 18 Nm (13.28 lb ft)
Page 44 SHIVER 900 Characteristics Pos. Description Type Quantity Torque Notes Water vent connector 3 Nm (2.21 lb ft) Loct. 262 YLINDER Pos. Description Type Quantity Torque Notes Chain tensioner fastener screw M6x30 13 Nm (9.59 lb ft) Cylinder plate fastening screw M6x16 9 Nm (6.64 lb ft)
Page 45 SHIVER 900 Characteristics LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover / Clutch side cover fas- 13 Nm (9.59 lb ft) tening screw Clutch fastening nut M24x1.5 177 Nm (130.55 lb ft) Chamfer Oil filler cap on clutch cover M25x1.25...
Page 46 SHIVER 900 Characteristics ATER PUMP Pos. Description Type Quantity Torque Notes Clutch side cover fixing screw M6x40 13 Nm (9.59 lb ft) Pump cover / Clutch side cover fas- M6x25 13 Nm (9.59 lb ft) tening screw Pump cover / Clutch cover / clutch M6x60 13 Nm (9.59 lb ft)
Page 47 SHIVER 900 Characteristics GNITION Pos. Description Type Quantity Torque Notes Spark plug 13 Nm (9.59 lb ft) Free wheel ring fastening screw M6x18 14 Nm (10.33 lb ft) 3M SCOTCH GRIP 2353 Rotor fastening screw - Crankshaft M14x1.5 191 Nm (140.87 lb ft)
Page 48 SHIVER 900 Characteristics RANKCASE Pos. Description Type Quantity Torque Notes Half-crankcase coupling screw M8x80 28 Nm (20.65 lb ft) Half-crankcase coupling screw M6x65 13 Nm (9.59 lb ft) Special oil calibration screw M10x1 14 Nm (10.33 lb ft) CHAR - 48...
Page 49 SHIVER 900 Characteristics RANKCASE Pos. Description Type Quantity Torque Notes Crankcase-cylinder-head fastening M10x1.25x166 Distance-based tighten- SCOTCH GRIP stud bolts 2510 GREEN Bearing retainer fastening screws M6x12 10 Nm (7.38 lb ft) 3M SCOTCH GRIP 2353 or Loct. DRI- LOC 2045 BLUE...
Page 50 SHIVER 900 Characteristics EAR SELECTOR Pos. Description Type Quantity Torque Notes Gear sensor fastening screw 6 Nm (4.43 lb ft) Loct. 270 Selector plate fastening screw M5x12 5 Nm (3.69 lb ft) 3M SCOTCH GRIP 2353 Desmodromic drum/sprocket fasten- M8x1.25x17 15 Nm (11.06 lb ft)
Page 51: Nm (22.13 Lb Ft)
SHIVER 900 Characteristics RANKSHAFT Pos. Description Type Quantity Torque Notes Primary crankshaft fastening net M24x1.5 294 Nm (216.84 lb ft) Thoroughly de- grease both of the coupling surfaces (shaft cone and gear cone) Connecting rod fastening screws - M10x1x40 15 Nm (11.06 lb ft)
Page 52 SHIVER 900 Characteristics Specification Desc./Quantity Fitting clearance 0.050 - 0.064 mm (0.00197 - 0.00252 in) Crankcase - crankshaft - connecting rod MARKINGS ON THE INSIDE OF THE CRANKCASES Crankcases selectable in two classes (1 or 2), based on the diameter of the main housing.
Page 53 SHIVER 900 Characteristics • crankcase • flywheel side block journal • clutch side block journal the bearings to be used for their coupling can be selected based on the following table. MAIN BEARINGS Block journal Crankcase class 1 Crankcase class 2 Block journal class 4 (l.v.)
Page 54 SHIVER 900 Characteristics ** Crank pin selection class. *** Progressive traceability number and date. SHAFT CATEGORY Class Crank pin diameter (mm) 42.000 - 42.006 mm (1.65354 - 1.65377 in) 41.994 - 42.000 mm (1.65330 - 1.65354 in) 41.988 - 41.994 mm (1.65307 - 1.65330 in) 41.982 - 41.988 mm (1.65283 - 1.65307 in)
Page 55 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 56 SHIVER 900 Special tools PECIAL TOOLS Stores code Description 020709Y Engine support 020710Y Engine plate AP8140187 U-bolt for motor support 020850Y Primary gear lock 020712Y Handle for removing the flywheel cover 020713Y Flywheel extractor S-TOOLS - 56...
Page 57 SHIVER 900 Special tools Stores code Description 020714Y Dial gauge mount 9100896 Clutch bell stopper 020716Y Connecting stem lock 020470Y Pin snap ring fitting tool AP8140302 tool for installing seal rings 020718Y Camshaft gearwheel alignment pin S-TOOLS - 57...
Page 58 SHIVER 900 Special tools Stores code Description 020719Y Timing pin 020720Y Timing tool AP8140179 Valve springs compressor 020721Y Valve removal adaptor 020376Y Adaptor handle 020629Y 8 mm guide (0.31 in) 020412Y 15mm oil seal guide S-TOOLS - 58...
Page 59 SHIVER 900 Special tools Stores code Description 020439Y 17mm oil seal guide 020263Y Driven pulley assembly sheath 020365Y 22 mm guide (0.87 in) 020364Y 25-mm guide 020483Y 30-mm guide 020441Y Oil seals punch S-TOOLS - 59...
Page 60 SHIVER 900 Special tools Stores code Description 020358Y 37 x 40 mm Adaptor 020357Y 32 x 35-mm Adaptor 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55-mm Adaptor 020724Y Punch cage with rollers gearbox control stem 020726Y Bushing extractor...
Page 61 SHIVER 900 Special tools Stores code Description 020884Y 46 mm wrench for steering ferrule AP8140180 Bearing extractor AP8140199 Tool storage panel 8140426 Hooks for panel Stores code Description AP8140149 Guard for assembly operations 020888Y Pre-load pipe clamp S-TOOLS - 61...
Page 62 SHIVER 900 Special tools Stores code Description AP8140148 Plunger-spacer separator plate AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight AP8140150 Bored shaft for bleeding plunger air CAUTION BEFORE USING THE "PRIMARY GEARWHEEL LOCK TOOL - 020850Y", IT IS NECESSARY TO MAKE THREE HOLES SO THAT IT MAY BE POSITIONED CORRECTLY ON THE ENGINE GUARD.
Page 63 SHIVER 900 Special tools S-TOOLS - 63...
Page 64 INDEX OF TOPICS MAIN AINTENANCE...
Page 65 SHIVER 900 Maintenance Scheduled maintenance table 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.
Page 66 SHIVER 900 Maintenance SCHEDULED MAINTENANCE TABLE RESERVED FOR THE USA-LATAM MARKET I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean, adjust or replace, if necessary, every 1000 Km (621 mi)
Page 67 SHIVER 900 Maintenance Recommended products Piaggio Group recommends the products of its "Castrol Official Partner" for the scheduled maintenance of its vehicles. Use lubricants and liquids having specifications that are equivalent, or superior, to the recommen- ded products. These indications also apply when topping up fluid levels.
Page 68 SHIVER 900 Maintenance • Remove the ignition coils. • Remove the spark plugs using a spe- cial key. • Check the distance between the elec- trodes using a thread thickness gauge. CAUTION DO NOT ATTEMPT IN ANY WAY TO CHANGE THE DIS- TANCE BETWEEN THE ELECTRODES.
Page 69 SHIVER 900 Maintenance • Loosen and tighten again the spark plug to the specified torque. CAUTION TIGHTEN THE SPARK PLUG CORRECTLY. OTHERWISE, THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE DAMAGED. USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG, OTHERWISE, ENGINE DURATION AND PERFORMANCE COULD BE COMPROMISED.
Page 70 SHIVER 900 Maintenance Replacement Check the engine oil level frequently. To change: 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.
Page 71 SHIVER 900 Maintenance Air filter • Remove the fuel tank. • Disconnect the vapour recovery tube. • Disconnect the air temperature sensor. • Remove the eight screws fixing the air filter cover. • Remove the filter case cover. MAIN - 71...
Page 72 SHIVER 900 Maintenance • Operating from both ducts, turn the up- per part of the intake duct anticlock- wise and remove it. • Remove the filter element. COVER THE INTAKE DUCTS WITH A CLEAN CLOTH TO PREVENT FOREIGN BODIES FROM ENTERING THE IN- TAKE DUCTS.
Page 73 SHIVER 900 Maintenance Exhaust valve clearance 0.15 - 0.20 mm (0.0059 - 0.0078 in) If the valve clearance is out of tolerance, carry out the adjustment procedure, as follows: • Position the front cylinder at TDC. • Remove the cam tower by unscrewing...
Page 74 SHIVER 900 Maintenance • Extract the bucket tappets. NOTE EACH TIME THE BUCKET TAPPETS ARE EXTRACTED, ENSURE THE COMPONENT IS ADEQUATELY GREASED. • Replace the calibrated pad with a pad having suitable thickness to compen- sate for the valve clearance measured earlier.
Page 75 SHIVER 900 Maintenance REPLACE THE FOUR RUBBER INSERTS AND THE GASKET EACH TIME THE BIG END COVER IS REMOVED. • Apply THREEBOND around the perim- eter of the big end cover along the gasket housings. • Apply THREEBOND to the head at the points indicated in figure.
Page 76 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 77 SHIVER 900 Electrical system RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Flanged, hex. head screws for fas- M6x20 10 Nm (7.38 lb ft) tening the voltage regulator to the frame Flanged SWP screws for fastening M5x20 2.5 Nm (1.84 lb ft)
Page 78 SHIVER 900 Electrical system EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Button head, hex. socket screw used M5x35 3 Nm (2.21 lb ft) for fastening the anti-rollover sensor ELE SYS - 78...
Page 79 SHIVER 900 Electrical system Components arrangement 1. Engine speed sensor 2. intake air pressure sensor 3. Intake air temperature sensor 4. Instrument panel ELE SYS - 79...
Page 80 SHIVER 900 Electrical system 5. Air temperature sensor for instrument panel indication 6. Headlamp 7. Starter relay 8. Coils 9. Spark plugs 10.Starter motor 11.Taillight 12.Secondary fuses 13.Main fuses 14.Handle position sensor 15.Gearbox in neutral sensor 16.Rpm sensor - pick up 17.Engine temperature sensor...
Page 81 SHIVER 900 Electrical system Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Once the electrical system has been replaced, the connectors have been reconnected and the various clamps and fasteners have been repositioned, carry out the checks described below.
Page 82 SHIVER 900 Electrical system Front side TABLE A - COLUMN LIGHT SWITCH / RIDE BY WIRE • Route the right hand column switch (1) and Ride by Wire gas control grip (2) wiring harness behind the front brake pipe (3).
Page 83 SHIVER 900 Electrical system TABLE A2 - COLUMN LIGHT SWITCH / RIDE BY WIRE • Secure the various wiring harnesses using a rubber clamp (7). TABLE A3 - COLUMN LIGHT SWITCH / RIDE BY WIRE • Connect the connectors and insert them in the safety cap (8).
Page 84 SHIVER 900 Electrical system TABLE B - INSTRUMENT PANEL • The clutch switch wiring harness (1), which may be identified by the grey tape, and the front stop switch wiring harness (2) must be routed over the column switch wiring harness and the brake/clutch pipes.
Page 85 SHIVER 900 Electrical system TABLE B2 - INSTRUMENT PANEL • After fastening the ambient air temper- ature sensor (4) and securing the re- spective wiring harness (5), route the wiring harness behind the instrument panel support (7) using a clamp (6).
Page 86 SHIVER 900 Electrical system TABLE C - FRONT ABS SENSOR • using the cable clamp (1) fasten the ABS sensor (3) wiring harness (2) and route it through the hole on the right hand fork foot. TABLE C1 - FRONT ABS SENSOR •...
Page 87 SHIVER 900 Electrical system TABLE C2 - FRONT ABS SENSOR • Fasten the ABS sensor wiring harness to the brake pipe using the cable clamps (5) and two clamps (6), under the lower steering plate and in align- ment with the brake pipe fastening plate, under the steering headstock.
Page 88 SHIVER 900 Electrical system TABLE A - MAIN WIRING HARNESS - ENGINE WIRING HARNESS • The main wiring harness (1) must be positioned on the right hand side of the motorcycle/engine, as indicated TABLE A1 - MAIN WIRING HARNESS - ENGINE WIRING HARNESS •...
Page 89 SHIVER 900 Electrical system TABLE A2 - MAIN WIRING HARNESS - ENGINE WIRING HARNESS • Connect the main wiring harness (1) to the engine wiring harness (2) using a clamp (3) at the point indicated by the grey tape. TABLE A3 - MAIN WIRING HARNESS - ENGINE WIRING HARNESS •...
Page 90 SHIVER 900 Electrical system TABLE B - ENGINE EARTH • It is important to respect the output di- rection of the battery earth (1), main wiring harness earth (2) and engine wiring harness earth (3) cables. • After fitting an elastic washer and the appropriate screw, tighten the latter, applying the pre-defined torque.
Page 91 SHIVER 900 Electrical system • The main injection relay (4), fan control relay (5) and starter relay (6), which are located on the left hand side of the filter box, must be secured to their respective fastening points using the rubber supports.
Page 92 SHIVER 900 Electrical system TABLE F - PRE-ASSEMBLING THE ABS SUP- PORT BRACKET • Pre-assemble the supports (1) for the connectors on the ABS support brack- et (2) and the seal (3). TABLE G - PROCEDURE FITTING THE ABS CONTROL UNIT CONNECTOR CORRECTLY •...
Page 93 SHIVER 900 Electrical system TABLE G3 - PROCEDURE FITTING THE ABS CONTROL UNIT CONNECTOR CORRECTLY • If the initial position of the lever is not as indicated in the "TABLE G", the con- nector will not couple correctly and the distance measurement will be greater (approx.
Page 94 SHIVER 900 Electrical system TABLE H1 - ABS CONTROL UNIT • The wiring harness (3) must be routed behind the brake pipes, as indicated. TABLE I - OIL TEMPERATURE SENSOR • Connect the oil temperature sensor connector (1) to the corresponding...
Page 95 SHIVER 900 Electrical system TABLE I1 - OIL TEMPERATURE SENSOR • Connect the intermediate wiring har- ness connector (2) to the correspond- ing connector on the main wiring harness (3), which must be attached to the dedicated support mounted on the base of the filter box.
Page 96 SHIVER 900 Electrical system TABLE M1 - VOLTAGE REGULATOR/TIMING SENSOR • The voltage regulator wiring harnesses must be routed internally through the frame, as indicated. TABLE M2 - VOLTAGE REGULATOR/TIMING SENSOR • The timing sensor regulator connector must be connected correctly and fas- tened to the support (5) inserted on the control unit cover.
Page 97 SHIVER 900 Electrical system TABLE M3 - VOLTAGE REGULATOR/TIMING SENSOR • The main wiring cabinet regulator con- nector must be connected correctly and positioned above the timing sen- sor regulator connector. TABLE N - HORN • The horn must be fastened to its sup-...
Page 98 SHIVER 900 Electrical system TABLE O1 - SIDE STAND • Install the side stand and route the side strut sensor wiring harness (1) as indi- cated, fastening it to the gear sensor (4) wiring harness using a clamp (3). TABLE O2 - SIDE STAND •...
Page 99 SHIVER 900 Electrical system TABLE P - FRONT LAMBDA PROBE • Connect the front lambda probe con- nector (1) correctly, then fasten it to the cable clamp pre-installed on the ABS control unit support . TABLE P1 - FRONT LAMBDA PROBE •...
Page 100 SHIVER 900 Electrical system TABLE Q - REAR LAMBDA PROBE • Connect the rear lambda probe con- nector correctly, then secure the probe wiring harness (2) using a clip (1). TABLE Q1 - REAR LAMBDA PROBE • Using a clip (3), fasten the rear lambda probe wiring harness (2) to the saddle support frame.
Page 101 SHIVER 900 Electrical system TABLE A2 - REAR BRAKE SWITCH-REAR ABS SENSOR • Secure the rear ABS sensor (1) and rear brake switch (7) wiring harness to the rear brake pipes (3) using the clamps (6). TABLE A3 - REAR BRAKE SWITCH-REAR ABS SENSOR •...
Page 102 SHIVER 900 Electrical system TABLE B1 - MAIN SADDLE SUPPORT WIRING HARNESS • The main wiring harness (1) must be routed under saddle support frame crossbar. TABLE C - STARTER RELAY • Check that the two screws used for fastening the cables are secured cor- rectly.
Page 103 TABLE D3 - SADDLE SUPPORT ZONE • Insert the AMP (Aprilia Multimedia Platform) connector (6) in the dedica- ted space and the main fuse (7), con- necting it to the support saddle sup- port.
Page 104 SHIVER 900 Electrical system TABLE D4 - SADDLE SUPPORT ZONE • Position the secondary fuses (8), cou- pling the rubber support to the tabs present on the saddle support. • fasten the branch of the main wiring harness (9) using two clamps (10). Po-...
Page 105 SHIVER 900 Electrical system TABLE E - NUMBER PLATE HOLDER • Fasten the direction indicator and li- cense plate light wiring harnesses to the number plate holder frame using two clamps. TABLE E1 - NUMBER PLATE HOLDER • Make sure that the anti-vibration foam is fitted on the number plate light.
Page 106 SHIVER 900 Electrical system TABLE A1 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX • Route the branch with the throttle body connections through the lateral open- ing. TABLE A2 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX •...
Page 107 SHIVER 900 Electrical system TABLE A5 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX • Fit the filter box side cover, position the engine wiring harness (1) using the grey reference point that can just be distinguished from outside the cover.
Page 108 SHIVER 900 Electrical system TABLE A10 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX • Install the air temperature sensor (12) and connect it to the engine wiring har- ness. TABLE A11 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX •...
Page 109 SHIVER 900 Electrical system TABLE A13 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX • Route the flywheel wiring harness (15) under the tab on the control unit sup- port box. TABLE A14 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX •...
Page 110 SHIVER 900 Electrical system TABLE A15 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX • After connecting the gear sensor con- nector (18), attach it to the support on the base of the filter box (19). • Using a clamp (20), fasten the fly- wheel, gear sensor and side stand switch wiring harnesses together.
Page 111 SHIVER 900 Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. COMPLETE HEADLAMP 4. FRONT LEFT TURN INDICATOR ELE SYS - 111...
Page 112 SHIVER 900 Electrical system 5. LOW BEAM LIGHT BULB 6. FRONT POSITION LIGHT BULB 7. HIGH BEAM LIGHT RELAY 8. LIGHTS RELAY 9. HORN 10.LEFT LIGHT SWITCH 11.STOP/POSITION BULB 12.INSTRUMENT PANEL 13.FRONT STOP SWITCH 14.REAR STOP SWITCH 15.CLUTCH SWITCH 16.IGNITION SWITCH 17.MAIN INJECTION RELAY...
Page 113 SHIVER 900 Electrical system 43.USB PORT (OPTIONAL) 44.DIAGNOSTICS SOCKET 45.FALL SENSOR 46.SIDE STAND SWITCH 47.GEAR SENSOR 48.REAR CYLINDER PRESSURE SENSOR 49.FRONT CYLINDER PRESSURE SENSOR 50.REAR CYLINDER MOTORISED THROTTLE VALVE 51.FRONT CYLINDER MOTORISED THROTTLE VALVE 52.INTAKE AIR TEMPERATURE SENSOR 53.WATER TEMPERATURE SENSOR 54.7SM ENGINE CONTROL UNIT...
Page 114 SHIVER 900 Electrical system Conceptual diagrams Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC- TORS; NOTE THAT THE DRAWING ALWAYS DEPICT THE CONNECTOR/COMPONENT VIEWED FROM THE WIRING HARNESS SIDE, I.E. FROM THE SIDE ON WHICH THE CABLES LEADING FROM THE MAIN WIRING HARNESS ENTER THE CONNECTOR/COMPONENT.
Page 115 SHIVER 900 Electrical system of circuit tested. Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the resistance in the circuit is zero or of a few tenths of an Ohm. IMPORTANT: THE CIRCUIT MUST BE UNPOWERED DURING THIS TEST. IF THE CIRCUIT IS POWERED, THE RESULTS OF THIS TEST ARE MEANINGLESS.
Page 116 SHIVER 900 Electrical system Electrical specifications • 14 Ohm Pin out 1. Grey colour, from the instrument panel to the antenna - Section 0.5 2. Grey colour, from the instrument panel to the antenna - Section 0.5 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
Page 117 SHIVER 900 Electrical system Error cause • There is a fault in the instrument panel Troubleshooting • Replace the instrument panel System not programmed Storing new keys NOTE REGARDLESS OF THE LANGUAGE SET IN THE DASHBOARD FUNCTIONS, THE KEY PRO- GRAMMING PROCEDURE CAN ONLY BE VIEWED IN ENGLISH.
Page 118 SHIVER 900 Electrical system • At this point, on the digital display of the motorcycle, after the automatic restart of the dynamic presentation screen, a message will appear with a countdown of 20 seconds to insert the second key to be programmed.
Page 119 SHIVER 900 Electrical system Azzeramento icona manutenzione The system displays the function as follows: • After the maintenance interval thresh- olds are exceeded (excepting the first), an icon with the adjustable wrench is shown on the digital display. To reset Service proceed as follows: •...
Page 120 SHIVER 900 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.
Page 121 SHIVER 900 Electrical system ESISTANCE MEASUREMENT Winding stage Ambient temperature (ohm) Afterwards heat stabilisation (ohm) Stage 1 0.15 - 0.20 0.18 - 0.23 Stage 2 0.15 - 0.20 0.18 - 0.23 Stage 3 0.15 - 0.20 0.18 - 0.23 Zero load voltage •...
Page 122 SHIVER 900 Electrical system OLD SHORT CIRCUIT CURRENT 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 •...
Page 123 SHIVER 900 Electrical system 3. Ground - Green/pink colour from the engine to the clutch switch - Section 0.5 4. - Yellow/pink colour from the RH lights switch to the 7SM control unit PIN 78 (engine stop) - Section CAUTION...
Page 124 SHIVER 900 Electrical system Rear light Characteristic Rear daylight running light /stop light 12V - 5/21W x 2 Fuses It is necessary to check the fuses whenever an electrical component fails to operate or malfunctions or when the engine does not start.
Page 125 SHIVER 900 Electrical system AUXILIARY FUSES DISTRIBUTION Specification Desc./Quantity A) 10A fuse Lights relay/high beam relay, buttons and brake lights/horn, daylight running lights (front, rear)/license plate B) 15A fuse ECU live positive lead F) 7,5A fuse ECU permanent positive lead...
Page 126 SHIVER 900 Electrical system To check the ABS fuse (I) • Remove the protective cover, take out the fuse (I) and check whether the fila- ment (2) is broken. In this case change it with one of the same amperage.
Page 127 SHIVER 900 Electrical system • HW number/ - (indicates the Hardware number) • Approval number / - • Author of the latest progr. / - (author of the latest programming) • Mapping / - (indicates the mapping number) • Programming date / - (control unit programming date) •...
Page 128 SHIVER 900 Electrical system • Lambda probe / - (indicates if the lambda probe is operating) • Engine mode / - • Tone wheel / - (tone wheel status) • Ign. Activ. rec. status / - (ignition activation recognition status) •...
Page 129 SHIVER 900 Electrical system NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. P0605 ROM Error Electrical diagnosis: • Circuit not functioning Error cause: • Replace the injection control unit. The instrument cluster indicates the presence of this error with the MI warning light on fixed.
Page 130 SHIVER 900 Electrical system P1606 Hardware and software incompatibility Error cause • Incorrect engine control unit mapping This error is indicated by lighting up in a fixed manner the general warning light. Troubleshooting • Call the Help Desk NOTE THIS ERROR DETERMINES THE ENGINE STOP AN THE DEACTIVATION OF THE STARTER MO- TOR.
Page 131 SHIVER 900 Electrical system • Incorrect control unit set up Error cause: Probably there is an attempt to set up the control unit with an inadequate map. NOTE: The instrument panel does not indicate the presence of this error even in the ATT status.
Page 132 SHIVER 900 Electrical system P0560 Battery voltage • too high/too low Error cause • If too high: too high a voltage has been detected at PIN 42. If too low: too low a voltage has been detected at PIN 42.
Page 133 SHIVER 900 Electrical system Speed sensor FRONT VEHICLE ABS SENSOR Function: Generates a signal used by the ABS control unit to determine the speed value of the wheel. Operation / Operating principle: Magneto-resistive sensor: generates a square wave signal with an amplitude of approximately 1V between PIN13 and PIN14 of the ABS control unit.
Page 134 SHIVER 900 Electrical system • Connect to the ABS control unit diagnosis. LOGIC ERRORS Speed sensor 5D91 the signal changes in intermittent manner • faulty sensor or signal interference. Troubleshooting: • Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed.
Page 135 SHIVER 900 Electrical system • 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.
Page 136 SHIVER 900 Electrical system • Electrical fault in sensor or wiring harness. Troubleshooting: • Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the yellow/brown cable between PIN 2 of the sensor on the wiring harness side and PIN 11 of the ABS control unit connector.
Page 137 SHIVER 900 Electrical system 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 no acceleration after pressure reduction •...
Page 138 SHIVER 900 Electrical system Position: • on the vehicle: on the flywheel cover • connector: under the tank, on the left side, between the filter housing an the frame (2 way white connector) Electrical specifications: 0.79 kohm at ambient temperature Pin out: 1.
Page 139 SHIVER 900 Electrical system • Check the integrity of the electrical circuit, the cleanliness of the flywheel teeth and the correct positioning of the sensor in its seat: if not ok restore; if ok, replace the sensor. NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN.
Page 140 SHIVER 900 Electrical system • If open circuit, short circuit to negative: a voltage equal to zero was detected at PIN 39 of the ENGINE connector. This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light.
Page 141 SHIVER 900 Electrical system and that the ground is present at PIN 5, if present correctly replace the handle sensor, if not present check the continuity of the malfunctioning cable: if the continuity is present replace the control unit, if not present replace the wiring harness...
Page 142 SHIVER 900 Electrical system intake air pressure sensor Location: • on the vehicle: inside the filter housing • connector: on the sensor Pins: 1. Power supply 2. Ground 3. Output signal DIAGNOSTIC TOOL: PARAMETERS Front cylinder intake sensor Example value: 1003 mbar Pressure read through the front sensor.
Page 143 SHIVER 900 Electrical system • If open circuit, short circuit to negative: check the Marelli control unit connector and the sensor connector; if NOT OK restore, if everything is OK, with key OFF, check the continuity between Marelli control unit connector PIN 24 and the sensor connector PIN 3: if there is no...
Page 144 SHIVER 900 Electrical system P1600 Error due to unexpected air intake in the front cylinder manifold Functional diagnosis: • signal not plausible. Error cause: • Small difference detected between the estimated pressure and the measured pressure: the measured pressure is higher than the estimated one (for example, the pipe between sensor and throttle body is squashed or there is a hole in the intake manifold).
Page 145 SHIVER 900 Electrical system • 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 a very evident defect in the intake and pressure reading sys- tem.
Page 146 SHIVER 900 Electrical system • Small difference detected between the estimated pressure and the measured pressure: the measured pressure is below the estimated one (for example, smeared throttle body). This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light.
Page 147 SHIVER 900 Electrical system P0115 Engine temperature sensor • open circuit, shorted to positive / shorted to negative. Error cause • If open circuit, short circuit to positive: an excessive voltage was detected at PIN 12 of the ENGINE connector. If short circuit to negative: voltage equal to zero has been detected. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Page 148 SHIVER 900 Electrical system Air temperature sensor Function indicates to the control unit the temperature of the intake air, used to calculate the oxygen, to opti- mise the required fuel quantity for the correct com- bustion Operation / Operating principle...
Page 149 SHIVER 900 Electrical system P0110 Air temperature sensor • open circuit, short circuit to positive / short circuit to negative Error cause • If open circuit, short circuit to positive: an excessive voltage was detected at PIN 37 of the ENGINE connector.
Page 150 SHIVER 900 Electrical system • Heater circuit: 7-9Ω at ambient temp. Pin out: 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white cable) 4. Heater power supply (white cable) DIAGNOSTIC TOOL:PARAMETERS Lambda probe •...
Page 151 SHIVER 900 Electrical system Electrical continuity is required in the wiring for the relay to activate correctly: no errors are generated in case of no activation. DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0130 Front lambda probe Electrical diagnosis: • Short circuit to positive.
Page 152 SHIVER 900 Electrical system (PIN 3): if NOT OK, restore the wiring harness; if OK, check the continuity of the Green/ Black cable (between PIN 3 of the sensor connector and ENGINE PIN 32) and restore the wiring harness. •...
Page 153 SHIVER 900 Electrical system the switching from "HIGH RATIO" to "LOW RATIO" is missing for a certain"adjusted" number of upper dead points (PMS or TDC). The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Page 154 SHIVER 900 Electrical system • Example value with key ON: about 3300 mV • Example value with engine on: 100-1000 mV If there is a short circuit at + 5 V or higher, the lambda probe parameter is not equal to the value read...
Page 155 SHIVER 900 Electrical system • Excessive voltage detected (battery voltage) at PIN 9 and 38 of the ENGINE connector. Caution: the "lambda probe" parameter is not the actual read value but a recovery value is displayed. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Page 156 SHIVER 900 Electrical system Troubleshooting • Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards 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 the continuity between the ENGINE connector PIN 9 and PIN 38 and restore the wiring harness.
Page 157 SHIVER 900 Electrical system Injector Function Provide the correct amount of fuel at the correct time. Operation / Operating principle Injector coil is energised for the petrol passage to open Level in electrical circuit diagram: Coils and injectors Position: •...
Page 158 SHIVER 900 Electrical system • The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel tank, on the right side of the filter housing; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to the control unit is closed to ground for 4 ms per each second.
Page 159 SHIVER 900 Electrical system on the injector connector: if there is, restore the wiring harness of the filter housing; if not, replace the sensor. • If short circuit to negative: disconnect the injector connector, turn the key to ON and check...
Page 160 SHIVER 900 Electrical system 1. + 12 V - Orange/Green colour, from the fuel pump to the power supply 2. ground - Blue colour - Section 1.5 3. + 12 V (signal) reserve sensor - Green/Grey colour - Section 0.5 4.
Page 161 SHIVER 900 Electrical system Coil Function Spark generation Operation / Operating principle With inductive discharge Level in electrical circuit diagram: Coils and injectors Position: • on the vehicle: on the big end covers. • connector: For each coil 3 way black connector.
Page 162 SHIVER 900 Electrical system Rear coils: The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel tank, on the right side of the filter housing. However, CHECK the relay identification with the cables colour - blue taping) for 5 seconds and the violet/grey coil cable is closed to ground for 2 ms per each second.
Page 163 SHIVER 900 Electrical system • Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil with the diagnostic tool and check the voltage at PIN 27 of the connector: if there is voltage, restore the wiring harness, if the voltage is 0, replace the coil.
Page 164 SHIVER 900 Electrical system • Example value with key ON: 0,0° • Example value with engine on: -0.2° Reading the intake pressures, the system tries to balance the intake pressure through the front and rear cylinder, operating on the throttle valves positions: an acceptable value should be between -0.5 and +0.5...
Page 165 SHIVER 900 Electrical system is not engaged, at approximately ???? rpm the throttle valves opening s very small and the requested torque is very low (approximately 5-7°) Potentiometer 2 rear throttle valve (degrees) • Example value with key ON: 8.2°...
Page 166 SHIVER 900 Electrical system • Performed/Not performed Indicates if the self-learning with the diagnostic tool was performed/not performed: if it was performed one time, it will always remain performed unless a control unit EEPROM reset is carried out DIAGNOSTIC TOOL: ELECTRICAL ERRORS...
Page 167 SHIVER 900 Electrical system tinuity of the circuit between the two ends; if not ok, restore the wiring harness, if ok, check the ground insulation of the circuit (from the throttle body connector or control unit connec- tor); if ground insulated, check that at PIN 2of the throttle boy connector there is power supply (+5 V) and that at PIN 6 there is ground;...
Page 168 SHIVER 900 Electrical system tor); if ground insulated, check that at PIN 2of the throttle boy connector there is power supply (+5 V) and that at PIN 6 there is ground; if they are correct, replace the throttle body. P2119 Front throttle valve command circuit Electrical diagnosis: •...
Page 169 SHIVER 900 Electrical system tenths of an Ohm. Otherwise, restore the wiring harness; if ok, replace the complete throttle body. P2126 Rear throttle body potentiometer 2 Functional diagnosis: • Signal not plausible. Error cause: • Signal outside the specified value determined based on the values of the intake pressure.
Page 170 SHIVER 900 Electrical system • Test failed. Error cause: • Position of the throttle valve stopper outside of the specified range (at each key ON). Troubleshooting: • Check the cleanliness of the throttle body and the intake duct. If ok, replace the throttle body.
Page 171 SHIVER 900 Electrical system • Position of the throttle valve, maintained by the springs, outside the specified range (at each key ON). The instrument panel indicates this error by lighting up in a fixed manner the MI warning light. Troubleshooting: •...
Page 172 SHIVER 900 Electrical system • The throttle valve power supply voltage is too low to correctly perform the self-learning test (at each key ON). The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Page 173 SHIVER 900 Electrical system • Using the diagnostic tool, erase the error, then perform the throttle self-learning procedure. If the error is displayed again, it may mean a mechanical problem at the throttle boy. • Check the cleanliness of the throttle body and the intake duct. Check if there are any me- chanical ruptures.
Page 174 SHIVER 900 Electrical system Pin out: 1. Voltage: 5 V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 175 SHIVER 900 Electrical system electric voltage, identifies the engaged gear and transmits the information via CAN to the instru- ment panel, the other for the idle indication whose voltage is reduced to zero if in the neutral position. Level in electrical circuit diagram:...
Page 176 SHIVER 900 Electrical system DIAGNOSTIC TOOL: STATUSES Gearbox in neutral • Yes/No gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6 DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0914 Gear sensor • short circuit to positive or open circuit/ short circuit to negative.
Page 177 SHIVER 900 Electrical system • on the vehicle: on the handlebar. • connector: on the sensor. Electrical specifications: • Clutch engaged: closed circuit (con- tinuity) • Clutch released: open circuit (infinite resistance). Pin out: 1. voltage 5V 2. ground lead...
Page 178 SHIVER 900 Electrical system • If the error is active only with the lever engaged: the problem is generated by the engaged clutch contact of the which is interrupted or by the released clutch contact which is in short circuit to ground.
Page 179 SHIVER 900 Electrical system Side stand functional diagnosis: up/down Troubleshooting: • Indication on the diagnostic tool always down: perform the connector check procedure: if not ok, restore; if ok, disconnect the two ends from the sensor and check the PIN 1 continuity to ground: if there is no continuity, restore cable harness;...
Page 180 SHIVER 900 Electrical system 2. Signal - Pink/White colour, from VEHICLE PIN 65 to the fall sensor, passing through multiple connector - Section 0.5 3. Ground - Green/Pink colour, from ENGINE PIN6/PIN17 to the fall sensor, passing through multiple connector - Section 0.5...
Page 181 SHIVER 900 Electrical system proximately 12 V, restore the wiring harness (there is a short circuit to battery); if 5 V, connect a 10 kohm resistance to PIN 1 of the sensor connector and to he vehicle ground: if, with key ON, the measured voltage upstream the resistance decreases, replace the instrument pan- el;...
Page 182 SHIVER 900 Electrical system CHECK the identification of the relay with the colour of the cables). Electrical continuity is required in the wiring for the relay to activate correctly: no errors are generated if the relay fails to acti- vate...
Page 183 SHIVER 900 Electrical system RUN/STOP switch Function Indicates the control unit if the rider wishes to en- able engine start-up or to keep the engine running. Operation / Operating principle If you want to stop the engine or to prevent it from...
Page 184 SHIVER 900 Electrical system cable: if it is missing, restore the wiring harness; if there is, check the ground insulation of the Yellow/Red cable: if there is continuity with the ground, restore the wiring harness; if ok, turn the key to OFF and perform the VEHICLE connector and engine-vehicle wiring harness connector check: if not ok, restore;...
Page 185 SHIVER 900 Electrical system Engine pinout key: • PIN 1 - • PIN 2 - • PIN 3 - Motorised throttle valve (+) (rear cylinder) • PIN 4 - Analogic ground 2 • PIN 5 - Power ground • PIN 6 - Analogic ground 1 •...
Page 186 SHIVER 900 Electrical system • PIN 20 - Engine rpm sensor (-) • PIN 21 - Throttle valve potentiometer 2 signal (rear cylinder) • PIN 22 - Front cylinder lambda probe (-) • PIN 23 - • PIN 24 - Intake pressure sensor signal (front cylinder) •...
Page 187 SHIVER 900 Electrical system Vehicle pinout key: • PIN 53 - Front cylinder injector • PIN 54 - • PIN 55 - • PIN 56 - Clutch sensor • PIN 57 - Analogic ground 2 • PIN 58 - Engine start-up •...
Page 188 SHIVER 900 Electrical system • PIN 74 - • PIN 75 - • PIN 76 - • PIN 77 - • PIN 78 - Engine stop input • PIN 79 - • PIN 80 - H CAN line Engine-vehicle connector pinout key: •...
Page 189 SHIVER 900 Electrical system Dashboard Instrument panel pinout key: • PIN 1 - • PIN 2 - Antenna 1 • PIN 3 - Antenna 2 ELE SYS - 189...
Page 190 SHIVER 900 Electrical system • PIN 4 - Oil temperature sensor • PIN 5 - Air temperature sensor • PIN 6 - Arrow reset • PIN 7 - Light relay • PIN 8 - • PIN 9 - Battery positive •...
Page 191 SHIVER 900 Electrical system ABS Modulator ABS control unit pinout key: • PIN 1 - Power ground 1 • PIN 2 - Power ground 2 • PIN 3 - • PIN 4 - Ignition switched live • PIN 5 - H CAN line •...
Page 192 SHIVER 900 Electrical system of the electric system and consequently its total mass. With this communication line, it was possible to avoid useless duplications of various sensors on the motorcycle, since the signals coming from them are divided among the three electronic processing units (instrument panel, control unit and ABS).
Page 193 SHIVER 900 Electrical system 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. DIAGNOSTIC TOOL: ELECTRICAL ERRORS U1125 Frame counter "Sensor Box" CAN line diagnosis Electrical diagnosis: •...
Page 194 SHIVER 900 Electrical system • In case of CAN error during acquisition, system warns that the procedure can not be com- pleted due to a communication problem on the CAN line. • If the signal is not plausible, there was a transcription error of the value of the rear wheel radius from the non volatile memory (EEPROM) to the volatile memory (RAM) at key ON.
Page 195 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 196 SHIVER 900 Engine from vehicle HASSIS Pos. Description Type Quantity Torque Notes Cyl. head, hex. socket screws used M12x282 80 Nm (59.00 lb ft) for fastening the side fairings to the engine TORX cyl. head screws used for fas- M12x53 80 Nm (59.00 lb ft)
Page 197 SHIVER 900 Engine from vehicle NGINE CCESSORIES EVER MECHANISMS Pos. Description Type Quantity Torque Notes Flanged, hex. head screw used for M10x1.25x26 50 Nm (36.88 lb ft) Pre-impregnated fastening the pinion screw Cyl. head, hex. socket screw used for M6x20 10 Nm (7.38 lb ft)
Page 198 SHIVER 900 Engine from vehicle • Disconnect the timing sensor (3) and the voltage regulator connectors (4). • Remove the three clutch pump fasten- ing screws (4). • Remove the clutch pump (5) and use the clamps to secure the pump so that the piston cannot fall out.
Page 199 SHIVER 900 Engine from vehicle • Remove the two screws (6) used to fasten the pinion cover (7), taking care to retrieve the respective bushings. • Remove the cover (7). • Remove the two clutch pump support fastening screws (8).
Page 200 SHIVER 900 Engine from vehicle • Remove the gear lever (11) • Disconnect the vehicle stand switch connector (12). • Remove the three screws (13) used to fasten the stand support. • Remove the stand support (14). ENG VE - 200...
Page 201 SHIVER 900 Engine from vehicle • Remove the screw (15) used to fasten the pinion, retrieving the washer (16) and the spring washer (17) and taking care to reposition them correctly during reassembly. • Remove the pinion (18) and detach the drive chain (19).
Page 202 SHIVER 900 Engine from vehicle • Remove the two screws (23) used to secure the cable clamp (24) positioned under the swingarm, and remove it. • Remove the two screws (25) used to fasten the right hand rider's footrest. •...
Page 203 SHIVER 900 Engine from vehicle • Remove the two screws (29) used to fasten the plate positioned under the steering headstock. • Move the complete ABS system (30) towards the outside so that it is easier to remove the engine.
Page 204 SHIVER 900 Engine from vehicle • Access the left hand side of the motor- cycle, unscrew the front nut (3) and remove it. • Access the right hand side of the mo- torcycle, partially extract the central pin (4) and remove the spacer (5) position on the internal, left hand side of the frame.
Page 205 SHIVER 900 Engine from vehicle • Position a central stand in order to sup- port the engine and a trestle under the rear of the motorcycle in order to raise • Lower the engine partially, unscrew the screws (13) used to fasten the earth cables to the engine, and remove them.
Page 206 INDEX OF TOPICS NGINE...
Page 207 SHIVER 900 Engine Gearbox Diagram 1. Complete desmodromic 2. Fork 3. Primary fork 4. Fork shaft 5. complete index lever 6. Gear stopper lever spring 7. Threaded rod 8. Selector stopper plate 9. Screw 10.Selector shaft 11.Flat washer 14x30x1 12.Selector spring 13.Threaded rod M8x1.25...
Page 208 SHIVER 900 Engine 17.Spring 18.Tip for spring 19.Domed head torx screw 20.O-Ring 21.Gear sensor 22.Spacer 23.O-Ring 24.Selector stopper 25.Self-locking nut Gearbox shafts Gearbox shafts diagram Key: 1. Primary transmission shaft Z=14 2. 2nd gear on primary Z=17 3. 3rd - 4th gear on primary Z=20/22 4.
Page 209 SHIVER 900 Engine 8. Shoulder washer 9. Shoulder washer 10.Snap ring 11.Floating bushing 12.Secondary transmission shaft 13.1st gear on secondary Z=36 14.2nd gear on secondary Z=32 15.3rd gear on secondary Z=30 16.4th gear on secondary Z=28 17.5th gear on secondary Z=26 18.6th gear on secondary Z=25...
Page 210 SHIVER 900 Engine • Remove the three gear selection forks. CAUTION THE FORK FOR THE PRIMARY SHAFT IS SMALLER THAN THAT OF THE SECONDARY SHAFT. THE FORKS FOR THE SECONDARY SHAFT ARE THE SAME. • Remove the shim. • Carefully turn the engine support.
Page 211 SHIVER 900 Engine • If the external diameter of the counter- sink is equal to or less than 15.50 mm, rework the threading with a male M10 x 1.25. Use a manual male finisher or a low input machine series male.
Page 212 SHIVER 900 Engine EAR SELECTOR Pos. Description Type Quantity Torque Notes Gear sensor fastening screw 6 Nm (4.43 lb ft) Loct. 270 Selector plate fastening screw M5x12 5 Nm (3.69 lb ft) 3M SCOTCH GRIP 2353 Desmodromic drum/sprocket fasten- M8x1.25x17 15 Nm (11.06 lb ft)
Page 213 SHIVER 900 Engine Selector plate spring With a thickness gauge, check that the spring is not deformed by over-stretching. Gearbox Selector Shaft Removal • Place the left hand crankcase in a press and extract the roller cage with the specific tool.
Page 214 SHIVER 900 Engine Starter motor GNITION Pos. Description Type Quantity Torque Notes Spark plug 13 Nm (9.59 lb ft) Free wheel ring fastening screw M6x18 14 Nm (10.33 lb ft) 3M SCOTCH GRIP 2353 Rotor fastening screw - Crankshaft M14x1.5 191 Nm (140.87 lb ft)
Page 215 SHIVER 900 Engine Removing the starter motor • In order to remove the starter motor complete with the support bracket, it is necessary to remove the two screws (1). • If the bracket needs to be removed from the starter motor, first remove the two screws (2) and then the other screws (1).
Page 216 SHIVER 900 Engine Pos. Description Type Quantity Torque Notes Bracket to starter motor fastening M6x14 7 Nm (5.16 lb ft) Loct. 242 screw Starter motor bracket to crankcase M6x16 13 Nm (9.59 lb ft) fastening screw Removing the flywheel cover •...
Page 217 SHIVER 900 Engine 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.
Page 218 SHIVER 900 Engine • Remove the tool from the rotor and re- move the screw complete with the washer. • Screw the special tool's left-handed pin onto the outer body. • Keeping the outer body blocked, screw in the pin in such a way as to extract the flywheel from the crankshaft.
Page 219 SHIVER 900 Engine • Remove the starter's transmission gear bearing. • In the event of a malfunction, the start- er's transmission gear bearing cannot be overhauled and must be completely replaced. Freewheel removal • Heat the magneto flywheel with the specific heater.
Page 220 SHIVER 900 Engine • Apply the flywheel to the crankshaft. • Apply the screw and the washer with- out tightening. • Position the appropriate tool to lock the flywheel in place. • Holding the flywheel still using the ap- propriate tool, tighten the screw on the crankshaft.
Page 221 SHIVER 900 Engine Clutch side LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover / Clutch side cover fas- 13 Nm (9.59 lb ft) tening screw Clutch fastening nut M24x1.5 177 Nm (130.55 lb ft) Chamfer Oil filler cap on clutch cover M25x1.25...
Page 222 SHIVER 900 Engine LUTCH Pos. Description Type Quantity Torque Notes Clutch spring fastening screw 12 Nm (8.85 lb ft) ATER PUMP Pos. Description Type Quantity Torque Notes Clutch side cover fixing screw M6x40 13 Nm (9.59 lb ft) Pump cover / Clutch side cover fas- M6x25 13 Nm (9.59 lb ft)
Page 223 SHIVER 900 Engine Pos. Description Type Quantity Torque Notes Pump cover / Clutch cover / clutch M6x60 13 Nm (9.59 lb ft) side half-crankcase fastening screw Water pump control crown fastening 12 Nm (8.85 lb ft) Loct. 244 Water pump impeller (brass insert) 4 Nm (2.95 lb ft)
Page 224 SHIVER 900 Engine Pos. Description Type Quantity Torque Notes Flywheel side clutch control support / 13 Nm (9.59 lb ft) half-crankcase fastening screw Based on the engine design development, there are two types of clutch crankcases, associated to the specific water pumps.
Page 225 SHIVER 900 Engine • upon refitting, before tightening the clutch nut, check that the measure has not changed. If it is different, turn the crank shaft in such a way as to properly align the engine's oil pump control gear on the clutch bell with the oil pump's driven gear.
Page 226 SHIVER 900 Engine • Remove the clutch crankcase. • Unscrew and remove the six screws, loosening them by a quarter of a turn at a time, by stages, and working in a diagonal fashion, while recovering the washers and the clutch springs.
Page 227 SHIVER 900 Engine • Block the clutch bell using the appro- priate tool and unscrew the nut on the hub. Specific tooling 9100896 Clutch bell stopper • Remove the disc spring. • Remove the clutch hub. • Remove the special washer between the clutch hub and the clutch bell.
Page 228 SHIVER 900 Engine • Remove the clutch bell. • Retrieve the spacer and the roller bear- ings. • Retrieve the shim. Checking the clutch plates • Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions.
Page 229 SHIVER 900 Engine • 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).
Page 230 SHIVER 900 Engine • Remove the pin that blocks the rotation of the oil pump control gear. Check for any damage or signs of wear on the clutch bell that could lead to irregular clutch functionality. Grind down the teeth or replace the bell if necessary.
Page 231 SHIVER 900 Engine Checking the springs • Check the springs for signs of damage, and replace them if necessary. • Measure the free length of the clutch springs, and replace them if necessa- Free length of the clutch spring: 66.5 mm (2.62 Assembling the clutch •...
Page 232 SHIVER 900 Engine • Place the washer correctly between the clutch housing and the hub. • Position the clutch hub. • Install the clutch cover. • Before tightening the clutch nut, check to make sure that the measurement has not changed with respect to that which was measured during the disas- sembly phase.
Page 233 SHIVER 900 Engine • Position the clutch hub nut and tighten it using the appropriate tool. Specific tooling 9100896 Clutch bell stopper • After having tightened the nut, proceed with the chamfering. • Insert the flat ring (1). • Insert the disc ring (2).
Page 234 SHIVER 900 Engine • Position the thrust plate. • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally. • Replace the gasket upon refitting. Head and timing ENG - 234...
Page 235 SHIVER 900 Engine EAD COVER Pos. Description Type Quantity Torque Notes Special head cover fastening screw 9 Nm (6.64 lb ft) Pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 20 Nm (14.75 lb ft) Threaded plug M12x1.5 10 Nm (7.38 lb ft) Loct.
Page 236 SHIVER 900 Engine Removing the head cover The following operations are valid for both of the heads. • Unscrew and remove the four screws, and retrieve the rubber blocks. • Remove the head cover. Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO THE REMOVAL OF ONE HEAD ONLY, BUT ARE VALID FOR BOTH.
Page 237 SHIVER 900 Engine Cylinder head Pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 20 Nm (14.75 lb ft) Threaded plug M12x1.5 10 Nm (7.38 lb ft) Loct. drise AL 506 Nut for fastening the stud bolts to the M10x1.25...
Page 238 SHIVER 900 Engine Removing the overhead camshaft • Remove the clutch side crankcase. • Turn the crankshaft of the head for which the camshafts need to be re- moved to TDC. In order to remove the head camshafts, it is nec- essary to remove the head covers.
Page 239 SHIVER 900 Engine • 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 springs compressor 020721Y Valve removal adaptor •...
Page 240 SHIVER 900 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.
Page 241 SHIVER 900 Engine • a: 35.13 / 35.17 mm (1.3831 / 1.3846 in); Limit: 35.00 mm (1.3779 in); • b: 28 mm (1.1023 in); • Fasten the camshaft in horizontal po- sition, as shown in the figure, and make it spin to check the eccentricity with a dial gauge;...
Page 242 SHIVER 900 Engine Check the valve eccentricity: valve 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.
Page 243 SHIVER 900 Engine Timing IMING SYSTEM Pos. Description Type Quantity Torque Notes Cam shaft gear fastening nut M15x1 88 Nm (64.91 lb ft) Thoroughly de- grease both of the coupling surfaces (axle cone and gear cone) Timing lay shaft fastening screw M24x1.5...
Page 244 SHIVER 900 Engine Pos. Description Type Quantity Torque Notes Special mobile / fixed slider fastening 18 Nm (13.28 lb ft) 3M SCOTCH GRIP screw 2353 Cam tower / head fastening screws M6x37 13 Nm (9.59 lb ft) Follow the number-...
Page 245 SHIVER 900 Engine Removing the chain tensioner • Unscrew and remove the screw, and retrieve the washer and the internal spring. • Unscrew and remove the two screws. • Remove the chain tensioner and re- trieve the gasket. Chain removal •...
Page 246 SHIVER 900 Engine • Extract the timing chain from the crank- shaft. NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED. • Remove the timing chain complete with the gear.
Page 247 SHIVER 900 Engine • Unscrew and remove the fixed chain tensioner slider's screw. • The head must be removed in order to remove it. REAR CYLINDER HEAD • In order to remove the rear head's chain sliders, it is necessary to remove the flywheel.
Page 248 SHIVER 900 Engine Installing the chain tensioner • 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.
Page 249 SHIVER 900 Engine • Rotate the crankshaft anticlockwise until the front cylinder piston is posi- tioned at top dead centre, while check- ing that there is sufficient play on the camshafts. • The front cylinder top dead centre po- sition must correspond to position (A).
Page 250 SHIVER 900 Engine • Align the play compensation gear- wheel with the main distribution gear- wheel using the dedicated tool. Specific tooling 020718Y Camshaft gearwheel alignment pin • Position the cam tower. • Tighten the screws provisionally. • Time the camshafts, using the appro- priate pins.
Page 251 SHIVER 900 Engine • Remove the gearwheel alignment tool. Specific tooling 020718Y Camshaft gearwheel alignment pin • Reposition the cam tower and the cam- shafts, applying the pre-defined tight- ening torque. • Rotate the camshaft anticlockwise until the rear cylinder piston is at TDC (B).
Page 252 SHIVER 900 Engine • Remove the gasket on the cylinder base. See also Chain removal Removing the cylinder head Disassembling the piston • Remove the big end and the cylinder. • Extract the pin locking ring. • Lock the connecting rod using the spe- cific tool.
Page 253 SHIVER 900 Engine • Lock the connecting stem with elastic straps FOR SAFETY REASONS, COVER THE CRANKCASE WITH A CLEAN MATERIAL TO AVOID THE FALL OF THE SAFE- TY RINGS IN THE CRANKCASE. • Remove the upper ring, the second ring and the oil ring.
Page 254 SHIVER 900 Engine Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions. • Check cylinder sliding surface for signs of friction and scratches. Also check the seal sur- faces for damages.
Page 255 SHIVER 900 Engine 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 together if not complying with specifications.
Page 256 SHIVER 900 Engine • 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.
Page 257 SHIVER 900 Engine • The elastic bands are different from one another, and must be mounted with the "N" marking facing upwards. • Apply the lower oil scraper ring to the piston with the opening facing the out- put side.
Page 258 SHIVER 900 Engine • Position the piston on the connecting rod and insert the pin using the appro- priate tool. Specific tooling 020470Y Pin snap ring fitting tool • Insert the piston's missing stopper ring using the appropriate tool, as descri- bed above, to lock the pin in place.
Page 259 SHIVER 900 Engine • Using the band tightener, compress the piston's bands and insert the cylin- der onto the stud bolts. NOTE BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL. See also Selecting the base gasket Selecting the base gasket •...
Page 260 SHIVER 900 Engine 020714Y Dial gauge mount • Turn the crankshaft to TDC (the rever- sal point of the dial gauge's rotation). • Lock the crankshaft at TDC using the appropriate tool. • Calculate the difference between the two measurements: use the chart be-...
Page 261 SHIVER 900 Engine • Position the gasket on the cylinder base. • Insert the head onto the stud bolts. • Apply the nuts (1) to the stud bolts and tighten them to the required torque val- ue, proceeding in a crossover fashion.
Page 262 SHIVER 900 Engine BEFORE REMOVING THE BIG END COVERS, CAREFULLY CLEAN THE SURFACES OF THE BIG END AND THE COVER. CAUTION REPLACE THE FOUR RUBBER INSERTS AND THE GASKET EACH TIME THE BIG END COVER IS REMOVED. CAUTION BEFORE REMOVING THE BIG END COVERS, CAREFULLY CLEAN THE SURFACES OF THE BIG END AND THE COVER.
Page 263 SHIVER 900 Engine Crankcase - crankshaft RANKCASE Pos. Description Type Quantity Torque Notes Crankcase-cylinder-head fastening M10x1.25x166 Distance-based tighten- SCOTCH GRIP stud bolts 2510 GREEN Bearing retainer fastening screws M6x12 10 Nm (7.38 lb ft) 3M SCOTCH GRIP 2353 or Loct. DRI-...
Page 264 SHIVER 900 Engine RANKCASE Pos. Description Type Quantity Torque Notes Half-crankcase coupling screw M8x80 28 Nm (20.65 lb ft) Half-crankcase coupling screw M6x65 13 Nm (9.59 lb ft) Special oil calibration screw M10x1 14 Nm (10.33 lb ft) ENG - 264...
Page 265 SHIVER 900 Engine RANKSHAFT Pos. Description Type Quantity Torque Notes Primary crankshaft fastening net M24x1.5 294 Nm (216.84 lb ft) Thoroughly de- grease both of the coupling surfaces (shaft cone and gear cone) Connecting rod fastening screws - M10x1x40 15 Nm (11.06 lb ft)
Page 266 SHIVER 900 Engine 020850Y Primary gear lock • Heat up the crankshaft gearwheel re- taining nut using a suitable heater • Remove the nut and the flat washer. • Remove the motor pinion locking tool. • Using a generic extractor tool, remove...
Page 267 SHIVER 900 Engine • Remove the gearbox control rod, tak- ing care to retrieve the washer. • Heat up the gearbox selector support plate screws. • Unscrew the three gearbox selector plate fastening screws and remove them.. • Remove the plate.
Page 268 SHIVER 900 Engine • Press the springs on the selector sprocket simultaneously in order to re- move it. • Unscrew the threaded pin used to fas- ten the selector drum and remove it. • Move the index lever to one side so that it is possible to remove the selector drum.
Page 269 SHIVER 900 Engine • 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.
Page 270 SHIVER 900 Engine • Rotate the engine and the engine sup- port to the horizontal position. • Using a rubber mallet, strike the guards gently in order to separate them. • Open the guards. • If necessary, unscrew the two pick-up tube fastening screws and remove them.
Page 271 SHIVER 900 Engine 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.
Page 272 SHIVER 900 Engine • 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 Checking crankshaft endfloat • The shaft axial clearance on the crank- case should be checked with a dial gauge mounted on the specific dial gauge support.
Page 273 SHIVER 900 Engine • 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 Bushing extractor Installing • The orientation of the semi-bushings...
Page 274 SHIVER 900 Engine Installing the crankshaft • Place the left side crankcase half on the engine support adequately. • Place the crankshaft on the seat of the crankcase half with caution. Refitting the crankcase halves • In order to reposition the guards, repeat the procedure described in the section "OPENING THE GUARDS"...
Page 275 SHIVER 900 Engine Conceptual diagrams Key: 1. Filter head support. 2. Oil pump. 3. Oil pressure regulator valve. 4. Oil pressure sensor. ENG - 275...
Page 276 SHIVER 900 Engine 5. Oil filter. 6. Oil pressure regulator screw. 7. Secondary transmission shaft lubrication. 8. Primary transmission shaft lubrication. 9. Clutch discs lubrication. 10.Oil pressure sensor. 11.Main bushing lubrication. 12.Piston oil jets. 13.Water pump shaft lubrication. 14.Distribution command gearwheels.
Page 277 SHIVER 900 Engine Oil pump UBRICATION Pos. Description Type Quantity Torque Notes Oil drainage plug M16x1.5 17 Nm (12.54 lb ft) +/- Oil pressure sensor M10x1 13 Nm (9.59 lb ft) Fitting fixing of the oil filter 20 Nm (14.75 lb ft)
Page 278 SHIVER 900 Engine Pos. Description Type Quantity Torque Notes Oil filter 14 Nm (10.33 lb ft) Oil pressure regulation valve M16x1.5 41 Nm (30.24 lb ft) Oil pump / bulkhead fastening M6x45 5 Nm (3.69 lb ft) 3M SCOTCH GRIP...
Page 279 SHIVER 900 Engine • Retrieve the shim. • Undo and remove the two screws fixing the oil pump. • Remove the entire pump. Inspection • Undo and remove the two fixing screws. ENG - 279...
Page 280 SHIVER 900 Engine • 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). •...
Page 281 SHIVER 900 Engine • 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). Installing NOTE PAY ATTENTION TO ALIGN THE REFERENCES ON STA- TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE.
Page 282 SHIVER 900 Engine • Tighten both oil pump fixing screws. • Fit the shim washer. • Insert the oil pump gearwheel, making sure that the machined groove coin- cides with the pin on the pump. • Insert the safety washer.
Page 283 SHIVER 900 Engine • Using a screwdriver, raise and bend the safety washer on the side opposite the slot until it is touching the nut. ENG - 283...
Page 284 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 285 SHIVER 900 Power supply Fuel pump pos. Description Type Quantity Torque Notes Flanged, hex. head front fuel tank M6x30 6 Nm (4.43 lb ft) fastening screws Fuel pump fastening nuts 6 Nm (4.43 lb ft) Removing • Remove the fuel tank.
Page 286 SHIVER 900 Power supply • Remove the fuel pump. Injection Removing the throttle body HROTTLE BODY Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M6x60 12 Nm (8.85 lb ft) Loct. 242 fastening the inlet coupling Button head, hex.
Page 287 SHIVER 900 Power supply • Remove the filter casing. • Working on both bodies, undo and re- move the four screws and slide off the filter support. • Remove the upper plate. • Remove both bodies. UPON REFITTING, REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE.
Page 288 SHIVER 900 Power supply • Remove the plate. • Working on both bodies, undo and re- move the screw and detach the body. • Working on the body in question, re- move the injector, slide off the clip and the injector itself.
Page 289 INDEX OF TOPICS SUSP USPENSIONS...
Page 290 SHIVER 900 Suspensions Front Handlebar ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Stainless steel, cyl. head Pozidriv M8x25 25 Nm (18.44 lb ft) screws used for fastening the upper U-bolt to the lower U-bolt Electronic accelerator control fasten- 4 Nm (2.95 lb ft)
Page 291 SHIVER 900 Suspensions • Remove the two screws used for fas- tening the front brake pump U-bolt. • Move the front brake pump to one side. • Remove the two screws used for fas- tening the clutch pump U-bolt. •...
Page 292 SHIVER 900 Suspensions • Remove the anti-vibration weights. • Remove the left hand knob with the as- sistance of compressed air. • Remove the two screws used for fas- tening the left hand column switch and disconnect it from the handlebars •...
Page 293 SHIVER 900 Suspensions • Remove the two screws used for fas- tening the left hand column switch. • Remove the four screws and the U- bolt. • Remove the handlebars SUSP - 293...
Page 294 SHIVER 900 Suspensions Front fork RONT FORK Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M6x40 10 Nm (7.38 lb ft) closing the fork feet Button head, hex. socket screws M5x16 6 Nm (4.43 lb ft)
Page 295 SHIVER 900 Suspensions The standard front fork setting is adjusted to suit most high and low speed riding conditions, wheth- er the vehicle is partially or fully loaded. However, the setting can be modified for specific needs according to vehicle use.
Page 296 SHIVER 900 Suspensions • Remove the cable clamp fastening screw positioned inside the fork foot in order to free the ABS sensor wiring hardness. NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE ROD ONLY, BUT APPLY EQUALLY TO BOTH RODS.
Page 297 SHIVER 900 Suspensions THE FOLLOWING OPERATIONS APPLY WHEN REMOVING THE RIGHT HAND STEM • Taking care not to damage it, secure the fork vertically in a vice, using the appropriate protection devices. • Unscrew the upper cap (1). Specific tooling AP8140149 Guard for assembly operations •...
Page 298 SHIVER 900 Suspensions • Extract the shaft (6) and remove it. • After removing the locking plate and the device used to compress the spring, remove the upper plate (7) and the pre-loading pipe (3). • Remove the spring (8) allowing the oil inside the stem to drip out.
Page 299 SHIVER 900 Suspensions • Taking care not to damage it, secure the sleeve horizontally in a vice, using the appropriate protection devices. • Extract the dust guard (9). Specific tooling AP8140149 Guard for assembly operations • Remove the seeger ring (10) from in- side the sleeve.
Page 300 SHIVER 900 Suspensions • Remove the complete plunger (13). • Observing the indicated sequence, ex- tract and remove the slider bushing (14), the guide bushing (15), the ring (16), the oil seal (17), the seeger ring (10) and the dust guard (9).
Page 301 SHIVER 900 Suspensions • Unscrew and remove the cap (1). • Unscrew the special nut (2) and re- move it. • Remove the buffer (3). • Drain the oil into a container having sufficient capacity, extending the stem several times in order to ensure the oil is drained completely.
Page 302 SHIVER 900 Suspensions • Taking care not to damage it, secure the sleeve horizontally in a vice, using the appropriate protection devices. • Extract the dust guard (4). Specific tooling AP8140149 Guard for assembly operations • Remove the seeger ring (5) from inside the sleeve.
Page 303 SHIVER 900 Suspensions If the scratches are deep, replace the stem. Using a dial gauge, check than any bending of the stem is below the limit value. If it is over the limit, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK- ENED MAKING THE VEHICLE DANGEROUS TO USE.
Page 304 SHIVER 900 Suspensions THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE RIGHT HAND STEM • Observing the indicated sequence, ex- tract and remove the dust guard (1), the seeger ring (2), the oil seal (3), the ring (4), the guide bushing (5) and the slider bushing (6).
Page 305 SHIVER 900 Suspensions • Using a suitable tool, complete with striking hammer, insert oil seal into its housing (3). Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight • Position the seeger ring (2) inside the sleeve.
Page 306 SHIVER 900 Suspensions • Insert the spring (10). • Insert the pre-load tube (11), making sure that it is aligned correctly. The narrower part must be inserted into the spring. • Insert the upper plate (12) on the pre- load pipe •...
Page 307 SHIVER 900 Suspensions • Insert the shaft (16) into the plunger. • Before positioning the cap, adjust the hydraulic regulator screw so that the internal distance is as close as possi- ble to 13 mm (0.51 in). • Screw the cap (17) onto the plunger as far as it will go.
Page 308 SHIVER 900 Suspensions • Tighten the cap on the sleeve, applying the pre-defined torque. THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE LEFT HAND STEM • Observing the indicated sequence, ex- tract and remove the dust guard (1), the seeger ring (2), the oil seal (3), the ring (4), the guide bushing (5) and the slider bushing (6).
Page 309 SHIVER 900 Suspensions • Position the seeger ring (2) inside the sleeve. • Insert the dust guard (1) into its hous- ing correctly. • Place the fork stem vertically on a work surface. • Fill the stem with the quantity of oil in- dicated in the "Refilling oil"...
Page 310 SHIVER 900 Suspensions • Insert the special nut (8) and tighten it as far as it will go. • Insert the cap (9) and tighten it as far as it will go. • Ensure that the cap cannot rotate, and then tighten the nut.
Page 311 SHIVER 900 Suspensions Filling oil THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE RIGHT HAND STEM • Place the fork stem vertically on a work surface. • Fill the STEM with the indicated quan- tity of oil. WARNING OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.
Page 312 SHIVER 900 Suspensions Steering bearing TEERING Pos. Description Type Quantity Torque Notes Headstock ferrule (pre-tightening) 50 Nm (36.88 lb ft) Steering assembly settling Headstock ferrule (tightening) 15 Nm (11.06 lb ft) Flanged upper steering plate fasten- 25 Nm (18.44 lb ft)
Page 313 SHIVER 900 Suspensions Adjusting play • Secure the rear of the motorcycle using suitable belts and position a central stand under the engine in order to maintain the front wheel in a raised po- sition. • After removing the instrument panel...
Page 314 SHIVER 900 Suspensions Headlight assy. • Unscrew the three screws used for fas- tening the upper steering plate. • Remove the upper steering plate. • Apply the pre-tightening torque to the ferrule using the dedicated tool. • Execute two complete rotations to the left, and two to the right.
Page 315 SHIVER 900 Suspensions • Tighten the sleeving blocking screws, applying the pre-defined torque. • Loosen the nut used for fastening the upper steering plate again. • Tighten the upper steering plate cen- tral closure screw, applying the pre- defined torque.
Page 316 SHIVER 900 Suspensions Shock absorbers HOCK ABSORBER Pos. Description Type Quantity Torque Notes Cyl head, hex. socket upper shock M10x50 50 Nm (36.88 lb ft) Pre-impregnated absorber fastening screw screw Cyl head, hex. socket lower shock M10x59 50 Nm (36.88 lb ft)
Page 317 SHIVER 900 Suspensions TO COUNT THE NUMBER OF CLICKS OF THE ADJUSTER (1) ALWAYS START FROM THE MOST RIGID SETTING (COMPLETE CLOCKWISE ROTATION). TO PREVENT DAMAGE TO THE ADJUSTER SCREWS (1), NEVER FORCE THEM BEYOND THE END OF TRAVEL IN EITHER DIRECTION.
Page 318 SHIVER 900 Suspensions (*) = clockwise (**) = anticlockwise 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.
Page 319 INDEX OF TOPICS CHAS HASSIS...
Page 320 SHIVER 900 Chassis Wheels Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle nut 80 Nm (59.00 lb ft) Flanged, hex. head phonic wheel M8x20 30 Nm (22.13 lb ft) Pre-impregnated and brake discs fixing screws screws Removal •...
Page 321 SHIVER 900 Chassis • Working on both sides, loosen the screws on the fork feet • Slide out the pin from the left hand side of the motorcycle. • Remove the wheel. See also Front mudguard • Retrieve the spacer present on the left hand side.
Page 322 SHIVER 900 Chassis Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel. CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. CHECKING ROTATION • Manually rotate the inner race of each bearing. The race must turn smoothly without im- pediment or noise.
Page 323 SHIVER 900 Chassis • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim if, after replacing the bearings, the value is not within the specified limit.
Page 324 SHIVER 900 Chassis Rimozione • Place the vehicle on a suitable rear support stand. • To make it easier to carry out these op- erations, we recommend removing the chain guard. • Remove the external screw (1). • Access the left hand side of the motor- cycle and loosen the internal screw (2).
Page 325 SHIVER 900 Chassis • Working on both sides of the vehicle, loosen the locknuts (5) and adjust the regulator screws (6) in order to release the tension on the drive chain. • Rotate the wheel forwards and disen- gage the drive chain (7) from the sprocket.
Page 326 SHIVER 900 Chassis • Remove the wheel shaft (10), com- plete with guide (11). • Remove the rear wheel (12). • Remove the spacers from both sides (13). • Remove the complete sprocket as- sembly (14). CHAS - 326...
Page 327 SHIVER 900 Chassis • Remove the internal spacer (15) Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. REAR WHEEL BEARINGS Check the bearings installed on the wheel. CHECKING ROTATION • Manually rotate the inner race of each bearing. The race must turn smoothly without im- pediment or noise.
Page 328 SHIVER 900 Chassis REAR WHEEL AXLE • 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 •...
Page 329 SHIVER 900 Chassis Swinging arm WINGARM Pos. Description Type Quantity Torque Notes Swingarm pivot bolt fastening nut 90 Nm (66.38 lb ft) Swingarm pivot bolt fastening nut 12 Nm (8.85 lb ft) swingarm bolt regulator bushing Swingarm pivot bolt fastening swing- 60 Nm (44.25 lb ft)
Page 330 SHIVER 900 Chassis • Remove the rear wheel. • Support the vehicle by means of the engine service stand and a hoist with belts fastened to the rear section of the frame. • Remove the rear service stand. • Undo and remove the two lower swing- arm screws.
Page 331 SHIVER 900 Chassis Removing the rear wheel • Working on the right side, unscrew and remove the swingarm bolt. UPON REMOVING THE REAR SWINGARM PAY ATTEN- TION NOT TO JAM THE GEARING CHAIN. See also Removing the rear wheel Drive chain Removing The transmission chain, although "closed", has a...
Page 332 SHIVER 900 Chassis To dismantle and remove the chain, proceed as follows: • Partially remove the pins (3) using a generic chain breaker. • Remove the outer plate (4). • Remove the outer O-ring rings (5). • Remove the inner plate (6).
Page 333 SHIVER 900 Chassis • Collect the inner O-ring rings (7) and completely remove the transmission chain. Installing • After fitting the chain on the pinion and on the crown, put the inner O-rings (1) back onto the hammerlock pins (2) and connect the two ends of the transmis- sion chain.
Page 334 SHIVER 900 Chassis • Check that the links in the transmission chain are not seized and that it can move in both directions. • Use a generic clincher to re-tighten the pins of the link (checking riveting at points "A").
Page 335 SHIVER 900 Chassis BACKSLASH CHECK To check clearance: • 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 around 25 mm (0,98 in).
Page 336 SHIVER 900 Chassis • loosened pins; • dry, rusty, flattened or jammed chain links; • excessive wear; • missing sealing rings; • excessively worn or damaged pinion or sprocket teeth; IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSE AND/OR THE SEAL RINGS ARE DAMAGED OR MISSING, THE ENTIRE CHAIN UNIT (PINION, SPROCKET AND CHAIN) NEEDS TO BE REPLACED.
Page 337 SHIVER 900 Chassis Pedaline OOTRESTS Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M6x12 10 Nm (7.38 lb ft) fastening the rider/passenger rubber footrests Cyl. head, hex. socket screws used M8x25 18 Nm (13.28 lb ft) Loct.
Page 338 SHIVER 900 Chassis • Remove the complete footrest. To dismantle the footrest, proceed as follows: • Remove the two screws (2) used to fasten the heel guard plate. • Remove the heel guard plate (3). • Remove the seeger ring (4)
Page 339 SHIVER 900 Chassis • Extract the pin (5) and remove it. • Remove the pedal, complete with spring (6). • Remove the two screws (7) used to fasten the rubber pad. • Separate the pedal (8) from the rubber pad (9).
Page 340 SHIVER 900 Chassis • Remove the pin (10). RH RIDER FOOTREST • Remove the fastening screw (1) from the brake pipe retaining plate in order simplify the mounting operations. • Remove the two fastening screws (2). • Position the cloth in order to protect the...
Page 341 SHIVER 900 Chassis • Remove the safety O-ring (4) from the pin that blocks the brake pump control rod. • Rotate the pin (5) to release the brake pump control rod and slide it out in or- der to remove it.
Page 342 SHIVER 900 Chassis To dismantle the footrest, proceed as follows: • Disconnect the brake lever return spring (7) and remove it. • After unscrewing the pin (8) it is possi- ble to remove the complete brake lever (9). The pin (8) consists of the following elements: •...
Page 343 SHIVER 900 Chassis • Undo the screw (14) in order to remove the peg (15) from the lever, complete with rubber protection pad. • Unscrew the brake lever spring cou- pling pin (16) and remove it. • Remove the two screws (17) used to fasten the heel guard plate.
Page 344 SHIVER 900 Chassis • Remove the seeger ring (19) • Extract the pin (20) and remove it. • Remove the pedal, complete with spring (21). • Remove the two screws (22) used to fasten the rubber pad. CHAS - 344...
Page 345 SHIVER 900 Chassis • Separate the pedal (23) from the rub- ber pad (24). • Remove the pin (25). PASSENGER FOOTRESTS THE FOLLOWING OPERATIONS ARE VALID FOR BOTH FOOTRESTS • Remove the two screws (1) used to fasten the support bracket.
Page 346 SHIVER 900 Chassis • Remove the seeger ring (3) • Extract the pin (4). • While pressing the side plates, remove the complete pedal. Check that the plates (5) are aligned correctly be- fore dismantling the pedal, taking care not to lose the spring (6) and the ball (7).
Page 347 SHIVER 900 Chassis Stand TAND Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M8x30 25 Nm (18.44 lb ft) fastening the stand plate to the en- gine Screw for fastening the stand to the M10x1.25 10 Nm (7.38 lb ft)
Page 348 SHIVER 900 Chassis • Release the spring coupling plate (2) and remove it. • Unscrew the nut (3) and remove it, complete with washer (4). • Unscrew the pin (5) and remove it. • Remove the stand (6). CHAS - 348...
Page 349 SHIVER 900 Chassis • To remove the stand, complete with support plate, disconnect the side stand switch connector and remove the three screws (7) that fasten the plate to the engine. Exhaust ILENCER Pos. Description Type Quantity Torque Notes Lambda probes 40 Nm (29.50 lb ft)
Page 350 SHIVER 900 Chassis Removing the tail pipe • Remove the saddle, the rear grab-bar, the rear light assembly and the number plate support. • Loosen the clamp between the ex- haust end and the manifold. • Remove the two support bracket fas- tening screws (2) and retrieve the spacer washers.
Page 351 SHIVER 900 Chassis • Retrieve the washers (5), the spacers (6) and the rubber grommets (7), and replace them if necessary. Removing the exhaust manifold FRONT MANIFOLD • Remove the lower fairing and cut the upper clamp (1) that fastens the front lambda probe wiring harness to the ABS pump support frame.
Page 352 SHIVER 900 Chassis • Loosen the clamp (4) that unites the front manifold with the central manifold • Remove the two nuts (5) used to fasten the front manifold to the head. • Remove the front manifold (6). • Loosen the lower clamp (7) that con- nects the rear manifold to the central manifold.
Page 353 SHIVER 900 Chassis • Loosen the upper clamp (8) that con- nects the terminal to the central mani- fold. • Remove the central manifold (9). REAR MANIFOLD • Remove the clamp (10) that fastens the rear lambda probe wiring harness to the rear frame.
Page 354 SHIVER 900 Chassis • Remove the two nuts (12) used to fas- ten the rear manifold to the head. • Remove the rear manifold (13), sliding out from underneath the motorcycle. CHAS - 354...
Page 355 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 356 SHIVER 900 Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. BRAKING SYSTEM pos. Description Type Quantity Torque Notes Flanged, hex. head screw used for M6x25 10 Nm (7.38 lb ft)
Page 357 SHIVER 900 Braking system Foreword Key: 1. Rear brake calliper 2. Modulator 3. Front bleed valve 4. Front brake reservoir 5. Front brake callipers 6. Rear brake pump 7. Rear brake reservoir BRAK SYS - 357...
Page 358 SHIVER 900 Braking system Operating diagram Key: 1. Instrument panel 2. Ignition switch 3. Main injection relay 4. ABS control unit BRAK SYS - 358...
Page 359 SHIVER 900 Braking system 5. Front ABS sensor 6. Rear ABS sensor 7. Start-up relay 8. ABS control unit fuse 9. Main fuse 10.Battery 11.BLUEDASCH set-up (optional) 12.Diagnostics socket 13.7SM engine control unit ABS Electronic Control Unit pin-out • PIN1 - Power ground 1 •...
Page 360 SHIVER 900 Braking system ABS OPERATION General specifications: The front circuit is the same as the rear one. • The ABS inlet valve (10 - 12) is normally open and it is closed only when the system inter- venes to avoid wheel locking.
Page 361 SHIVER 900 Braking system • With the system in stand-by mode, the ABS processor controls the wheel speed instant by instant to assess any slippage of the wheels. • 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.
Page 362 SHIVER 900 Braking system A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly. CAUTION WHEN THE ABS STARTS WORKING, A PULSING IS FELT ON THE BRAKE LEVER. THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND.
Page 363 SHIVER 900 Braking system Attivazione/Disattivazione dispositivo ABS Soltanto a moto ferma è possibile modificare lo stato di attivazione/disattivazione del sistema ABS ed è possibile farlo in due modi distinti: 1) Dalla schermata principale, mediante uno spos- tamento breve verso sinistra o verso destra è pos- sibile disattivare o riattivare il sistema ABS Per tornare al menù...
Page 364 SHIVER 900 Braking system • the ABS warning light flashes. Once the vehicle speed exceeds 5 km/h (3.1 mph): - if errors are not detected: the ABS warning light turns off - if at least one malfunction is detected: the ABS warning light turns on permanently.
Page 365 SHIVER 900 Braking system PARAMETERS screen page This screen shows the parameters measured by the several sensors (engine revs, engine temper- ature, etc.) or values set by the control unit (injec- tion time, ignition advance, etc.) PARAMETERS AND STATUSES P.A.D.S. characteristic.
Page 366 SHIVER 900 Braking system ERRORS screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS Description Code Symptom Front wheel speed sensor...
Page 367 SHIVER 900 Braking system • Select the vehicle and the component. • Select Self-diagnosis. • Go to the page Error codes. • Select an error and show the Ambient parameter error(where provided). • Repeat the operation by selecting each error and showing the corresponding Ambient parameter error (where provi- ded).
Page 368 SHIVER 900 Braking system • Go to the page Report and then on Print and select the virtual PDF printer. • If there is no PDF printer, there are several free programs, ask the infor- mation systems to install it.
Page 369 SHIVER 900 Braking system ADJUSTMENTS P.A.D.S. characteristic. Value/example Units of Notes measure ment Front bleed Rear bleed Encoding Resets the vehicle code and obtains it automati- cally from the CAN line at the next key ON Modulator MODULATOR REMOVAL •...
Page 370 SHIVER 900 Braking system Rear brake calliper EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Special brake pipe coupling fasten- M10x1 10 Nm (7.38 lb ft) ing screw Button head, hex. socket screws M5x9 4 Nm (2.95 lb ft)
Page 371 SHIVER 900 Braking system Front brake calliper RONT BRAKE CALLIPERS Pos. Description Type Quantity Torque Notes Flanged, hex. head screws for fas- M10x1.25 50 Nm (36.88 lb ft) tening the brake callipers to the fork stanchions Special screws for fastening the 25 Nm (18.44 lb ft)
Page 372 SHIVER 900 Braking system Rear brake disc EAR WHEEL Pos. Description Type Quantity Torque Notes Wheel axle nut M25x1.5 120 Nm (88.51 lb ft) Button head, hex. socket screw used M5x16 6 Nm (4.43 lb ft) for fastening the sensor to the brake...
Page 373 SHIVER 900 Braking system • Unscrew the five screws (1) used to fasten the brake disc and remove them. • Remove the phonic wheel (2) and the brake disc (3). DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1).
Page 374 SHIVER 900 Braking system Front brake disc RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle nut 80 Nm (59.00 lb ft) Flanged, hex. head phonic wheel M8x20 30 Nm (22.13 lb ft) Pre-impregnated and brake discs fixing screws...
Page 375 SHIVER 900 Braking system • Unscrew the six screws (1) used to fas- ten the brake disc and remove them. • Remove the phonic wheel (2) and the brake disc (3). DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1).
Page 376 SHIVER 900 Braking system Removal • Turn the pins and remove both cotter pins. • Remove both pins. • Collect the anti-vibration springs. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
Page 377 SHIVER 900 Braking system 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 LEAKAGE.
Page 378 SHIVER 900 Braking system Installing • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. • Screw the pin.
Page 379 SHIVER 900 Braking system • Replace the damaged brake pump with a new one. • Connect the brake pipe to the new brake pump. • Fill the tank with fresh brake fluid. CAUTION PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT THE END OF THE CHAPTER.
Page 380 SHIVER 900 Braking system • Install the fully pre-filled, new control unit. • In order to ensure that the brake fluid remains inside the ABS control unit, first remove the protective plugs from the braking circuit couplings and con- nect the corresponding pipes.
Page 381 SHIVER 900 Braking system ing device in order to prevent the liquid from escaping from the system when it is open. • Close the front calliper bleeder screw and remove the bleeder bottle. • Replace the damaged calliper with a new one.
Page 382 SHIVER 900 Braking system • Once the procedure with PADS has been completed, repeat the TRADITIONAL BLEEDING procedure to remove any remaining air from the system. CAUTION PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT THE END OF THE CHAPTER.
Page 383 SHIVER 900 Braking system • 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. 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.
Page 384 INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
Page 385 SHIVER 900 Clutch system LUTCH CONTROL Pos. Description Type Quantity Torque Notes Clutch pump U-bolt fastening screws 10 Nm (7.38 lb ft) Special screw for fastening the pipe 25 Nm (18.44 lb ft) to the clutch cylinder Special screw for fastening the pipe 25 Nm (18.44 lb ft)
Page 386 SHIVER 900 Clutch system Removing the clutch master cylinder • Remove the rear-view mirror, drain the oil from the clutch system and, after re- moving the rubber clamp (1), remove the pump pipe retaining screws (2). • Disconnect the clutch switch connec- tors (3).
Page 387 SHIVER 900 Clutch system Removing the clutch slave cylinder • Drain the oil from the clutch system and remove the retaining screw (1) from the control cylinder pipe. • Undo and remove the three control cyl- inder fastening screws (2) •...
Page 388 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 389 SHIVER 900 Cooling system OOLING SYSTEM Pos. Description Type Quantity Torque Notes Flanged, hex. head used for fasten- M6x20 10 Nm (7.38 lb ft) ing the trellis expansion tank Flanged, hex. head screw used for M6x25 10 Nm (7.38 lb ft) fastening the trellis radiator Button cyl.
Page 390 SHIVER 900 Cooling system Key: Yellow = Air purge Orange = Refilling Red = From engine Blue = To the pump Key: 1. Front cylinder. 2. Rear cylinder. 3. Thermostat. 4. Direction of travel of vehicle. COOL SYS - 390...
Page 391 SHIVER 900 Cooling system Electric fan • Remove the radiator • Undo and remove the three screws and collect the washers; remove the electric fan. See also Removing the radiator Coolant replacement • Remove the right side fairing. • Unscrew and remove the screw and remove the protection.
Page 392 SHIVER 900 Cooling system • Remove the cap. • Empty the system into the specific con- tainer. • 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...
Page 393 SHIVER 900 Cooling system Water pump ATER PUMP Pos. Description Type Quantity Torque Notes Clutch side cover fixing screw M6x40 13 Nm (9.59 lb ft) Pump cover / Clutch side cover fas- M6x25 13 Nm (9.59 lb ft) tening screw...
Page 394 SHIVER 900 Cooling system • Drain the cooling circuit completely. • - Unscrew the and remove the five wa- ter pomp cover fastening screws. • - Loosen the clip and remove the cover. REMOVING THE PUMP ROTOR • Remove the H2O pump cover.
Page 395 SHIVER 900 Cooling system REMOVING THE COMPLETE H2O PUMP • Remove the clutch cover. • Unscrew and remove the three H2O pump retaining screws. • Remove the H2O pump and extract the control chain. NOTE WHEN REMOUNTING THE PUMP, REPLACE THE "O- RINGS"...
Page 396 SHIVER 900 Cooling system • Apply a large quantity of grease to the sides of the H2O pump so that it is eas- ier to insert the cover. CAUTION WHEN MOUNTING THE COVER, MAKE SURE THAT IT IS INSERTED PERPENDICULARLY TO THE GUARD, APPLY- ING EVEN PRESSURE OVER THE ENTIRE SURFACE IN ORDER TO AVOID DAMAGING THE O-RINGS.
Page 397 SHIVER 900 Cooling system • Remove the screw that fastens the horn support bracket to the engine • Disconnect the horn from its connec- tors and remove it. • Disconnect the electric fan connector. • Release the clamps of the pipes that...
Page 398 SHIVER 900 Cooling system • Operating from the right side of the mo- torcycle, release and remove the radi- ator from the chassis. Removing the expansion tank • Remove the right side fairing. • Unscrew and remove the screw and remove the protection.
Page 399 SHIVER 900 Cooling system Thermostatic valve Traditional circuit, three-way thermostatic valve: 1. Hot water inlet from big ends. 2. Outlet to short circuit (direct to the pump). 3. Outlet to radiator Thermostat specifications: Characteristic Temperature at start of stroke 85° +/- 2°...
Page 400 INDEX OF TOPICS BODYW ODYWORK...
Page 401 SHIVER 900 Bodywork Seat • Rest the vehicle on its stand. • Insert the key (1) in the lock. • Turn the key (1) anticlockwise, pull out and lift the saddle (2). There is a handy document/tool kit compartment in the vehicle tail fairing. Remove the saddle (2) to reach it.
Page 402 SHIVER 900 Bodywork Headlight assy. EADLAMP Pos. Description Type Quantity Torque Notes Button head, hex. socket screws M6x15 10 Nm (7.38 lb ft) used to fasten the headlight bracket to the bottom yoke Button head, hex. socket screws M5x16 3 Nm (2.21 lb ft)
Page 403 SHIVER 900 Bodywork • Disconnect the direction indicator con- nectors. • After removing the lower front light as- sembly fastening nut, remove the pin, taking care to retrieve the "T" bushings from both sides. See also Instrument cluster support •...
Page 404 SHIVER 900 Bodywork Taillight assy. AILLIGHT Pos. Description Type Quantity Torque Notes Button head hex. socket upper tail- M5x16 4 Nm (2.95 lb ft) light fastening screw Rear indicators fastening 3 Nm (2.21 lb ft) Reflector fastening 2 Nm (1.47 lb ft) License plate light fastening 5 Nm (3.69 lb ft)
Page 405 SHIVER 900 Bodywork • Access the vehicle from underneath the exhaust terminal and unscrew the lower rear light assembly fastening screw (3) and retrieve the "T" bushing (4). • Remove the rear light assembly (5). License plate holder • Remove the saddle and the rear light assembly.
Page 406 SHIVER 900 Bodywork • To make it easier to route the direction indicators/license plate light wiring har- ness, we recommend removing the rear light assembly in order to remove the clamp (2) used to fasten the wiring harness to the number plate support frame.
Page 407 SHIVER 900 Bodywork IR FILTER CASING Pos. Description Type Quantity Torque Notes Self-tapping, SWP air pressure sen- 5x20 2 Nm (1.48 lb ft) sor fastening screws Self-tapping air temperature sensor 2.9x12 2 Nm (1.48 lb ft) fastening screws SWP filter box lid fastening screws 5x20 2 Nm (1.48 lb ft)
Page 408 SHIVER 900 Bodywork • Unscrew the intake ducts (4) anticlock- wise and remove them. • Remove the air filter (5). • Remove the starter relay (6) from the support present on the base of the filter box. • Detach the Ride by Wire control con-...
Page 409 SHIVER 900 Bodywork • Remove the fan control relay (8) from the support present on the base of the filter box. • Remove the main injection relay (9) from the support present on the base of the filter box. •...
Page 410 SHIVER 900 Bodywork • Remove the lights relay (12) from the support present on the base of the filter box. • Remove the highbeam lights relay (13) from the support present on the base of the filter box. • Remove the two instrument cannister support fastening screws (14).
Page 411 SHIVER 900 Bodywork • Remove the nine screws used to fas- ten the cover (17). • Remove the tenth screw used to fasten the cover (18) positioned in corre- spondence with steering headstock. • Remove the metallic cable clamp (19), taking care to retrieve the washer (20).
Page 412 SHIVER 900 Bodywork • Remove the upper part (21) of the filter box. • Remove the two screws (22) used to fasten the air pressure sensors. • Disconnect the connectors and re- move the sensors. • Remove the two clamps (23) used to fasten the wiring harness to the throttle body.
Page 413 SHIVER 900 Bodywork • Access the right hand side of the mo- torcycle and remove the three screws (25) used to fasten the side panel mounted on the filter box in order per- mit the passage of the wiring harness.
Page 414 SHIVER 900 Bodywork • Disconnect the cable clamp (30) from the base of the filter box. • Remove the clamps (31) in order to de- tach the wiring harness from the base of the filter box. • Remove the two screws (32) that fas- ten the plate used to connect the filter box to the frame.
Page 415 SHIVER 900 Bodywork • Remove the two screws (35) used to fasten the control unit cover. • Slide the control unit cover (36) off ver- tically. • Disconnect the two connectors (37) from the control unit. BODYW - 415...
Page 416 SHIVER 900 Bodywork • Slide the control unit (38) out vertically. • Remove the screw (39) used to fasten the control unit support to the base of the filter box. • Remove the clamp (40) from the con- trol unit support and release the wiring harnesses.
Page 417 SHIVER 900 Bodywork • Detach the cable clamp (42) from the base of the filter box. • Remove the four clamps positioned on the front part of the filter box (43) and release the wiring harness. NOTE DURING REASSEMBLY, REPLACE THE CLAMPS IN THE POSITIONS IDENTIFIED BY THE GREY TAPE.
Page 418 SHIVER 900 Bodywork • Remove the three screws (48) that fas- ten the cable guide (49) and free the wiring harness. • Remove the base from the filter box (50). Lower cowl RONT MUDGUARD NGINE FAIRING Pos. Description Type Quantity...
Page 419 SHIVER 900 Bodywork Pos. Description Type Quantity Torque Notes Button head hex. socket screws for M6x20 10 Nm (7.38 lb ft) fastening the engine fairing to the support • After positioning the vehicle on the side stand, unscrew and remove the lower fairing fastening screws, working on both sides of the vehicle.
Page 420 SHIVER 900 Bodywork OCKS Pos. Description Type Quantity Torque Notes Button head, hex. socket ignition lock M8x40 25 Nm (18.44 lb ft) fastening screw Ignition lock fastening shear head Manual screw Flanged, hex. head screws used to M6x25 10 Nm (7.38 lb ft) fasten the saddle lock to the saddle Cyl.
Page 421 SHIVER 900 Bodywork pos. Description Type Quantity Torque Notes Flanged, hex. head front fuel tank M6x30 6 Nm (4.43 lb ft) fastening screws Fuel pump fastening nuts 6 Nm (4.43 lb ft) BODYW - 421...
Page 422 SHIVER 900 Bodywork IDE FAIRINGS Pos. Description Type Quantity Torque Notes Self-tapping, cyl. head slot drive 4.2x16 3 Nm (2.21 lb ft) screws used for fastening the grilles to the duct covers Self-tapping, cyl. head slot drive 4.2x16 3 Nm (2.21 lb ft)
Page 423 SHIVER 900 Bodywork • Remove the side panel fixing screws before the radiator. • Remove the four screws fixing the side panels to the tank covers. • Release the side panels from the ducts. • Remove the duct front screws.
Page 424 SHIVER 900 Bodywork • Remove the duct rear screws. • Raise the tank partially and remove the duct central fixing screws. • Remove the ducts. • Disconnect the vent pipes from the fuel collection tank and remove it. • Operating from the right side of the mo- torcycle, disconnect the vent pipe.
Page 425 SHIVER 900 Bodywork • Disconnect the fuel pump connector. • Remove the fuel pump connector be- low the chassis crosspiece so that the tank can be removed later. • Remove the nut and remove the cen- tral fixing screw of the tank.
Page 426 SHIVER 900 Bodywork • Remove the front screws of the tank cover. • Remove the rear screws of the tank cover. • Remove the central screws of the tank cover. • Remove the three outer screws indica- ted on the tank cap.
Page 427 SHIVER 900 Bodywork • Carefully remove the inner screw of the tank cap so that it does not fall into the tank. • Remove the complete cap. • Remove the tank cover. Front mudguard BODYW - 427...
Page 428 SHIVER 900 Bodywork RONT MUDGUARD NGINE FAIRING Pos. Description Type Quantity Torque Notes Button head hex. socket screws M5x9 4 Nm (2.95 lb ft) Loct. 243 used to fasten the mudguard to the calliper mounting bracket Button head hex. socket screws for M6x20 10 Nm (7.38 lb ft)
Page 429 SHIVER 900 Bodywork • Remove the protection cover (2). • Remove the clamps (3). NOTE DURING REASSEMBLY, ENSURE THAT ALL THE CLAMPS AND THE WIRING HARNESS ARE IN THE CORRECT PO- SITION. • Disconnect the license plate light (4) and rear light assembly (5) connector.
Page 430 SHIVER 900 Bodywork • Remove the two screws (7), complete with "T" bushings (8). • Remove the four front screws (9) • Remove the grab bar (10), taking care to retrieve the "T" bushings (11). BODYW - 430...
Page 431 SHIVER 900 Bodywork Instrument cluster support NSTRUMENTS Pos. Description Type Quantity Torque Notes Button head, hex. socket instrument M5x12 3 Nm (2.21 lb ft) panel adapter fastening screws Self-tapping, SWP screws used to 5x14 3 Nm (2.21 lb ft) fasten the instrument cluster and cover to the support plate Button head, hex.
Page 432 SHIVER 900 Bodywork • Remove the instrument panel cover (2). • Remove the two instrument panel sup- port fastening screws (3). • Loosen the nuts used for fastening the special screws (4) so that it is possible to remove them.
Page 433 SHIVER 900 Bodywork • Disconnect the connector (6) and re- move the instrument panel (7). • Remove the four screws (8) in order to separate the instrument panel (7) from the plastic support (9) Tail guard EAR BODYWORK Pos. Description...
Page 434 SHIVER 900 Bodywork Pos. Description Type Quantity Torque Notes Self-tapping screws used for fasten- M5x19 4 Nm (2.95 lb ft) ing the tail fairings to the battery com- partment Self-tapping, cyl. head Pozidriv 4.2x16 3 Nm (2.21 lb ft) screws used for fastening the grab- bar to the tail fairings Button head, hex.
Page 435 SHIVER 900 Bodywork • Remove the external screw used for fastening the tail fairing to the side fair- ing. • Remove the two internal screws used fro fastening tail fairing to the side fair- ing and separate them. • If necessary, in order to remove the ig- nition switch assembly, disconnect the saddle opening cable and remove it.
Page 436 SHIVER 900 Bodywork • Remove the upper fastening screw (2) and retrieve the "T" bushing with the rubber grommet. • If the number plate support has not been removed, remove the screw (3) and the respective washer and grom- met.
Page 437 SHIVER 900 Bodywork BODYW - 437...
Page 438 INDEX OF TOPICS PRE DE DELIVERY...
Page 439 SHIVER 900 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...
Page 440 SHIVER 900 Pre-delivery - 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.
Page 441 SHIVER 900 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...
Page 442 ABS: 191, 356, 364 Accessories: Air filter: 71 Air temperature sensor: 148, 180 Battery: 119, 131 Brake: 370–372, 374, 375, 377 Brake calliper: 370, 371 Brake disc: 372, 374 Brake pads: 375, 377 Bulbs: CAN line: 191 Chain: 13, 245–248, 252, 331 Chain tensioner: 245–248 Clutch: 176, 221, 223, 225, 228–231, 385–387 Coil: 161...
Page 443 Gearbox selector: 213 Handlebar: 290 Head cover: 236, 247, 261 Headlight: 314, 402 Identification: 11 Instrument panel: 180 Intake pressure sensor: 141 Keys: 117 License plate holder: 405, 436 Magneto flywheel: 217, 247, 266 Maintenance: 8, 65 Mudguard: 321, 427 Oil filter: 70 Oil pressure sensor: 173 Radiator: 198, 391, 396...
Page 444 Use: 288, 364 Water pump: 393 Wiring diagram: 111...

APRILIA SHIVER 900 Service Station Manual

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Summary of Contents for APRILIA SHIVER 900

Page 23: Table Of Contents

Page 36: M10X1.25

Page 37: Nm (18.44 Lb Ft)

Page 39: Description Type Quantity

Page 40: Torque Notes

Page 43: Nm (18.44 Lb Ft)

Page 51: Nm (22.13 Lb Ft)

Table of Contents