APRILIA DORSODURO 1200 ABS - ATC Manuals

APRILIA DORSODURO 1200 ABS - ATC Manuals

Manuals and User Guides for APRILIA DORSODURO 1200 ABS - ATC. We have 1 APRILIA DORSODURO 1200 ABS - ATC manual available for free PDF download: Service Station Manual

APRILIA DORSODURO 1200 ABS - ATC Service Station Manual

APRILIA DORSODURO 1200 ABS - ATC Service Station Manual (409 pages)

Brand: APRILIA | Category: Motorcycle | Size: 15.23 MB

Table of Contents

Index of Topics
5
Characteristics
8
Rules
8
Safety Rules
8
Maintenance Rules
9
Running-In
11
Chassis Number
12
Dimensions and Mass
12
Engine Number
12
Vehicle Identification
12
Capacities
13
Engine
13
Transmission
13
Drive Chain
14
Electrical System
14
Frame and Suspensions
14
Brakes
15
Wheels and Tyres
15
Chassis
16
Front Side
16
Supply
16
Tightening Torques
16
Oil Cooling Radiator
17
Front Fork
18
Steering
18
Instrument Panel
19
Front Mudguard
20
Handlebar
20
Clutch Pump
21
Front Brake Pump
22
Headlamp
23
Front Bodywork
24
Front Wheel
25
Central Part
26
Description
26
- Front Brake
  26
- Front Chassis
  26
M8X20
26
- Nm (59 Lbf Ft)
  26
  - Centre Frame
    27
  - Footrests
    28
  - Stand Assembly
    28
  - Fuel Tank
    29
Loctite 518
29
- Air Filter Box
  30
- Fuel Pump
  30
- Locks
  33
- Saddle Mounting
  34
- Throttle Body
  34
- Swingarm
  35
- Rear Suspension
  36
- Exhaust System
  37
- Rear Wheel
  37
- Rear Brake
  38
- Tail Light
  39
- Rear Bodywork
  40
- ABS System
  42
- Head
  43
- Head Cover
  43
- Cylinder
  44
- Timing System
  45
- Crankshaft
  46
- Oil Pump
  47
- Gear Selector
  48
- Clutch Cover
  49
- Clutch
  50
- Water Pump
  50
- Ignition
  51
- Crankcase
  52
- Assembly Clearances
  53
- Crankcase - Crankshaft - Connecting Rod
  53
- Cylinder - Piston Assy
  53
- Overhaul Data
  53
- Crankcase Classes
  54
- Internal Marking on Second Generation Crankcases
  54
- Crankshaft Classes
  55
- Main Bushings
  55
- Bushings
  57
- Connecting Rods
  57
- Shaft Category
  57
- Recommended Products Chart
  58
- Special Tools
  60
- Maintenance Chart
  67
- Routine Maintenance Table
  67
- Front Spark Plug
  68
- Rear Spark Plug
  69
- Check
  70
- Engine Oil
  70
- Replacement
  71
- Engine Oil Filter
  72
- Air Filter
  73
- Checking the Valve Clearance
  74
- Troubleshooting
  78
- RUN/STOP Switch
  81
- Check Fuel Pump
  82
- Diagnosis Instrument Connection Check
  82
- Electrical System Installation
  82
- Auxiliary Injection Relay 31 Check
  83
- Main Injection Relay 17 Check
  84
- Starter Button Check
  84
- Components Arrangement
  88
- Auxiliary Injection Relay
  89
- Light Logic Relay
  89
- Main Injection Relay
  89
- Start-Up Relay
  89
- Fan Control Relay
  90
- High Beam Lights Relay
  90
- Recovery Logic Relay
  90
- Motorcycle Division
  91
- Special Checks for the Correct Connection and Laying of Cables
  91
- Back Side
  110
- General Wiring Diagram
  114
- Checks and Inspections
  117
- Conceptual Diagrams
  117
- Connector Check Procedure
  117
- Continuity Check
  117
- Ground Conection Check
  118
- Immobiliser
  118
- System Components
  118
- Voltage Check
  118
- Instrument Panel: Errors
  119
- Dashboard
  120
- Diagnosis
  120
- Installing a New Instrument Panel
  120
- Instrument Panel Errors
  121
- Service Warning Light Reset
  123
- Start-Up System Check
  123
- Lights List
  124
- Control Unit
  125
- Fuses
  125
- Control Unit- Diagnosis
  127
- Diagnosis Instrument: Parameters ISO
  127
- Parameters
  127
- Activation
  128
- Statuses
  128
- Electrical Errors
  129
- Logic Errors
  130
- Battery
  131
- Vehicle Front Speed Sensor
  133
- Vehicle Rear Speed Sensor
  134
- Engine Rpm Sensor
  136
- Engine Speed Sensor
  136
- Throttle Grip Position Sensor
  138
- Twistgrip Position Sensor
  138
- Adjustable Parameters
  143
- Intake Pressure Sensor
  144
- Engine Temperature Sensor
  148
- Air Temperature Sensor
  151
- Lambda Sensor
  152
- Injector
  156
- Coil
  160
- Front Central Coil
  161
- Front Side Coil
  161
- Rear Central Coil
  161
- Rear Side Coil
  161
- Engine Oil Pressure Sensor
  175
- Neutral Sensor
  176
- Clutch Lever Sensor
  178
- Side Stand Sensor
  179
- Bank Angle Sensor
  180
- Electric Fan Circuit
  181
- Connectors
  183
- Ecu
  184
- Can Line
  189
- Can Protocol
  189
- Can System Advantages
  189
- Engine from Vehicle
  193
- Vehicle Preparation
  195
- Removing the Engine from the Vehicle
  201
- Installing the Engine to the Vehicle
  206
- Diagram
  210
- Gearbox
  210
- Gearbox Shafts Diagram
  211
- Disassembling the Gearbox
  212
- Removing the Gear Selector
  215
- Checking the Gear Selector
  217
- Pawl
  217
- Reassembling the Gear Selector
  217
- Selector Spring
  217
- Gearbox Selector Shaft
  218
- Starter Motor
  218
- Removing the Starter Motor
  219
- Generator Side
  220
- Removing the Flywheel Cover
  220
- Removing the Flywheel Cover Components
  221
- Magneto Flywheel Removal
  222
- Freewheel Removal
  223
- Installing the Flywheel
  224
- Clutch Side
  226
- Removing the Clutch Cover
  227
- Disassembling the Clutch
  229
- Checking the Clutch Plates
  232
- Checking the Clutch Housing
  233
- Mushroom Valve Check
  233
- Checking the Clutch Hub
  234
- Checking the Pusher Plate
  234
- Main Driven Gear Check
  234
- Assembling the Clutch
  235
- Checking the Springs
  235
- Clutch-Side Cover Oil Seal Installation
  238
- Installing the Clutch Cover
  238
- Heads
  239
- Head Cover Removal
  240
- Front Head
  241
- Head Cover Fitting
  241
- Removing Camshafts
  241
- Camshaft Lobes
  242
- Camshaft Toothed Wheel Check
  242
- Inspecting Camshafts
  242
- Installing Camshafts
  243
- Front Head Removal
  244
- Front Head Check
  247
- Rear Head
  247
- Rear Head Removal
  250
- Rear Head Check
  254
- Valve Removal
  254
- Valve Check
  256
- Valve Stem Deviation
  256
- Spring Check
  257
- Timing
  258
- Cam Timing
  259
- Installing the Chain Tensioner
  259
- Cylinder-Piston Assembly
  262
- Removing the Cylinder
  262
- Disassembling the Piston
  263
- Checking the Cylinder
  265
- Checking the Piston
  265
- Piston Ring End Gap
  266
- Piston Ring Side Clearance
  266
- Piston Rings
  266
- Cylinder-Piston Coupling
  267
- Selecting the Base Gasket
  269
- Base Gasket
  270
- Crankcase - Crankshaft
  271
- Splitting the Crankcase Halves
  272
- Removing the Crankshaft
  275
- Bearings and Oil Seal Check
  276
- Inspecting the Crankcase Halves
  276
- Oil Filter and Oil Delivery Pipe Check
  276
- Lubrication Check
  277
- Crankshaft Axial Clearance Check
  278
- Inspecting the Crankshaft Components
  278
- Removal
  278
- Assembling the Connecting Rod
  279
- Installing
  279
- Installing the Crankshaft
  279
- Refitting the Crankcase Halves
  280
- Lubrication
  284
- Power Supply
  293
- Injection
  294
- Operating Logic
  295
- Ride by Wire
  295
- Injection/Ignition Control
  296
- Marelli 7SM Electronic Control Unit
  296
- Pressure Sensors
  296
- Ride by Wire System Control
  296
- System Safety Checks
  297
- Removing the Throttle Body
  298
- Using Navigator for Injection System
  300
- Front
  302
- Removing the Front Wheel
  302
- Suspensions
  302
- Checking the Front Wheel
  304
- Front Wheel Bearings
  304
- Radial and Axial Clearances Check
  304
- Wheel Axle
  304
- Front Fork Diagram
  306
- Removing the Fork Legs
  307
- Disassembling the Fork
  308
- Checking the Components
  312
- Stem
  312
- Reassembling the Fork
  314
- Filling Oil
  318
- Adjusting Play
  319
- Steering Bearing
  319
- Steering Ring Nut
  321
- Steering Upper Plate
  322
- Assembling
  323
- Rear
  325
- Removing the Rear Wheel
  325
- Checking the Rear Wheel
  327
- Rear Wheel Axle
  328
- Rear Wheel Gaskets
  328
- Rear Wheel Rim
  328
- Removing
  329
- Shock Absorbers
  329
- Swinging Arm
  331
- Adjusting
  333
- To Check Clearance
  333
- Checking the Chain, the Pinion and the Sprocket for Wear
  334
- Cleaning and Lubrication
  335
- Stand
  335
- Exhaust
  336
- Removing the Tail Pipe
  336
- Removing the Exhaust Manifold
  338
- Engine Oil Cooler
  340
- Removing the Lambda Sensor
  340
- Abs
  343
- Braking System
  343
- Interventions Rules
  343
- ABS ECU Control Unit Pin Configuration
  344
- Foreword
  345
- Operating Diagram
  346
- ABS Operation
  347
- General Specifications
  347
- ABS System Description
  348
- ABS Enable/Disable
  349
- Riding with an Active ABS System
  349
- Guide to Diagnosis
  350
- ABS Faults - Guide to the Diagnosis
  351
- Abs Screen Pages
  352
- ECU INFO Screen Page
  352
- Using Navigator for the Abs
  352
- PARAMETERS Screen Page
  353
- ACTIVATION Screen Page
  354
- ERRORS Screen Page
  355
- SETTINGS Screen Page
  356
- Modulator Removal
  357
- Rear Brake Calliper
  358
- Front Brake Calliper
  359
- Front Brake Pads
  359
- Bleeding the Braking System
  360
- Rear Brake Pads
  360
- Bleed System after Brake Pump Replacement
  361
- Preliminary Operations
  361
- Regular Bleeding System
  361
- Brake Bleeding after ABS Control Unit Replacement
  362
- Brake Bleeding after Calliper Replacement
  363
- Braking System Bleeding
  363
- Bleeding System with Navigator
  364
- Brake Fluid Replacement
  364
- Changing the Brake Fluid
  364
- Purging Process to Change the Braking System Fluid
  364
- Clutch System
  367
- Circuit Diagram
  369
- Cooling System
  369
- Electric Fan
  369
- Coolant Replacement
  370
- Cover Removal
  372
- Pump Rotor Removal
  372
- Complete H20 Pump Removal
  373
- Removing the Radiator
  373
- Thermostatic Valve
  375
- Headlight Assy.
  382
- Disassembling the Lock
  384
- Taillight Assy.
  385
- Footrest
  387
- Right Footrest
  387
- Left Footrest
  388
- Side Body Panels
  388
- License Plate Holder
  389
- Air Box
  390
- Instrument Cluster Support
  396
- Tail Guard
  397
- Aesthetic Inspection
  400
- Pre-Delivery
  400
- Tightening Torques Inspection
  400
- Levels Check
  401
- Road Test
  401
- Functional Inspection
  402
- Specific Operations for the Vehicle
  402
- Static Test
  402
- Index
  405

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