Page 1 Rev. 1.10 11-2009...
Page 3 BIMOTA DB7 WORKSHOP MANUAL 2008 BIMOTA SPA All rights reserved The reproduction, in whole or part, of the topics covered in this publication, is forbidden: all rights are reserved to Bimota to which will require (written) authorization specifying the reasons. Bimota...
Page 4 MANUAL PURPOSE – WARNINGS This manual has been written by Bimota SpA primarily intended for use by dealers Bimota and their skilled mechanics. Describes the service procedures for maintenance, repair and replacement of original parts of the motorcycle in question.
Page 5 USE OF THE MANUAL This manual is an easy guide for technicians. All the procedures indicated in the manual are illustrated in a detailed way and regards the operations of disassembly, assembly, inspection and repair. 1) The manual is divided in chapters. The name and the relative number, placed in a frame on the right upper corner of each page, indicating the current chapter.
Page 6 INDEX GENERAL INFORMATIONS TECHNICAL SPECIFICATIONS USE AND MAINTENANCE BODYWORK CONTROLS AND DEVICES WHEELS-BRAKES-SUSPENSIONS FRAME EXHAUST - INTAKE...
Page 7 INJECTION - IGNITION ELECTRICAL SYSTEM...
Page 8: Table Of Contents
Table of contents MANUAL PURPOSE – WARNINGS SYMBOLS USE OF THE MANUAL INDEX CHAPTER 1 GENERAL INFORMATIONS 1.1 - IDENTIFICATION OF THE MOTORCYCLE Sub 1-2 Punching of the frame (European version) ..............Sub 1-2 Punching of the frame (United States version)..............Sub 1-2 Punching of the engine (European / united states version)..........Sub 1-3 Frame tag........................Sub 1-3 1.2 - PRODUCTS SPECIFICATIONS...
Page 9 2.2 - SIZE Sub 2-10 2.3 - LUBRICANTS AND REFUELING Sub 2-11 2.4 - TORQUE WRENCH SETTINGS Sub 2-12 Frame torque wrench settings..................Sub 2-12 Engine torque wrench settings..................Sub 2-18 2.5 - SERVICE TOOLS Sub 2-21 Specific equipment for engine..................Sub 2-21 Specific equipment for frame..................Sub 2-25 CHAPTER 3 USE AND MAINTENANCE...
Page 10 3.5 - DIAGNOSTIC INSTRUMENTS Sub 3-48 3.5.1 - Walbro diagnosis....................Sub 3-48 3.6 - Software installation.....................Sub 3-49 3.6.1 - Installation of diagnosis software Service OEM 564.........Sub 3-49 3.6.2 - USB drivers installation..................Sub 3-49 3.7 - Vehicle connection for diagnostic.................Sub 3-49 3.7.1 - Diagnostic software...................Sub 3-52 3.7.2 - Real time parameter view..................Sub 3-55 3.7.3 - Diagnosis......................Sub 3-56...
Page 11 CHAPTER 6 WHEELS – BRAKES – SUSPENSIONS 6.1 - FRONT WHEEL Sub 6-2 Front wheel dismantling....................Sub 6-3 6.2 – FRONT FORKS Sub 6-5 Forks disassembly.......................Sub 6-6 6.3 – FRONT BRAKE Sub 6-8 Front brake disassembly....................Sub 6-9 Dual discs dismantling....................Sub 6-11 6.4 –...
Page 12 7.7 - TAIL Sub 7-19 7.8 - LICENSE PLATE HOLDER Sub 7-20 CHAPTER 8 EXHAUST – INTAKE 8.1 - EXHAUST Sub 8-2 Exhaust dismantling....................Sub 8-3 8.2 - FUEL TANK Sub 8-7 Fuel tank dismantling....................Sub 8-8 Fuel tank reassembling....................Sub 8-8 Fuel pump dismantling....................Sub 8-9 Gas cap dismantling....................Sub 8-9 8.3 - THROTTLE BODY...
Page 13 CHAPTER 10 ELECTRICAL SYSTEM 10.1 - WIRING DIAGRAM Sub 10-2 Utilities wiring diagram....................Sub 10-2 Injection wiring diagram.................... Sub 10-3 10.2 - FUSE BOX Sub 10-4 10.3 - WIRING ARRANGEMENT ON MOTORCYCLE Sub 10-5 10.4 - LIGHTING DEVICES Sub 10-21 Dipped light bulb replacement................Sub 10-21 High-beam light bulb replacement................Sub 10-22 Low-beam light bulb replacement................Sub 10-22...
Page 14: Identification Of The Motorcycle Sub
GENERAL INFORMATIONS CHAPTER 1 GENERAL INFORMATIONS 1.1 - IDENTIFICATION OF THE MOTORCYCLE Sub 1-2 Punching of the frame (European version) ..............Sub 1-2 Punching of the frame (United States version)..............Sub 1-2 Punching of the engine (European / united states version)..........Sub 1-3 Frame tag........................Sub 1-3 1.2 - PRODUCTS SPECIFICATIONS Sub 1-4...
Page 15: Punching Of The Frame (European Version)
INFORMATIONS 1.1 - IDENTIFICATION OF THE MOTORCYCLE The Bimota DB7 is marked by two identification numbers, respectively for the frame and for the engine and by a plate with the data of the model. The numbers which identify the model must be mentioned when asking for spare parts.
Page 16: Punching Of The Engine (European / United States Version)
XBE X 000001 Frame tag The label with the data regarding the model is positioned on the left side of DB7. In the Europe version (1) is placed on the left aluminium plate of the frame. In the USA version (2) is placed on the left side of the frame near the steering head tube (2).
Page 17: Products Specifications
GENERAL INFORMATIONS 1.2 - PRODUCTS SPECIFICATIONS The table shows the characteristics relating to the various products used for lock, lubrication and seal. Recommended Specifications product Loctite 222 Low strength threadlocker. Medium strength threadlocker, tolerates slight oily contaminations. Loctite 243 Loctite 270 Stud lock high strength threadlocker.
Page 18: Hazardous Products / Warnings
GENERAL INFORMATIONS 1.3 - HAZARDOUS PRODUCTS / WARNINGS FUEL Always work in well-ventilated areas. Keep cigarettes, sparks and flames away from the working area, or place where the fuel is stored. The fuel is extremely flammable and, under certain conditions, can explode. Keep out of reach of children. USED MOTOR OIL The used motor oil, if repeatedly left in contact with the skin for long periods of time, may be the origin of epithelial cancers.
Page 19: Technical Specifications
TECHNICAL SPECIFICATIONS CHAPTER 2 TECHNICAL SPECIFICATIONS 2.1 -TECHNICAL DATA Sub 2-2 Colors..........................Sub 2-2 Particulars........................Sub 2-2 Engine.......................... Sub 2-2 Drive………........................Sub 2-3 Drive system ........................Sub 2-3 Timing system / valves....................Sub 2-3 Tension belts adjustment at cold…................Sub 2-4 Engine shaft........................Sub 2-4 Cylinder / piston......................Sub 2-5 Gearbox........................Sub 2-5 Cooling system......................Sub 2-6 Front wheel........................Sub 2-6...
Page 20: Particulars
TECHNICAL SPECIFICATIONS 2.1 - TECHNICAL SPECIFICATIONS Colors Code Description Additional description X 14451 Bimota red Lechler X 14446 Pearl white Lechler Particulars Reference Technical specs Dimensions Total length 2040 mm Total width 730 mm Total height 1105 mm Wheel base...
Page 21: Engine
TECHNICAL SPECIFICATIONS Engine Reference Technical specs Type 4 stroke, 90° L twin Bore 104 mm Stroke 64,7 mm Displacement 1099 cm³ Compression ratio 12,5 ± 0,5 :1 Shaft horsepower (95/1/CE) 113 kW (154 CV) / 9750 min-1 Shaft torque (95/1/CE) 118 Nm (Kgm) / 8000 min-1 Min rpm 1300 ±...
Page 22: Timing System/Valves
TECHNICAL SPECIFICATIONS Timing system/valves Reference Assembly value Check value With valves clearance 1 mm Opening 15° BTDC Intake Closing 58° ABDC Timing system diagram Opening 60° BBDC Exhaust Closing 20° ATDC Intake valve diameter 42 mm Exhaust valve diameter 34 mm Intake 11.8 mm With valves clearance 0 mm Exhaust 10.6 mm...
Page 23: Cylinder/Piston
TECHNICAL SPECIFICATIONS Cylinder/piston Reference Normal value Limit value Max. out-of-round wear 0.03 mm Max. conical shape 0.03 mm Cylinder Section A diameter 104.000 mm ÷ 104.010 mm Section B diameter 104.010 mm ÷ 104.020 mm Section C diameter 104.020 mm ÷ 104.030 mm Piston –...
Page 24: Cooling System
TECHNICAL SPECIFICATIONS Cooling system Reference Technical spec Type Liquid cooled, closed circuit type, with double fan curved radiator and mixing thermostat Coolant capacity 2.7 ± 0.5 lt Front wheel Reference Normal value Limit value Tire tread min. thickness Max wear point 2 mm Tyre pressure At cold...
Page 25: Rear Wheel
TECHNICAL SPECIFICATIONS Rear wheel Reference Normal value Limit value Tire tread min. thickness Max wear point 2 mm Tyre pressure At cold 2.3 bar Wheel pivot imperfection In 100 mm 0.2 mm Wheel rim imperfection radial 0.8 mm 2 mm axial 0.5 mm 2 mm...
Page 26: Hydraulic Brakes
Sub 2-7 TECHNICAL SPECIFICATIONS Hydraulic brakes Reference Normal value Limit value FRONT Brake disc Type Dual semi-floating holed discs Thickness 5 ± 0.1 4.5 mm (min) Slide material Steel Diameter 320 mm Braking surface 39,6 cm² Brake caliper Model BREMBO Type 34-4 pot Pot diameter...
Page 27: Injection System / Ignition
TECHNICAL SPECIFICATIONS Injection system – ignition Reference Technical spec Ignition Type Electronic inductive spark Spark plugs Model NGK (MAR10A-J) Starting Type Starter motor Fuel system Reference Technical spec Lead-free fuel 95 - 98 RON Throttle body Ø 60 mm Injectors per cylinder Holes per injector Feeding system Model...
Page 28: Size Sub
TECHNICAL SPECIFICATIONS 2.2 - SIZE Sub 2-10...
Page 29: Lubricants And Refueling
TECHNICAL SPECIFICATIONS 2.3 - LUBRICANTS AND REFUELING Refueling Type Quantity Fuel tank, reserve included Lead-free fuel ,with octane number 18,0 dm³ (litres) – reserve included to the origin of at least 95 Lubricant circuit Lubricant circuit 3,7 dm³ (litres) Brakes (front-rear) and clutch Brake DOT 4 circuit Front fork...
Page 30: Torque Settings
TECHNICAL SPECIFICATIONS 2.2 - TORQUE SETTINGS Frame torque settings Description Size (mm) Torque (Nm) Notes GENERAL Screw M4 Screw M5 Screw M6 10-12 Screw M8 22-25 Screw M10 Screw M12 85-90 SIDE STAND Side stand rotation screw Loctite 243 Side stand plate to carter locking screw M10x25x1,5 Loctite 128455 Locking screw of the small plate side stand switch holder...
Page 31 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes ELECTRICAL SYSTEM Control Unit locking screw M4x20 Loctite 243 Screw + locking nut of the fuse box to the frame M5x10 Screw + horn locking nut M6x16 Voltage regulator locking screw M6x20 Lambda sensor M18x1,5 Battery box locking screw...
Page 32 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes SWING ARM Eccentric clamp fixing screw M8x22 Loctite 243 Loctite 243 Swing arm plates fixing screw M10x1,25 (grease under head) Fixing screw of the upper and lower chain slider M4x8 Loctite 243 Fixing screw of the side chain slider M4x12 Loctite 243...
Page 33 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes Fixing screw of the master cylinder clamp to semi-handlebar M&x1x25 Throttle control covers fixing screw M6x1x20 Fixing screw of the oil tank plate holder to clutch pump M6x10 Loctite 243 Clutch small piston fixing screw M6x16 FRAME Fixing screw of aluminium plates to frame...
Page 34 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes OIL RADIATOR Oil radiator nipple on carter M14x1,5 Loctite 243 Oil radiator hose union on carter nipple M16x1,5 Lub with motor oil Oil radiator hose union on radiator nipple M16x1,5 Lub with motor oil Fixing screw of the radiator stirrup to head M6x12 Screw + fixing nut of the radiator to stirrup...
Page 35 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes SEAT Rider's seat fixing screw M5x12/16 Rear small seat fixing screw M5x12 FRONT FENDER Fixing screw of front fender to holder M5x10 Fixing screw of fender holder small plate M5x16 BODYWORK Fixing screw of plexiglass to upper fairing M4x16 3/man Fixing nut of upper fairing and rear view mirrors to holder...
Page 36: Engine Torque Settings
TECHNICAL SPECIFICATIONS Engine torque settings Description Size (mm) Torque (Nm) Notes Idler and tensioner pulley mounting studs M20x1 LOCK 2 or TB1324 Camshaft pulley retaining nut M17x1 GREASE A Rocker arm shaft covers M12x1,25 LOCK 2 or TB1324 LOCK 4 – Restrain the insert Coolant temperature sensor on coolant outlet union M12x1,5 when tightening...
Page 37 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes Gear stop lever bolt M8x1,25 LOCK 2 or TB1324 Blow-by valve bolt M6x1 Chain side secondary bearing retaining bolt M6x1 LOCK 2 Clutch side primary bearing retaining bolt M6x1 LOCK 2 or TB1324 Crankcase screw –...
Page 38 TECHNICAL SPECIFICATIONS Description Size (mm) Torque (Nm) Notes Selector claw bolt M6x1 LOCK 2 or TB1324 Idler and tensioner pulley bolts M20x1 LOCK 2 or TB1324 Camshaft pulley retaining nut M15x1 GREASE A Timing belt driveshaft gear nut M14x1 GREASE A Idler and tensioner pulley nut M8x1,25 GREASE A...
Page 39: Service Tools
TECHNICAL SPECIFICATIONS 2.5 – SERVICE TOOLS Specific equipment for engine Part no. Description 88713.2011 Tool to lock crankshaft at Top Dead Centre 88713.2676 Wrench for tightening cylinder head nuts Stand for cylinder head assembly 88713.2103 88765.1523 Timing check tool 88713.1821 Wrench for tightening timing belt tensioner pulley shafts 88713.2861 Camshaft oil seal installer...
Page 40 TECHNICAL SPECIFICATIONS Part no. Description 88713.2069 Rocker spring tensioning kit 88765.1524 Timing belt pulley timing tools 88765.1518 Valve lift gauge 88713.2878 Fork-type feeler gauge 0.1 mm, 0.2 mm, 0.3 mm 88713.2874 Alternator holding tool for tightening nut Tool for installing O-rings on crankcase studs 88713.1920 Plate for gear selector fork positioning 88713.2827...
Page 41 TECHNICAL SPECIFICATIONS Part no. Description 88713.2133 Clutch centre wrench Clutch cover assembly tool 88700.5665 88713.1010 Exhaust gases pick-up connector Tool for tightening timing belt driveshaft pulley 88713.1805 88765.1188 Top Dead Centre test gauge 88713.2102 Wrench for tightening primary sprocket ringnut Water pump front seal installer 88713.0869 88713.0870...
Page 42 TECHNICAL SPECIFICATIONS Part no. Description Sparkplug wrench 88713.2877 88713.2842 Inlet/exhaust valve guide installer 88713.2846 Exhaust valve seat installer 88713.2847 Inlet valve seat installer 88713.2870 Connecting rod guide tool 88713.2834 Punch and sleeve for installing camshaft circlip 88713.2832 Timing belt tensioner pulley wrench Sub 2-24...
Page 43: Specific Equipment For Frame
TECHNICAL SPECIFICATIONS Specific equipment for frame Part no. Description 507097010 Special tool for swingarm eccentric adjustement 507097100 Special tool for steering head nut tightening Sub 2-25...
Page 44: Use And Maintenance
MAINTENANCE CHAPTER 3 USE AND MAINTENANCE 3.1 - PRELIMINARY CHECKS Sub 3-3 Running-in period......................Sub 3-3 Check-up before run.....................Sub 3-4 3.2 - STARTING - ENGINE WARM UP Sub 3-5 3.3 - TABLE OF PERIODIC MAINTENANCE Sub 3-6 Dealer operations......................Sub 3-6 Customer operations....................Sub 3-7 3.4 - MAINTENANCE OPERATIONS Sub 3-8...
Page 45: Vehicle Connection For Diagnostic.........................................................................sub
MAINTENANCE 3.7 - Vehicle connection for diagnostic.................Sub 3-49 3.7.1 - Diagnostic software...................Sub 3-52 3.7.2 - Real time parameter view..................Sub 3-55 3.7.3 - Diagnosis......................Sub 3-56 3.7.4 - End of line......................Sub 3-57 3.7.5 - Hour meter......................Sub 3-58 3.8 - Installation of Windownloader OEM 2000 program (use for ECUC).....Sub 3-58 3.8.1 - Calibration update program................Sub 3-59 3.9 - Installation of EcugLoader-1000 program (use for ECUG)........Sub 3-61 3.9.1 - Calibration update program................Sub 3-61...
Page 46: Running-In Period
Running in period During the running in period carefully follow the maintenance program as recommended in the manufacturer's warranty manual. The non compliance of these rules relieve Bimota from any liability for any damage to the engine and its duration.
Page 47: Check-Up Before Run
MAINTENANCE Check-up before run Failure of the inspections before leaving can cause damage to the vehicle and result in serious injury to the rider. Before traveling check the following points: - control the level of fuel in the tank. - control the tension and lubrication of the drive chain. - check the right functioning of all the service lights.
Page 48: Starting - Engine Warm Up
MAINTENANCE 3.2 – STARTING - ENGINE WARM UP This vehicle is equipped with automatic choke (stepper motor). These function allows you to automate the process of engine warm up. Move the starting switch (1) to the ON position (2). Verify that a green light N (gear in neutral) and red (oil pressure) on the dashboard are on. Allow the engine to start spontaneously without operating the twist throttle.
Page 49: Table Of Periodic Maintenance
MAINTENANCE 3.3 - TABLE OF PERIODIC MAINTENANCE Operations to be performed by the dealer Operations list with kind of work (kilometers, miles or expiration time) Km x1000 Mi x1000 22,5 37,5 Months Engine oil replacement Engine oil filter replacement Engine oil suction filter cleaning Engine oil pressure check-up Valve clearance check-up and/or adjustment (1) Tension check-up of timing system belts (1)
Page 50 MAINTENANCE Km x1000 Mi x1000 22,5 37,5 Months Front fork oil replacement Leak check of fork oil and rear shock Sprocket fixing check General lubrication and greasing Battery charging and check-up Motorcycle street test General cleaning * Perform the maintenance at the first expiration (km, mi , or months) (1) Work to carry out only at the km/Mi expiration reaching.
Page 51: Maintenance Operations
MAINTENANCE 3.4 - MAINTENANCE OPERATIONS Engine oil level control The engine oil level visible by the inspection window (1) positioned on the right side of the oil sump. Wait a few minutes after having switched off the engine in order to stabilize the level. Check the level with the vehicle in upright position and with warm engine (but switched off).
Page 52 MAINTENANCE Engine oil and filter cartridge replacement NOTES This operation must be performed at warm engine (engine off) because the oil in these conditions is more fluid and its drainage is faster and complete. Remove fairings. Remove the drain cap (3) with seal (A) of the engine oil sump and drain the exhausted oil. CAUTION Not waste exhausted oil and / or filter cartridges in the environment.
Page 53 MAINTENANCE Every two oil changes is advisable to clean the suction oil filter net. Unscrew the four screws (5) of the outer cap (6) and remove the cap. Be careful to the gasket (7). Remove the filter element (8), check the OR seals (9) and replace them if needed. Sub 3-10...
Page 54 MAINTENANCE Proceed to its cleaning with compressed air and fuel being careful not to tear the net. Replace the filter net (8), the seal (7) and OR seal (9) on the cap (6). Remove the load cap (2) and fill with the prescribed oil to up to the mark which identify the MAX level on the inspection window.
Page 55: Valves Clearance Check-Up
MAINTENANCE Valves clearance check-up Operate as described under "valves clearance check-up and adjustment" subchapter. With the valve in the resting position and using a thickness gauge inserted between the skid of the rocker arm (A) and the lower side of the cam (B), verify that the clearance is like the one prescribed.
Page 56: Valves Clearance Adjustment
MAINTENANCE With the valve in the resting position and using a thickness gauge inserted between the skid of the closing rocker arm (C) and the upper side of the cam (D), verify that the clearance is like the one prescribed. Closening rocker arm Intake working...
Page 57: Liquid Cooling Level Control
MAINTENANCE Liquid cooling level control Check coolant level in the expansion reservoir on the right side of the vehicle, at the intervals indicated in the "periodic service tab" . The proper level should be between the MAX and MIN marks on the reservoir itself. If the level is low it is necessary to provide for the topping;...
Page 58: Liquid Cooling Replacement
MAINTENANCE Liquid cooling replacement CAUTION This operation must be done to engine cold. If the operation is performed with the engine warm, it can cause losses of coolant or hot steam which may cause severe burns. Remove the right fairing and unscrew the cap (1) of the expansion tanks. Place a container under the engine and put the vehicle on the side stand.
Page 59: Air Filters Replacement And Cleaning
MAINTENANCE Air filter replacement and cleaning Intake air filter The air filter must be replaced at the intervals described on the "periodic service tab" . 1)Filter box 2)Air Filter 3)Rubber gasket filter support 4)Support sleeve air box 5)Screw 6)Sleeve 7)Air intake pipe to access to the air filter: remove the left side fairing (8) as described in the “fairings”...
Page 60 MAINTENANCE Unscrew and remove the 3 fixing screws (5), and release the sleeve holder (4) and sleeve (6) from the filter box (1) being careful to damage not the rubber gasket. The intake manifold (7) must not be removed from the sleeve (6). Remove the air filter (2) from the filter box (1).
Page 61 MAINTENANCE Air filter of the timing system cover Check the air filter (5) in the horizontal belt timing system cover (6): to remove it, remove the cover and unscrew the screws (7). When you‘ve checked, you can reassembly the filter (5) by tightening the screws (7) and reassembly the horizontal belt timing system cover (6).
Page 62: Front Brake Fluid Replacement
MAINTENANCE Front brake fluid replacement Remove the cover (1) with membrane from the brake fluid reservoir unscrewing the screws (2). To suck the fluid out from the reservoir. Enter the new oil inside the reservoir up to the mark MAX. Operate the lever two or three times so as to allow the circuit to go under pressure.
Page 63: Rear Brake Fluid Replacement
MAINTENANCE CAUTION During the filling operation keep the oil level above the MIN mark to prevent the formation of air bubbles inside the circuit. Drain the oil from the draining valve (3) until the leakage of liquid of different colour. Screw the draining valve (3) and restore the proper level of oil tank .
Page 64 MAINTENANCE Press the pedal two or three times so as to allow the circuit to go under pressure. Keep the pedal pressed. Connect a transparent hose to the draining valve (5) then dip the other end in a container placed in the floor .
Page 65: Brake Circuit Bleeding
MAINTENANCE Brake circuit bleeding CAUTION The fluid used in the brake circuit, apart damaging the paint, is very damaging in contact of eyes and skin; wash thoroughly with running water the interested parts in the event of accidental contact. Remove the cover (1) with membrane from the brake fluid reservoir (2) unscrewing the screws (3). Unscrew the cover (4) of the rear brake fluid reservoir (5).
Page 66 MAINTENANCE Connect to draining valve (3) or (5) of the caliper a bleeding device, commonly available in trade. Loosen the draining valve (3) or (5) and pump with the bleeding device until no more fluid exit from the circuit. NOTES When using a brake bleeding device, follow the manufacturer’s instructions.
Page 67: Brake Circuit Filling
MAINTENANCE Brake circuit filling CAUTION The fluid used in the brake circuit, apart damaging the paint, is very damaging in contact of eyes and skin; wash thoroughly with running water, the interested parts in the event of accidental contact. Fill the reservoirs (1) and (2) with prescribed oil taken from an intact container. IMPORTANT Keep always at level the oil of the circuit during the whole operation and leave the end of the transparent hose always dipped in the drained liquid.
Page 68 MAINTENANCE Move several times the lever or the brake pedal to fill the circuit and bleed the air. Connect to the bleeding valve (3) or (5) the brake bleeding device. NOTES When using a brake bleeding device, follow the manufacturer’s instructions. Pump with the bleeding device and loosen the bleed valve (3) or (5) checking always that the level does not fall below the MIN.
Page 69 MAINTENANCE Open the draining valve (3) or (5) of ¼ of turn and operate the lever or the brake pedal until fluid begins to exit from the valve then close the draining valve. Pull completely the lever or pedal then loosen the bleeding valve at least of ¼...
Page 70: Clutch Liquid Replacement
MAINTENANCE lutch liquid replacement CAUTION The fluid used in the clutch system, apart damaging the paint, is very damaging in contact of eyes and skin; wash thoroughly with running water, the interested parts in the event of accidental contact. Unscrew the cover (1) with membrane from the system clutch reservoir. Suck the oil inside the reservoir.
Page 71: Clutch Liquid Draining
MAINTENANCE CAUTION During the filling operation always maintain the oil liquid above the MIN to prevent formation air bubbles in the circuit. Drain the oil from bleeding valve (2) until the leakage of liquid of different colour. Re-screw the bleeding valve (2) and tighten to the recommended torque wrench and restore the proper oil level into the reservoir.
Page 72 MAINTENANCE Move the clutch lever up to the complete leakage of the fluid. To empty completely the circuit it is advisable to remove the clutch piston assembly (4) unscrewing the three fixing screws (3). Take off the clutch piston assembly (4) being careful to the OR gasket (5) positioned inside. Sub 3-29...
Page 73: Clutch Liquid Filling
MAINTENANCE Push on the small internal piston to make leak all the fluid content inside the cap. Proceed the reassembly of the piston assembly tightening the screws (3) to the prescribed torque. Tighten the bleeding valve to the prescribed torque. Clutch liquid filling CAUTION The fluid used in the clutch system, apart damaging the paint, is very damaging in contact of eyes...
Page 74 MAINTENANCE Move several times the clutch lever to fill the circuit and bleeding the air. Connect the bleeding device to the bleeding valve (2). NOTES When using a bleeding device, follow the manufacturer’s instructions. Pump with the bleeding device and loosen the drain valve (2) checking always that the level does not fall below the MIN.
Page 75: Steering Stem Bearings Clearance Adjustment
MAINTENANCE Repeat this last action until fluid free of air bubbles will come out from the transparent hose. Tight the bleeding valve (2) to the prescribed torque and install the protection cap. Bring the fluid at about 3 mm above the MIN reference level of the reservoir. Re-screw the cap (1) with the membrane.
Page 76 Unscrew and remove the screw (3) from the steering head. Now pull up the steering head (4). Tighten with the appropriate special tool Bimota (cod 507097100) the ring nut of the pivot steering (5) to get the correct bearings clearance.
Page 77: Chain Tension Adjustment
MAINTENANCE Tighten the screw (3), which fix the steering head to the steering pivot, to prescribed torque. Chain tension adjustment Move the motorcycle to find the position where the upper part of the chain is more tight. Place the motorcycle on its side stand with the gearbox in neutral (best if you have a central stand). Place the ruler in the position indicated by the arrow (see the sticker on the swing arm).
Page 78 MAINTENANCE To adjust tension proceed in the following way: Loosen the wheel axle (1). Turn both the right and left adjustment screws (2) of an equal number of turns to obtain the proper slack for the chain. Turn the adjustment screws counter clockwise to tighten the chain. Turn the adjustment screws clockwise and push the rear wheel forward to get more slack.
Page 79: Brake Pads Wear Check-Up And Replacement
MAINTENANCE Brake pads wear check-up and replacement CAUTION The fluid used in the brake circuit, apart damaging the paint, is very damaging in contact of eyes and skin; wash thoroughly with running water, the interested parts in the event of accidental contact.
Page 80: Filling Up Brake Fluid
MAINTENANCE Filling up brake fluid Turn the half handlebars to level the reservoir. Remove the tank cap by unscrewing the two screws (1) Remove the inner membrane from the reservoir and top up with the prescribed fluid to the maximum level. Reassemble the removed components.
Page 81 MAINTENANCE Proceed to pads replacement in the following way: Remove the safety split pins (1) (on the caliper inner side) from pads pin (2). Push the small pistons of the caliper completely inside their own seat, opening the used pads. Slip off the pads pin (2).
Page 82: Throttle Cable Regulation
MAINTENANCE Throttle cable regulation The throttle grip in all steering positions must have a play that measured on the end of the grip should be of 2 4mm. ÷ If adjustment is necessary, act on the regulator (1) and (2) placed in correspondence to the right side of the steering tube.
Page 83: Clutch Lever And Front Brake Lever Adjustment
MAINTENANCE Clutch lever and front brake lever adjustment The clutch lever and the front brake lever have a knob (2) for the adjustment of the distance between the lever itself and the half-handlebar grip. The levers distance is regulated by 10 knob clicks (2). Rotating clockwise the lever moves away from the handle grip.
Page 84: Rear Brake Pedal And Shift Lever Position Adjustment
MAINTENANCE Rear brake pedal and shift lever position adjustment In accordance to any pilot drive requirement it is possible to adjust the position of the shift pedal and rear brake pedal respect to the footpegs. To modify the position of the shift control pedal proceed as follows: Lock the shaft (1) and loosen the lock nuts (2) and (3).
Page 85: Fork Adjustment
MAINTENANCE Fork adjustment The motorcycle fork is adjustable in preload, rebound and compression. The adjustment is done by external screw adjusters: 1) to modify the internal springs preload; 2) to modify the hydraulic brake in rebound; 3) to modify the hydraulic brake in compression. Place motorcycle upright, in stable way.
Page 86 MAINTENANCE Rebound hydraulic brake: Rotate with a screwdriver the adjuster (2), placed on the top of each fork stem, to adjust the rebound hydraulic brake. SOFT: rotate the adjuster counter clockwise, towards to SOFT position, in case of light weights, and driving on normal and plain roads.
Page 87: Rear Shock Adjustment
MAINTENANCE Rear shock adjustment The rear shock absorber has external adjusters which enable to adequate the bike set up in accordance to load and driving requirements. It is adjustable in compression (high and low speed), in the spring preload and in rebound (high and low speed).
Page 88 MAINTENANCE Rebound hydraulic brake: The rebound adjuster (2) is placed in the upper part of the shock absorber and is adjustable both for low and high speeds. To adjust the rebound to high speed use a 15mm wrench while for low speed a 4mm hexagonal key.
Page 89: Steering Damper
MAINTENANCE Steering damper The steering damper (1) is under the dashboard support and it is fixed to the frame and to the forks. Its action contributes to make steering more precise and more stable, improving the driveability of motorbike specially in extreme conditions. Rotating clockwise the damper control (2) the steering will be harder and rotating it counter clockwise it will be softer.
Page 90: Rear Height Regulation / Bike Trim
To determinate the setting acts as follow: Place motorcycle upright on a plain surface. Loosen the screws (2) that tighten the clamps on cams. Rotate the cams (1) using the Bimota special tool cod. 507097010. Tighten the screws (2) (tightening torque: 22Nm). CAUTION The bike setup modification is a very delicate operation and can be dangerous if carried out with incompetence.
Page 91: Diagnostic Instruments
3.5 - DIAGNOSTIC ISTRUMENTS 3.5.1 - Walbro diagnosis Installation of Service Walbro OEM56, Windownloader OEM 2000 and ECUGLoader softwares for the diagnostic of Walbro ECUG/ECUG equipped Bimota models. Comments, critics or suggestions must be envoy at: BIMOTA S.p.A. Via Giaccaglia, 38...
Page 92: Software Installation
3.6.2. - USB drivers installation The USB drivers are in the “drvUsb” directory. When connecting the interface cable (cod. Bimota 506290140) Window will automatically provide to the installation of the new hardware: on this occasion indicate the position of drivers USB contained in the above mentioned CD.
Page 93 MAINTENANCE Bimota DB5 : the diagnosis connector (1) is placed on the left side of the upper fairing, near to the mirror holder arm. Bimota DB6 : the diagnosis connector (2) is placed behind the right triangular cover. Sub 3-50...
Page 94 MAINTENANCE Bimota Tesi 3D: the diagnosis connector (3) is placed on the left side of the headlight. BIMOTA DB7: the diagnosis connector (4) is placed behind the right fairing. Sub 3-51...
Page 95: Diagnostic Software
MAINTENANCE 3.7.1 - Diagnostic software NOTES To carry out the diagnosis of the parameter of the control unit it is necessary to: - Make sure that the main switch key is on OFF position. - Connect the diagnosis cable cod 506290140 to the diagnosis connector. Launch the diagnostic program named “Service OEM 564”.
Page 96 MAINTENANCE Click OK It will appear the following screen: Select the English.WCL file. It will appear the following screen: Sub 3-53...
Page 97 MAINTENANCE Enter the menu Open in top left and select device. Once selected device, it will appear the following screen, select file “CNS_G1BIM_03$US_NEW.dcn” for the control unit ECUG, or file CNS_C9B_04$US_NEW_SERVICE.dcn for ECUC control unit. It will appear the standard working screen called “console”: At this point it is necessary to select the COM port to use for the connection between the PC and the control unit (set as default on COM1).
Page 98: Real Time Parameter View
MAINTENANCE 3.7.2 - Real time parameters view To display the parameters on real time it is necessary to “start the console” by clicking directly on the “hammer” icon or selecting start from the console menu. This operation must be carried out with key ON and diagnosis cable connected to PC. From the console menu it is always possible to know the type of control unit connected.
Page 99: Diagnosis
MAINTENANCE 3.7.3 - Diagnosis To enter to the diagnosis it is sufficient to select menu ”Diagnostic”. This operation must be carried with key ON and diagnosis cable connected to PC. You can read the errors stored by the control unit pushing the button READ and cancel them with button RESET.
Page 100: End Of Line
MAINTENANCE 3.7.4 - End of line The menu End of Line is dedicated to the following operations: - reset TPS - setting of idle CO value of vertical and horizontal cylinder - offset the injection quoted plans. This operation must be carried out with key ON and diagnosis cable connected to PC. 1.
Page 101: Installation Of Windownloader Oem 2000 Program (Use For Ecuc)
MAINTENANCE 3.7.5 - Hour counter Entering in the menu Hours counter is possible to know how many working hours has the control unit. This operation must be carried out with key ON and diagnosis cable connected to PC. NOTES To switch from a function to another (for example from hour counter to diagnostic) is necessary to close the application and then open the subsequent.
Page 102: Calibration Update Program
MAINTENANCE 3.8.1 - Calibration update program NOTES To carry out the control unit programming is necessary: 1. Make sure that ignition key is on OFF position. 2. Connect diagnosis cable cod. 506290140 to diagnosis connector 3. Insert the two-way “bridge connector” on the corresponding diagnosis cable cod.506290140.
Page 103 MAINTENANCE The first operation is to select the communication port to use for the connection between the PC and the control unit (set by default on COM1). From menu file or from button ”sheet” is possible to select the version of the calibration to ”download”...
Page 104: Installation Of Ecugloader-1000 Program (Use For Ecug)
MAINTENANCE 3.9. - Installation of EcugLoader-1000 program (use for ECUG) For the installation from CD: 1. Insert the CD in the player 2. Copy the content of file ECUGLOADER-1000 on your PC where is more suitable for you. 3.9.1 - Calibration update program NOTES To carry out the control unit programming is necessary: −...
Page 105 MAINTENANCE It will appear the following screen: The first operation is to select the communication port to use for the connection between the PC and the control unit (set default on COM1). From menu file or from button ”sheet” is possible to select the version of the calibration to ”download”...
Page 106 MAINTENANCE After having selected the file you can start the download of the calibration pressing the button “red arrow” or selecting the download option from menu file. Wait about 3 minutes for download completion after which will appear the message “download successfully completed”...
Page 107: Bodywork
BODYWORK CHAPTER 4 BODYWORK 4.1 - FRONT FAIRING AND REARVIEW MIRRORS Sub 4-2 Rearview mirrors removal…..……………….………………………………………………Sub 4-2 4.2 - FAIRING Sub 4-4 Removal of side firings and lower fairing………….………..………………………….….Sub 4-4 4.3 - FRONT MUDGUARD Sub 4-6 Front mudguard removal...………………………………………………………………….Sub 4-6 4.4 - TAIL - SEAT Sub 4-7 Tail removal…..……………………………………………………………………………….Sub 4-7...
Page 108: Windshield And Rearview Mirrors
BODYWORK 4.1 - WINDSHIELD AND REARVIEW MIRRORS Rearview mirrors removal 1) dashboard 2) front fairing support 3) fairing cover 4) front fairing 5) windshield 6) rear view mirrors rubber 7) rear view mirrors 8) nut Sub 4-2...
Page 109 BODYWORK Unscrew and remove the four screws (9) then remove the fairing cover (3). Unscrew the two nuts (8) which fix the rearview mirrors (7) and the upper fairing (4) to the support (2). Repeat the same operations on the opposite side of the bike (refer to the drawing). Front fairing removal Unscrew the three fixing screws (10) of both side fairings (11) and widen with care or remove completely to remove the front fairing.
Page 110: Fairing
BODYWORK 4.2 - FAIRING Disassembly of side fairings and lower fairing 1) frontal lower fairing 2) lower fairing 3) side fairing Sub 4-4...
Page 111 BODYWORK Unscrew the two screws (4) which fix the frontal lower fairing (1) to the side fairings (3). Unscrew the fixing screw (5) under the lower fairing (2). Slip off the frontal fairing by pulling upward as indicated by the arrow. Unscrew and slip off the fixing screws (6) to remove the side fairings (3).
Page 112 BODYWORK 4.3 - FRONT MUDGUARD Front mudguard removal Unscrew and slip off the fixing screws (1) on both side of the front mudguard. Remove the front mudguard (2). To reassemble perform the removal operation in reverse order. Sub 4-6...
Page 113: Tail - Seat
BODYWORK 4.4 - TAIL – SEAT Tail removal Unscrew the screw (1) of the exhaust silencer holder. On both side of the bike unscrew the screws (2) which tie up the tail (3) to the frame plates. Slip off the tail (3) towards the direction indicated by the arrow paying attention to disconnect the rear turn signals cable and the rear lights cable (4).
Page 114 BODYWORK Seat removal To remove the rider seat is not necessary to removal the tail. Unscrew the six screws (1) under the tail and slip off the lower cover (2). Unscrew the three screws (3) inside the tail. Remove the seat (4) upwards, as indicated by the arrow. Sub 4-8...
Page 115 BODYWORK 4.5 - LICENSE PLATE HOLDER – REAR MUDGUARD Removal of license plate holder Remove the lower cover under the tail then disconnect the six connectors (4) of turn signals / tail lights which are inside. Unscrew the four screws (1) which fix the license plate holder (2) to the tail (3). Remove the license plate holder (2).
Page 116 BODYWORK Unscrew the two screws (5) to remove the license plate holder (6). Rear mudguard removal Unscrew the three fixing screws (1) and remove the rear mudguard (2). Sub 4-10...
Page 117 BODYWORK 4.6 – PINION COVER – CHAIN GUARD Unscrew the three fixing screws (1) to remove the pinion cover (2). Unscrew the three fixing screws (3) to remove the chain guard (4). Unscrew the two fixing screws (5) to remove the lower chain protection (6). Sub 4-11...
Page 118: Controls And Devices
CONTROLS AND DEVICES CHAPTER 5 CONTROLS AND DEVICES 5.1 - THROTTLE CONTROL Sub 5-2 Throttle twistgrip removal…..……..….….………………………………………………Sub 5-3 5.2 - FRONT BRAKE CONTROL Sub 5-4 Disassembly of front brake master cylinder……………..…..……..………………….….Sub 5-5 5.2 - REAR BRAKE CONTROL Sub 5-6 Rear brake removal…..…………..………………………………………………………….Sub 5-7 5.4 - HYDRAULIC CLUTCH CONTROL Sub 5-9 Disassembly of hydraulic clutch pump…………….……..…..……..………………….….Sub 5-5...
Page 119 CONTROLS AND DEVICES 5.1 - THROTTLE CONTROL 1) grip 2) throttle 3) right switch 4) throttle cables Sub 5-2...
Page 120 CONTROLS AND DEVICES Throttle twistgrip removal Slip off slightly the protection cap (1) of the throttle cable. Unscrew the screws (2) of the throttle (3) and open the throttle control. Disconnect the throttle opening and closing cables (4) by unhooking the cable ends (5) from their seats.
Page 121 CONTROLS AND DEVICES 5.2 - FRONT BRAKE CONTROL 1) complete master cylinder 2) aluminium brake lever 3) brake lever pawl 4) microswitch lever pivot 5) brake lever regulator pivot 6) radial master cylinder 7) screw 8) microswitch 9) rubber hose 10) screw 11) brake fluid tank plate holder 12) small rubber...
Page 122 CONTROLS AND DEVICES Disassembly of front brake master cylinder CAUTION The manufacturer of the brake pump, considering the importance of this part in terms of safety, suggests not working in any way inside the pump. An overhaul not correctly done, can seriously endanger the rider safety. The replacement operation must be limited to the control lever, the oil reservoir with relative holder components and pump holder.
Page 123 CONTROLS AND DEVICES 5.2 - REAR BRAKE CONTROL 1) screw 2) washer D5 3) oil reservoir 4) rear brake reservoir spacer 5) rubber hose 6) cable ties 7) screw 8) rear master cylinder 9) rear master cylinder rod 10) nut 11) nut 12) uniball 13) eccentric cam...
Page 124 CONTROLS AND DEVICES Rear brake removal Empty the brake circuit. Remove right fairing. CAUTION The manufacturer of the brake pump, considering the importance in terms of safety of this part, suggests not working in any way inside the pump. An overhaul not correctly done can seriously endanger the rider safety. Unscrew the special screw and hydro-stop switch (27) from the pump (8) and slip off the brake hose keeping the gaskets (28).
Page 125: Frame
CONTROLS AND DEVICES To remove the rear master cylinder (8) is necessary to remove the right engine plate (28). Unscrew the screws and the nut (29) and remove the right engine plate (28). Unscrew the fixing screws (7) of the rear brake pump (8) to the right plate engine (28). Remove the oil reservoir (3) together with its hose (5) from the frame unscrewing the screw (1).
Page 126 CONTROLS AND DEVICES 5.4 - HYDRAULIC CLUTCH CONTROL 1) complete clutch pump 2) screw 3) clutch pump 4) adjustment pin 5) aluminium clutch lever 6) pawl 7) special screw 8) oil reservoir bush 9) oil reservoir holder plate 10) screw 11) bleeding cap 12) oil reservoir 13) nut M5...
Page 127 CONTROLS AND DEVICES Disassembly of hydraulic clutch pump Empty the clutch pump circuit: Unscrew the special screw (16), keeping the gaskets (17) to disconnect the clutch control hose from the master cylinder group. Unscrew the fixing screws (2) of the mounting clamp and remove the clutch pump (3) from the handlebar.
Page 128 CONTROLS AND DEVICES 5-5 – GEARCAHNGE CONTROL 1) screw 2) screw 3) gearchange lever 4) nut 5) uniball 6) nut 7) nut 8) uniball 9) screw 10) L.H. footpeg holder 11) TSPEI screw 12) TBEI screw 13) L.H. foot guard 14) gearchange pedal 15) eccentric cam pawl 16) rubber...
Page 129 CONTROLS AND DEVICES Complete gearshift pedal removal Unscrew and remove the fixing screw (19) of the gearshift lever (14) with care to the OR ring (28) and to the flanged bush (24). Unscrew the lever fixing screw (2) from the gearshift shaft. Slip off the lever (3) and the complete gearshift pedal assembly from the motorcycle.
Page 130: Wheels-Brakes- Suspensions
WHEELS-BRAKES- SUSPENSIONS 6.1 - FRONT WHEEL Sub 6-2 Front wheel removal…....................Sub 6-3 6.2 – FRONT FORK Sub 6-5 Fork removal…..….......................Sub 6-6 6.3 – FRONT BRAKE Sub 6-8 Front brake removal……....................Sub 6-9 Brake discs removal..…....................Sub 6-11 6.4 – REAR WHEEL AND FINAL DRIVE Sub 6-12 Rear wheel removal……....................Sub 6-13 Final drive check-up………..................Sub 6-14...
Page 131 WHEELS-BRAKES- SUSPENSIONS 6.1 - FRONT WHEEL 1) front rim 3.50”x17” 2) spacer 3) wheel bearings 4) front wheel pivot spacer 5) front brake disks 6) screw M8x18 7) L.H. fork leg assembly 8) R.H. fork leg assembly 9) brake calipers spacers 10) R.H.
Page 132: Front Wheel Removal
WHEELS-BRAKES- SUSPENSIONS Front wheel removal Remove the front brake calipers together with their hoses by unscrewing the screws (12). Recover the spacers (9). CAUTION Not operate the brake lever when the calipers are dismantled. This might cause the expulsion of the pushing pistons of the brake pads.
Page 133 If there isn’t enough clearance between brake disk and caliper body, the brake disks can be damaged and the braking efficiency reduced. If you have not used a torque wrench for the installation, make check as soon as possible from a Bimota dealer that the installation is correctly performed. Sub 6-4...
Page 134 WHEELS-BRAKES- SUSPENSIONS 6.2 – FRONT FORK 1) L.H. fork leg 2) right fork stem 3) front wheel pivot 4) screw 5) washer 6) front fender right holder 7) screw 8) front wheel pivot spacer 9) screw 10) front fender left holder 11) front fender 13) screw 14) nylon washer...
Page 135: Forks Disassembly
Before slipping the forks off measure with a calliper or take note of the marks visible on the fork from above the steering head. They indicate the unthreading of the fork of the steering head recommended by Bimota. Loosen the clamp bolts (16).
Page 136 WHEELS-BRAKES- SUSPENSIONS Loosen the clamp bolts (18) securing the fork legs to the bottom steering clamp. Withdraw the fork legs (1) and (2) downwards in order to carry out to all the necessary maintenance operations. NOTES Reassembling the fork or changing the front height of the bike, do not slip the fork off more than three marks visible above the steering head and inside between the two fork legs as indicated in the picture above.
Page 137: Front Brake
WHEELS-BRAKES- SUSPENSIONS 6.3 – FRONT BRAKE 1) holed bolt 2) AI washer 3) front brake hose 4) pads 5) bleeding valve 6) bleeding valve cap 7) R.H. front caliper 8) L.H. front caliper 9) screw 10) front tire 11) spacer 12) front brake disk 13) screw 14) front rim...
Page 138 WHEELS-BRAKES- SUSPENSIONS Removal of the front brake system CAUTION Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In case of accidental contact, wash the affected area with abundant running water and consult a doctor if necessary.
Page 139 WHEELS-BRAKES- SUSPENSIONS Unscrew the four retaining bolts (9) securing the front calipers to the fork legs. Recover the spacers (11). Unscrew the special screws (1) from both calipers and recover sealing washers (2). Detach the front brake calipers from the brake hose (3). IMPORTANT The brake caliper manufacturer advises against any servicing of the internal components of calipers.
Page 140: Dual Discs Dismantling
WHEELS-BRAKES- SUSPENSIONS Dual disks dismantling NOTES The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor. Both parts must be changed together as a pair. Remove the front wheel. Unscrew the six fixing screws of the disk to the wheel (13). Remove the disks (12) on both side of the wheel.
Page 141: Rear Wheel And Secondary Drive
WHEELS-BRAKES- SUSPENSIONS 6.4 – REAR WHEEL AND SECONDARY DRIVE 1) nut 14) flange 2) rear sprocket 15) spacer 3) chain 16) sealed bearing 4) spacer 17) 90° valve 5) seeger ring 18) rear brake disk 6) sprocket holder flange 19) screw 7) pin 20) right spacer bush 8) spacer...
Page 142 Check the wheel again if the brake makes contact and if the wheel doesn't spin free. If you have not used a torque wrench for the installation, contact soon a Bimota dealer to check if the installation has been correctly done. If the installation is not correct you might have reduction in the braking performance of the bike.
Page 143: Secondary Drive Check-Up
WHEELS-BRAKES- SUSPENSIONS Secondary drive check up To check the wear of the secondary drive is necessary to proceed to the visual inspection of the front sprocket (24) and of the rear sprocket (2). If the teeth profile is shown as in figure (dotted line) the sprocket must be renewed.
Page 144 WHEELS-BRAKES- SUSPENSIONS Front sprocket removal Remove the front sprocket cover (22) unscrewing the screws (23). Loosen the chain and perform the disassembly of the chain using the appropriate tool. Remove the chain. Engage a low gear and unscrew the nut (26). Remove the nut (26) and the safety washer (25) on the sprocket.
Page 145: Rear Sprocket Removal
WHEELS-BRAKES- SUSPENSIONS Rear sprocket removal Remove the rear wheel. Remove the sprocket holder flange (6) from the rear wheel (14). Unscrew the six nuts (1) then remove the six pins (7). Remove the rear sprocket (2) from the sprocket holder flange (6). Sub 6-16...
Page 146: Rear Wheel Check-Up
WHEELS-BRAKES- SUSPENSIONS Rear wheel check up Visually inspect the wheel for cracks, scoring and deformation; change the wheel if damaged.Mount the rim on a balancing device. Using a dial gauge, measure rim run-out and out-of-round relative to the wheel shaft axis. If values are not within the limits is necessary to replace the wheel.
Page 147: Swing Arm
WHEELS-BRAKES- SUSPENSIONS 6.5 - SWING ARM 1) swingarm pivot 14) screw 2) right front swingarm spacer 15) lower chain guard 3) watertight bearing 16) screw 4) inner right swingarm spacer 17) left swingarm plate 5) swingarm 18) nut 6) lower chain slider 19) clip nut 7) screw 20) rear fender...
Page 148: Sub
WHEELS-BRAKES- SUSPENSIONS Swing arm removal Lift the bike from the ground with a proper central stand. Before proceeding to remove the swing arm it is necessary to remove the following particulars: - rear fender and chain guard - real wheel - rear brake - exhaust manifold of vertical cylinder - mono shock absorber...
Page 149 WHEELS-BRAKES- SUSPENSIONS Unscrew the three screws (29) then remove the upper chain slider (30). Unscrew the three screws (31) then remove the lower chain slider (32). Unscrew the two screws (14) of the swing arm caps that lock the two eccentric cams (13) Sub 6-20...
Page 150 WHEELS-BRAKES- SUSPENSIONS Remove the two eccentrics (13) from the swing arm. Unscrew the four screws (26) and remove the swing arm plate (23). Repeat the same operation on the opposite side. Sub 6-21...
Page 151: Rear Brake
WHEELS-BRAKES- SUSPENSIONS 6.6 - REAR BRAKE 1) holed nut 2) washer 3) rear brake hose 4) rear caliper 5) R.H. chain-tighten slider 6) screw 7) screw 8) speed sensor 9) rear wheel pivot 10) L.H chain-tighten slider 11) screw 12) rubber cap 13) bleeding valve 14) rear pads 15) hydro-stop...
Page 152 WHEELS-BRAKES- SUSPENSIONS Removal of the rear brake caliper IMPORTANT The brake caliper manufacturer advises against any servicing of the internal components of calipers. Incorrect overhaul of this safety-critical component can endanger rider safety. An overhaul not correctly done can seriously endanger the pilot safety. Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly.
Page 153: Speed Sensor Removal
WHEELS-BRAKES- SUSPENSIONS Speed sensor removal To remove the speed sensor (8) loosen the fixing screw (11). To replace the components mentioned above refer to what shown in the exploded draw at the beginning of chapter. Rear brake disc removal Unscrew and remove the five screws (16) that fix the brake disk to the rear wheel then remove the rear brake disk (17).
Page 154 WHEELS-BRAKES- SUSPENSIONS 6.7 - REAR SHOCK 1) nut 13) R.H. engine plate 2) rocker arm fixing screw 14) ring nut 3) screw 15) screw 4) swingarm pivot fixing screw 16) screw 5) L.H. engine plate 17) uniball 6) rocker arm pivot 18) nut 7) shim adjuster 19) rear shock to swingarm fixing screw...
Page 155: Rear Shock
(25) off then slip the lower screw (18) off and the respective lock-nuts. Check visually the shock and identify any oil leak or other problems. Replace the shock, if necessary. IMPORTANT For any problem related to shock functioning, contact Bimota authorized dealer. Sub 6-26...
Page 156: Rocker Arm Removal
WHEELS-BRAKES- SUSPENSIONS Rocker arm removal Unscrew and remove the two screws (15) and the relative fixing nuts (18) of the connecting rods (20) to the swing arm. Unscrew and remove the screw (16) then remove the fixing nuts (18). Sub 6-27...
Page 157 WHEELS-BRAKES- SUSPENSIONS Remove the special screw (2) from the L.H. engine plate (5). Remove the special screw (2) from R.H. engine plate (13) Remove with an Allen wrench the ring nut (14) from the R.H. engine plate (13). Sub 6-28...
Page 158 WHEELS-BRAKES- SUSPENSIONS Remove the rocker arm pivot (6) from the R.H. engine plate (13) then remove the rocker arm (10) paying attention to the nylon spacers (7). Sub 6-29...
Page 159: Frame
FRAME CHAPTER 7 FRAME 7.1 - HANDLEBAR Sub 7-2 Handlebar removal…....................Sub 7-3 7.2 - STEERING Sub 7-5 Steering head bearings adjustment................Sub 7-6 Disassembly of steering components................Sub 7-6 7.3 - STEERING DAMPER Sub 7-8 Steering damper removal…..................Sub 7-9 7.4 - FOOT PEGS Sub 7-10 Foot pegs support removal…….................Sub 7-11 7.5 - SIDETAND...
Page 160 FRAME 7.1 – HANDLEBAR 1) half-handlebar L.H./R.H. 2) screw 3) dowel 4) screw 5) shim 6) half-handlebar holder L 7) half-handlebar holder R 8) OR 9) dowel 10) throttle grip Sub 7-2...
Page 161 FRAME Handlebar removal To remove the R.H. handlebar it is necessary to remove the following particulars: - throttle grip - R.H. switch - front brake control To remove the left handlebar, is necessary to remove the following particulars: - L.H. switch - handle grip - clutch hydraulic control To remove the steering head (upper steering clamp):...
Page 162 FRAME IMPORTANT When reassembling the handlebars on the fork legs pay attention to insert the dowel bolt (3), screwed on the bottom of the steering head, in the relative housings of each handlebar supports (11). Apply the prescribed grease on the thread of fixing screws (4). Sub 7-4...
Page 163 FRAME 7.2 - STEERING 1) screw 2) screw 3) washer 4) steering head base assembly 5) dust seal 6) steering bearing 7) steering bearing bush 8) ring nut of steering pivot 9) screw 10) special screw 11) steering head 12) flanged M8 nut 13) screw 14) main switch spacer 15) main switch fixing screw...
Page 164: Disassembly Of Steering Components
Remove the steering head (11). Loosen the ring nut (8) and unscrew it from steering stem with the Bimota special tool cod.50709710. Sub 7-6...
Page 165 FRAME from the bottom of the steering tube remove the steering clamp base (4) assembly together with O- ring (18), dust seal (5) and crown of lower ball bearing (6). Loosen the fixing screws (13) of the steering tube. Remove the upper steering bearing bush together with o-ring, dust seal and bearing. Remove the lower steering bearing bush.
Page 166: Steering Damper
FRAME 7.3 - STEERING DAMPER 1) screw M6x25x TCEI CZ 2) bush 3) steering damper 4) bush 10x6,3x7 5) bush 6,5x10x5,5 6) screw M4x8 TBEI 7) screw M5x22 TCEI CZ 8) steering damper holder 9) screw M6x25 TEF 10) OR 11) nylon collar Sub 7-8...
Page 167 FRAME Steering damper removal Remove the upper fairing. Unscrew and remove the screw (1) which fixes the steering damper (3) to its holder (8), recovering the two bushes (2) and (4) and the o-ring (10). Unscrew the screw (3) which fixes the steering damper (3) to the frame, recovering the two bushes (5) and (2) and the o-ring (10).
Page 168: Foot Pegs
FRAME 7.4 - FOOT PEGS 1) screw 11) screw 2) R.H. footpeg holder 12) L.H. footpeg holder 3) screw 13) screw 4) R.H. foot guard 14) L.H. foot guard 5) screw 15) screw 6) pin 16) pin 7) footpeg fork 17) holder 8) R.H.
Page 169 FRAME Footpegs support removal In order to remove the L.H. footpeg assembly first remove the gearchange pedal unit (24) from the left footpeg support (2). Unscrew the two screws (11) which fix the support to the engine plate then remove the footpeg assembly (12).
Page 170 FRAME Foot pegs removal In order to remove the footpeg and the footpeg fork from the support (2) (12), unscrew and remove the screws (1) (13). In order to remove the footpeg (8) from the footpeg fork (7), remove the seeger (10) then slip the pin (6) off releasing the footpeg and the spring (9).
Page 171 FRAME 7.5 – SIDESTAND 1) screw M10x25 TCEI CZ 2) sidestand plate 3) complete sidestand 4) spring fixing screw 5) screw M4x8 TSPEI 6) sidestand foot 7) sidestand leg 8) screw M5x8 TBEI 9) screw 10) sensor plate 11) sidestand stopping plate 12) screw M5x10 TBEI 13) sensor support plate 14) sidestand switch...
Page 172 FRAME Sidestand removal Disconnect the connector of the sidestand switch (14) from the main cable. Unscrew the screws (1) which fix the sidestand support plate (2) to the engine then remove the sidestand assembly. Sidestand disassembly In order to remove the springs (15) and (16) release them from the sidestand support plate (2) and from the screw (4) on the back side of the leg (7).
Page 173 FRAME Unscrew the screw (9) which fixes the sidestand to the support plate then remove it. Unscrew the fixing screw (8) then remove the small plate (10). Unscrew the two screws (12) then remove the small plate (13). Unscrew the screw (12) then remove the small plate (11). IMPORTANT Mounting the sidestand in the support plate, check that there is not excessive clearance and that the two ends of the sidestand are not bent in respect to the stem.
Page 174 FRAME 7.1- FRAME AND CHASSIS PLATES 1) frame 2) L.H. frame plate 3) R.H. frame plate 4) screw TCEI M10x1,25 5) nut M12x1,25 Gally 6) screw M6x12 TBEI 7) velnut M6 8) L.H.fairing fixing plate 9) screw M8x20 TSPEI 10) spacer 11) engine pin 12) frame support 13) rubber pad...
Page 175 FRAME Frame and structural parts removal In order to remove the frame it needs to remove all the parts mounted on it, making reference to all the removal procedures reported in the specific sections. The structural parts of the frame are the front fairing support and the tail. Both have the function to support some of the motorcycle structures and for this reason they must be in perfect conditions.
Page 176 FRAME Frame removal Remove the rear frame support, unscrewing the screws (9) from both the frame plates. Unscrew and remove the four screws (4) then remove the L.H. chassis plate (2). Repeat the same operation for the R.H. chassis plate (3). Sub 7-18...
Page 177 FRAME 7.7 – TAIL 1) screw M4x20 TBEI 19) tail light fixing plate 2) nylon washer 20) cable ring 3) velnut M4 21) bush 4) tail lower cover 22) tail light 5) screw M8x35 TSPEI 23) license plate light 6) screw M8x20 TSPEI 24) license holder 7) license plate holder 25) screw M5x16 TBEI...
Page 178 FRAME 7.8 - LICENSE PLATE HOLDER 1) tail light plate 2) screw M5x12 TBEI 3) M5 nut 4) tail light 5) spacer 6) screw M4x10 TCEI CZ 7) screw M4x25 TCEI 8) reflex reflector 9) reflex reflector plate holder 10) screw M4x10 11) washer 12) M5 nut 13) D5 washer...
Page 179 EXHAUST - INTAKE CHAPTER 8 EXHAUST – INTAKE 8.1 - EXHAUST Sub 8-2 Exhaust removal…..................... Sub 8-3 8.2 - FUEL TANK Sub 8-7 Fuel tank removal…....................Sub 8-8 Fuel tank refitting..…....................Sub 8-8 Fuel pump removal…....................Sub 8-9 Filler cap removal......................Sub 8-9 8.3 - THROTTLE BODY Sub 8-10 Airbox and throttle body removal…................Sub 8-11 Injectors removal…....................Sub 8-13...
Page 180 EXHAUST - INTAKE 8.1 - EXHAUST 1) Silencer 19) bush 2) exhaust expansion 20) M6 nut 3) vertical cylinder head exhaust pipe 21) washer 4) horizontal cylinder head exhaust pipe 22) D6 washer 5) R.H. expansion cover 23) screw M6x16 TCEI CZ 6) L.H.
Page 181: Exhaust - Intake
EXHAUST - INTAKE Exhaust removal Remove the fairings. Unscrew the screw (13) which fix the silencer (1) to the support arm (17) and recover the bushes and gaskets. Remove the springs (12) and slip the silencer (1) off from the exhaust pipe. Sub 8-3...
Page 182 EXHAUST - INTAKE Unscrew the three nuts (20) that fix the vertical exhaust manifold (3) to the cylinder head. Remove the spring (12), slip the vertical exhaust manifold (3) off and recover the gasket (8). Sub 8-4...
Page 183 EXHAUST - INTAKE Remove the screw (36) which fixes the exhaust expansion (2) to the L.H. engine plate. Remove the spring (12). Unscrew the screw (13) which fix the exhaust expansion (2) to the R.H. engine plate and recover the bushes, washers and gaskets. Remove the exhaust expansion (2).
Page 184 EXHAUST - INTAKE Remove the lambda sensor (9) from the horizontal exhaust manifold (4). Unscrew the three nuts (20) which fix the horizontal exhaust manifold (3) to the cylinder head. Remove the horizontal exhaust manifold (4) and recover the gasket (8). Unscrewing the three screws (34) to remove the exhaust expansion cover (5) then recover the washers and bushes.
Page 185 EXHAUST - INTAKE 8.2 - FUEL TANK 1) fuel tank 13) fuel pump 2) sticker “bimota” 14) washer 6x18x1.6 3) filler cap 15) screw M5x16 TCEI CZ 4) screw M5x12 TCEI CZ 16) hose guide 5) D5 washer 17) bush...
Page 186: Fuel Tank Removal
EXHAUST - INTAKE Fuel tank removal Remove the tail. Remove the screw (6) which fixes the front of the tank. Remove the screws (20) on the back of the tank. If necessary, before removing the tank remove the drain hoses, the electric connector and the gasoline hose paying attention to gasoline leakages.
Page 187: Fuel Pump Removal
EXHAUST - INTAKE Fuel pump removal Unscrew the six screws (15) which fix the fuel pump to the tank. Slip the fuel pump (13) off from tank and recover the o-rings (24). Filler cap removal Open the filler cap, unscrew the four screws (4) and recover the washers. Remove the filler cap (3).
Page 188: Throttle Body
EXHAUST - INTAKE 8.3 - THROTTLE BODY 1) intake manifold 14) injector mounting support 2) screw 15) screw M5x30 TCEI CZ 3) clamp 16) injector 4) screw M5x16 TCEI CZ 17) horizontal injector joint 5) throttle body 18) vertical injector joint 6) stepper motor 19) screw M5x14 TCEI CZ 7) intake duct...
Page 189: Airbox And Throttle Body Removal
EXHAUST - INTAKE Airbox and throttle body removal Remove the fuel tank. Remove the air intake manifolds. Release the throttle cable. Disconnect the wiring (27) from the injectors (13). If needed disconnect the wiring (27) from the main electric wiring. Loosen the clamps (3) on the intake manifold (1).
Page 190 EXHAUST - INTAKE Disconnect the connector (28) of the injectors wiring to stepper motor. Loosen the connector (29) of injectors wiring to the throttle body potentiometer. Loosen the clamp (30) which fix the oil vent hose (31) to the oil expansion tank (32). Sub 8-12...
Page 191: Injectors Removal
EXHAUST - INTAKE Slip the air box (33) off from the throttle body (5) and the injectors (16). Injectors removal Unscrew the screw (19) to remove the injectors (16) complete of hoses (11) from the air box (33). Sub 8-13...
Page 192 EXHAUST - INTAKE Remove the injector hoses (11) from the air box. Remove the injectors wiring (27) from the air filter box. Sub 8-14...
Page 193: Stepper Motor Removal
EXHAUST - INTAKE Stepper motor removal In the middle of the throttle body is mounted the stepper motor (6). Disconnect the hoses (34) and (35) from the throttle body and the air filter box. Unscrew the two screws (36) and remove the motor. Sub 8-15...
Page 194 EXHAUST - INTAKE Air box - throttle body disassembly Unscrew the six screws (4) and remove the throttle body (5) from the air box (33). Sub 8-16...
Page 195 EXHAUST - INTAKE 8.4 - INTAKE – AIRBOX 1) manifold 2) screw M5x10 TBEI 3) fixing plate of oil expansion tank 4) oil expansion tank 5) screw M5x8 TBEI 6) air box – expansion tank union 7) air box 8) rubber gasket 9) airbox manifold holder 10) screw 11) air filter...
Page 196: Injection - Ignition
INJECTION - IGNITION CHAPTER 9 INJECTION – IGNITION 9.1 – SYSTEM COMPONENTS Sub 9-2 Electronic control system..................... Sub 9-2 Battery support......................Sub 9-3 Battery support removal…..................Sub 9-4 Fuel injector…......................Sub 9-6 Stepper motor.......................Sub 9-7 Air pressure sensor......................Sub 9-8 Coolant temperature sensor (engine)................Sub 9-8 Coolant temperature sensor (dashboard)..............Sub 9-9 Air temperature dash (dashboard)................Sub 9-9 Air temperature sensor (engine)................Sub 9-10...
Page 197 INJECTION - IGNITION 9.1 – SYSTEM COMPONENTS Electronic control unit The ECU (1) is an electronic unit, digital type with microprocessor. It controls the injectors and coils therefore adjusting the fuel injection and ignition, in according to the engine operating conditions detected by sensors listed here below: absolute pressure sensor (measures the atmospheric pressure) air temperature sensor (measures intake air temperature) engine temperature sensor (measures coolant temperature)
Page 198: Battery Support
Sub 9-2 INJECTION - IGNITION Battery support 1) nut M6 2) vibration damper 3) vibration damper 4) water cooler holder 5) screw M6x25 TBEI 6) rubber pad 7) flanged nut M6 8) screw M6x16 TCEI CZ 9) screw M6x14 TCEI CZ 10) washer 11) battery box mount 12) battery...
Page 199: Battery Support Removal
INJECTION - IGNITION Battery support removal The battery is placed on the motorcycle left side, under the side fairing. Remove the L.H. fairing. Remove the box cover (13) loosening the nuts (7). Disconnect first the negative pole (22) then the positive one (23). Remove the battery (12) from its box.
Page 200 INJECTION - IGNITION Disconnect the connector (24) from the main wiring, slip the starter contactor (19) off from the two fixing tongues and remove it. Slip the fuses box (25) off from the fixing tongue and remove it. Unscrew the screw (15) and remove the lights relay (26). Unscrew the two screw (8) (9) and recover the washers.
Page 201: Fuel Injector
INJECTION - IGNITION Fuel injectors The injectors (1) deliver the correct quantity of fuel required for optimal engine operation. The ECU controls injector opening by feeding current to the coil of an electromagnet which creates a magnetic field to attract the armature, thereby generating fuel spray. If we take the physical characteristics of the fuel to be constant (viscosity, density), as well as the injector delivery and pressure head (controlled by the fuel pressure regulator), the amount of fuel injected depends on the duration for which the injector is open.
Page 202: Stepper Motor
INJECTION - IGNITION Stepper motor The throttle body incorporates an automatic choke function performed by a stepper motor (1). The stepper motor shaft is fitted with a valve which opens a communicating passage between two ports; one of these ports (2) is connected to the intake manifold of the vertical cylinder while the other (4) is connected to the intake manifold of the horizontal cylinder.
Page 203: Air Pressure Sensor
INJECTION - IGNITION Air pressure sensor This sensor (1) is integrated in the ECU and indicates the atmospheric pressure. This data is managed by the ECU and is used to correct the calibration. NOTES The information about the atmospheric pressure is displayed through the use of the Service Walbro.
Page 204: Air Temperature Dash
INJECTION - IGNITION Coolant temperature sensor (dashboard) The sensor (1) is positioned along the horizontal hose of the coolant circuit, under the throttle body, and measures the water temperature which is then displayed on the dashboard. Air temperature (dashboard) The sensor (2) is positioned under the dashboard support and measures the external air temperature which is displayed on the dashboard.
Page 205: Ignition Coils
INJECTION - IGNITION Air temperature sensor (engine) The sensor (3) is positioned under the dashboard support frame and take the external temperature of the air that is used by the ECU to make eventual calibration corrections. Ignition coils Remove the fuel tank. Undo the nut (1) securing the coil to the cylinder head.
Page 206: Spark Plugs
INJECTION - IGNITION Checking the coils The coils used on this model are known as “cigar” coils. They are similar in appearance to a spark plug cap. They transform the low voltage from the ECU into high voltage for the spark plugs. To test the coils, proceed as follows: Measure the resistance between the two pins (1-15).
Page 207: Throttle Position Sensor
INJECTION - IGNITION Throttle position sensor The TPS (1) is powered by the ECU to which it sends a signal indicating the throttle position. This information is an indirect measure of the engine load and is used by the ECU as one of the main parameters for defining the fuel flow rate and spark advance.
Page 208: Injection Relay
INJECTION - IGNITION Injection relay The injection relay (1) is positioned behind the R.H. fairing, near the ECU. To remove the relay (1) first remove the side fairing as previously described. Disconnect the relay from the electrical system and apply 12 V (battery voltage) between contacts (86) and (85) (small contacts): you should hear a click that confirms that the internal electromagnet has switched.
Page 209 ELECTRICAL SYSTEM CHAPTER 10 ELECTRICAL SYSTEM 10.1 - WIRING DIAGRAM Sub 10-2 Utilities wiring diagram....................Sub 10-2 Injection wiring diagram.................... Sub 10-3 10.2 - FUSE BOX Sub 10-4 10.3 - WIRING ARRANGEMENT ON MOTORCYCLE Sub 10-5 10.4 - LIGHTING DEVICES Sub 10-21 Low-beam bulb replacement…................Sub 10-21 High-beam bulb replacement..................Sub 10-22...
Page 210: Wiring Diagram
ELECTRICAL SYSTEM 10.1 - WIRING DIAGRAM Utilities wiring diagram Sub 10-2...
Page 211: Injection Wiring Diagram
ELECTRICAL SYSTEM Injection wiring diagram Sub 10-3...
Page 212: Fuse Box
ELECTRICAL SYSTEM 10.2 - FUSE BOX The fuse box (1) is placed on the left side of the motorcycle, under the side fairing. To replace the fuses: Unhook the rubber fasteners (2) and open the fuse box cover (1). Replace the damaged fuse with a new one. The spare fuses (3) are placed in the fuse box.
Page 213: Wiring Arrangement On Motorcycle
ELECTRICAL SYSTEM 10.3 - WIRING ARRANGEMENT ON MOTORCYCLE The ways of the electrical wires have been optimized to have the minimum overall dimension. Every passage has been studied to not interfere during the motorcycle use with parts which might damage them or create malfunctions. The pictures outlined here below evidence the correct positioning of wires and of the cable ties.
Page 214 ELECTRICAL SYSTEM Sub 10-6...
Page 215 ELECTRICAL SYSTEM Sub 10-7...
Page 216 ELECTRICAL SYSTEM Sub 10-8...
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Page 219 ELECTRICAL SYSTEM Sub 10-11...
Page 220 ELECTRICAL SYSTEM Sub 10-12...
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Page 224 ELECTRICAL SYSTEM Sub 10-16...
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Page 228 ELECTRICAL SYSTEM Sub 10-20...
Page 229: Lighting Devices
ELECTRICAL SYSTEM 10.4 - LIGHTING DEVICES NOTES The halogen light bulbs in the headlight become hot when switched on and remain hot for some time after they are switched off. Allow bulbs to cool before replacing them. If possible replace the light bulbs wearing clean gloves. If you touch the light bulb with naked hands clean the bulb with alcohol to prevent overheating and breakage of the light bulb in a short time.
Page 230: High-Beam Light Bulb Replacement
ELECTRICAL SYSTEM High-beam light bulb replacement Remove the front fairing covers. Remove the rubber cover (1). Push the two fixing springs (2) out. Remove the burnt light bulb (3) disconnecting the connector (4) and replace it with a new one reversing the order of removal.
Page 231: Lights Relay
ELECTRICAL SYSTEM License plate light bulb replacement The license plate light bulb is accessible from the back side of the license plate support. Pull the light bulb socket (1) out. Remove the license plate light bulb (2). Install a new light bulb reversing the order of removal. Lights relay The lights relay (3) is placed on the right side of motorcycle and is fixed near to the ECU.
Page 232: Headlight Beam Adjustment
ELECTRICAL SYSTEM Headlight beam adjustment The motorcycle must be perfectly upright with the tires inflated to the correct pressure and with a rider seated, perfectly perpendicular to the longitudinal axis. Position the motorcycle 10 metres from a wall or a screen. On the wall or surface, draw a horizontal line at the same height from the ground as the centre of the headlight and a vertical line aligned with the longitudinal axis of the motorcycle.
Page 233: Left Handlebar Controls
ELECTRICAL SYSTEM 10.5 - INDICATING DEVICES Left handlebar controls Turn signal switch Move the turn signal switch (1) to left to signalize the turn left and right to turn right. Press to switch off the direction signal. Horn button Press the button (2) to operate horn. Headlight switch Push the switch of the headlight (3) on (HI) position to select the high beam and on (LO) position to select the low beam.
Page 234: Brake Light Switches
ELECTRICAL SYSTEM Brake light switches To check operation of the front (1) and rear (2) brake light switches, use a multimeter to check for electrical continuity between the terminals of the corresponding switch when the front or rear brake is applied. When the brake is released, there must be no electrical continuity between the terminals of the corresponding switch.
Page 235: Neutral Indicator Light
ELECTRICAL SYSTEM Neutral indicator light To check the neutral light switch (3) proceed as follows: The neutral light does not illuminate on the instrument panel. Remove the electric terminal connected to the neutral switch. Switch on the ignition switch (ignition key to ON position) and ensure that the light illuminates when the terminal is earthed.
Page 236: Oil Pressure Sensor
ELECTRICAL SYSTEM Oil pressure sensor If the engine oil pressure is not within the specified range, check the parts of the lubrication circuit and make the necessary repair. If the oil pressure is not within the specified range and the engine oil pressure warning light stay off turn on the dashboard (main switch position ON) without starting the engine, disconnect the electrical terminal from the oil pressure sensor and connect it to ground.
Page 237: Coolant Temperature Sensor
ELECTRICAL SYSTEM Coolant temperature sensor The coolant temperature sensor (1) sends an electrical signal to the engine ECU. To check that the sensor (1) is functioning correctly, read among the engine parameters represented on the display the value of the coolant temperature of the engine. With the engine completely cold, the air temperature should be similar to that of the coolant.
Page 238: Turn Signal Bulb Replacement
ELECTRICAL SYSTEM Turn signal bulb replacement (USA version only) In the Europe version in case of malfunctioning it is necessary to replace the whole rear turn signal or the rear view mirror group (which includes the front turn signal light), as they use LED and not bulbs.
Page 239: Rear Stop Light Replacement
ELECTRICAL SYSTEM Rear stop light replacement USA version To replace the rear stop light bulb, unscrew the screws (1) and take the red lens (2) out from the light support. Remove the light bulb (3) from the support. Replace the bulb (3) and re-insert it in the bulb support. Reassemble the red lens (2) on the light support.
Page 240: Rear View Mirror Adjustment
ELECTRICAL SYSTEM Rear view mirror adjustment Grasp the outer part of the mirror surface (1) and move it manually to the required position relative to the mirror support (2). Sub 10-32...
Page 241: Safety Devices And Protections
ELECTRICAL SYSTEM 10.6 SAFETY DEVICES AND PROTECTIONS Ignition switch Disconnect the ignition switch (A) from the wiring loom by opening its connector and use a multimeter to check its internal connections as follows: turn the key to OFF and connect a multimeter to contacts (1) and (4) to check electrical continuity. The resistance reading should be near zero and, if present, the continuity sound signal should be emitted.
Page 242: Sidestand Switch
ELECTRICAL SYSTEM Sidestand switch This motorcycle is equipped with an ignition stop switch. The engine cannot be started if the sidestand is opened, unless the gear is in neutral. If the sidestand is raised, the engine can be started with the gear in neutral or engaged gear with the clutch engaged.
Page 243: Dashboard
ELECTRICAL SYSTEM 10.7 - Dashboard Dashboard removal Remove the front fairing. Disconnect the wiring of the dashboard (1) Unscrew the three screws (2). Remove the dashboard (3). NOTES The dashboard is supplied as spare part in a single component and therefore it is not possible to order internal replacements.
Page 244: Dashboard
ELECTRICAL SYSTEM Dashboard 1) Turn signals (when the turn signal is being operated, the indicator light will flash at the same time.) 2) high-beam light indicator (lit when high-beam light is on) 3) Neutral indicator (lit when the neutral gear is selected) 4) Injection malfunction indicator (lit when there's a malfunction in the injection system) 5) Oil pressure indicator (lit when the engine oil pressure drops under the normal operating range.
Page 245: Multifunction Digital Display
ELECTRICAL SYSTEM Multifunction digital display When you turn ON the ignition switch, the display temporarily displays all the details and digital segments. The display functions are accessible through 3 different pages; to go from one page to the next one hold the starter button (placed on the right handlebar controls) for at least 3 seconds. The functions available are described in the following pages.
Page 246 ELECTRICAL SYSTEM PAGE 2 The second page shows the following functions: Speed Chronometer: push the ignition button to start up the chronometer. Each time you press the starter button, the time lap is recorded and the chronometer starts to register a new lap. It may be registered up to 20 laps.
Page 247 ELECTRICAL SYSTEM PAGE 3 The third page shows the following functions: -Maximum speed: displays the maximum speed reached during the selected lap. -Lap time: displays the lap time of the selected lap. -Lap number: displays the selected lap of which you want to see the recorded data (it can be recorded up to 20 laps).
Page 248: Diagnosis Instrument
ELECTRICAL SYSTEM 10.8 - DIAGNOSIS INSTRUMENT Using a multimeter to check the electrical systems Introduction This instrument allows you to measure resistances, voltages, and current values. Multimeters can be divided into two basic types: those with an analogue display and those with a digital display Units of the first type are equipped with a dial and needle.
Page 249 ELECTRICAL SYSTEM Measurement of resistance values and electrical continuity Resistance measurements must be taken only when the electrical device or section of the circuit is not powered and isolated from the main electrical system (i.e. not connected to the main electrical system). These measurements can be utilised to check the resistance value across several sensors.

bimota DB7 Workshop Manual

Injection - Ignition 9 Electrical System 10

CHAPTER 1 IDENTIFICATION of the MOTORCYCLE Sub

Chapter 2 Technical Specifications

Chapter 3 Use and Maintenance

Chapter 4 Bodywork

Chapter 5 Controls and Devices

Wheels-Brakes- Suspensions/Front Wheel

Chapter 6 Wheels-Brakes- Suspensions

Chapter 7 Frame

Chapter 8 Exhaust - Intake

Chapter 9 Injection - Ignition

Chapter 8 Injection - Ignition

Chapter 10 Electrical System

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