APRILIA DORSODURO 1200 ABS - ATC Service Station Manual
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APRILIA DORSODURO 1200 ABS - ATC Service Station Manual

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Table of Contents

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.
SERVICE STATION MANUAL
DORSODURO 1200 ABS - ATC
email: info@motomatrix.co.uk
897263

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  • Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. SERVICE STATION MANUAL 897263 DORSODURO 1200 ABS - ATC email: info@motomatrix.co.uk...
  • Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, Aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • 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 4 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. email: info@motomatrix.co.uk...
  • Page 5 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS...
  • Page 6 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. email: info@motomatrix.co.uk...
  • Page 7 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS CHAR HARACTERISTICS email: info@motomatrix.co.uk...
  • Page 8 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC 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.
  • Page 9 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics KEEP OUT OF THE REACH OF CHILDREN. DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING.
  • Page 10 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics When repairing, disassembling and reassembling the vehicle, strictly follow the recommendations re- ported below. BEFORE DISASSEMBLING COMPONENTS • Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
  • Page 11 That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND/OR DAMAGING THE VEHICLE.
  • Page 12 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics 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.
  • Page 13 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics Engine ENGINE Specification Desc./Quantity Model M555M Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 over- head camshafts. No. of cylinders Total engine capacity 1197 cm³...
  • Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics Drive chain RIVE CHAIN Specification Desc./Quantity Type Endless (without master link) and with sealed links. No. of links Model 525 ZRPK...
  • Page 15 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics USPENSION Specification Desc./Quantity Front Sachs upside-down stanchions with adjustable hydraulic damping and 43mm (1.69 in) diameter stanchions Travel 160 mm (6.3 in)
  • Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics Supply UEL SYSTEM Specification Desc./Quantity Type Electronic injection (Multipoint) Throttle valve diameter Ø 57 mm (2.44 in) Fuel Premium unleaded petrol, minimum octane rating of 95...
  • Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics IL COOLING RADIATOR pos. Description Type Quantity Torque Notes TEFL screw fastening oil radiator M6x25 10 Nm (7.37 lbf ft) TEFL screw fastening oil radiator M6x12 10 Nm (7.37 lbf ft)
  • Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RONT FORK pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lbf ft) Screw (Pumping member pin fixing 30 Nm (22.13 lbf ft)
  • Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes TCEI screw fastening instrument M6x20 10 Nm (7.37 lbf ft) panel mounting to fork yoke...
  • Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes TBEI screw fastening fork guard to M5x9 6 Nm (4.42 lbf ft) calliper mounting bracket...
  • Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics LUTCH PUMP pos. Description Type Quantity Torque Notes Clutch cylinder fastener 10 Nm (7.37 lbf ft) Union with breather and fixing pipe M10x1 25 Nm (18.44 lbf ft)
  • Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Pipe union fastening brake pipe to M10x1 25 Nm (18.44 lbf ft)
  • Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EADLAMP pos. Description Type Quantity Torque Notes TEFL screw fixing headlight mount- M6x16 10 Nm (7.37 lbf ft) ing to steering base...
  • Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RONT BODYWORK pos. Description Type Quantity Torque Notes TBEI screw fastening front side pan- M5x9 6 Nm (4.42 lbf ft) els to tank...
  • Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Wheel axle nut 80 Nm (59 lbf ft) TE flanged screw fastening front disc M8x20 30 Nm (22.13 lbf ft)
  • Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RONT BRAKE pos. Description Type Quantity Torque Notes Union with breather (fixing pipe to M10x1 25 Nm (18.44 lbf ft) callipers) TEFL screw (Fixing calliper to fork M10x1.25...
  • Page 27 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics ENTRE FRAME pos. Description Type Quantity Torque Notes Flanged nut fastening side panels to 80 Nm (59 lbf ft) engine CHAR - 27...
  • Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics OOTRESTS pos. Description Type Quantity Torque Notes Upper screw fastening passenger M8x35 25 Nm (18.44 lbf ft) Loct. 243 footrests to frame side panels...
  • Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics UEL TANK pos. Description Type Quantity Torque Notes TCEI screw fastening filler cap flange M5x12 6 Nm (4.42 lbf ft) Rear TE screw fastening tank M6x90 10 Nm (7.37 lbf ft)
  • Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics UEL PUMP pos. Description Type Quantity Torque Notes TEFL screw fastening fuel pump M5x16 3 Nm (2.21 lbf ft) Loctite 518...
  • Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics ENGINE pos. Description Type Quantity Torque Notes Flanged TE screw fastening pinion M10x1.25 50 Nm (36.88 lbf ft) Loctite 243 TCEI screw fastening Pin to gearbox M6x16 12 Nm (8.85 lbf ft)
  • Page 32 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Coil fixing screw 5.50 Nm (4.06 lbf ft) TE screw fastening regulator to M6x30 10 Nm (7.37 lbf ft)
  • Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics LOCKS pos. Description Type Quantity Torque Notes Switch fastener shear head Manual screw TE screw fastening saddle lock / bat- M6x25 10 Nm (7.37 lbf ft)
  • Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Intake union fastener screw 12 Nm (8.85 lbf ft) Loctite 242 Map sensor fixing screw 5.5 Nm (4.05 lbf ft)
  • Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics WINGARM pos. Description Type Quantity Torque Notes Swingarm Pin adjustment bushing 12 Nm (8.85 lbf ft) Swingarm pin ring nut 60 Nm (44.25 lbf ft) Swingarm pin nut 90 Nm (66.38 lbf ft)
  • Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper TCEI mounting screw M10x50 50 Nm (36.88 lbf ft) Lower TCEI mounting screw M10x80 50 Nm (36.88 lbf ft)
  • Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics XHAUST SYSTEM pos. Description Type Quantity Torque Notes SERPRESS self-locking nut fasten- 25 Nm (18.44 lbf ft) ing flange on head...
  • Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EAR BRAKE pos. Description Type Quantity Torque Notes Rear brake lever pin 10 Nm (7.37 lbf ft) Loctite 243 Flanged TE screw fastening pump to M6x16 10 Nm (7.37 lbf ft)
  • Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics AILLIGHT pos. Description Type Quantity Torque Notes TCEI license plate light fixing screw M5x25 6 Nm (4.42 lbf ft) TCEI rear turn indicator fixing screw 3 Nm (2.21 lbf ft)
  • Page 40 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EAR BODYWORK pos. Description Type Quantity Torque Notes Screws fastening battery cover to 5x14 2.6 Nm (1.92 lbf ft) compartment TBEI screw fastening battery com- M5x9 6 Nm (4.42 lbf ft)
  • Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EAR BODYWORK pos. Description Type Quantity Torque Notes TBEI screw fastening license plate M5x12 6 Nm (4.42 lbf ft) mounting to mounting...
  • Page 42 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics SYSTEM pos. Description Type Quantity Torque Notes ABS ECU fastener screw M6x25 10 Nm (7.37 lbf ft) Loctite 243 ABS ECU fastener nut 10 Nm (7.37 lbf ft)
  • Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EAD COVER pos. Description Type Quantity Torque Notes Special screw for fastening head 9 Nm (6.64 lbf ft) cover Special screw for fastening head 9 Nm (6.64 lbf ft)
  • Page 44 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics YLINDER pos. Description Type Quantity Torque Notes Chain tensioner fastener screw 13 Nm (9.59 lbf ft) Cylinder plate fastener screw 13 Nm (9.59 lbf ft) Chain tensioner adjustment screw 5.50 Nm (4.06 lbf ft)
  • Page 45 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics TIMING SYSTEM pos. Description Type Quantity Torque Notes Camshaft gear fastener nut M15x1 90 Nm (66.38 lbf ft) Timing drive gear fastener screw M24x1.5...
  • Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics pos. Description Type Quantity Torque Notes Decompression device fixing screw torx M8 28.5 Nm (21.02 lbf ft) 3M SCOTCH GRIP 2353 Fastener screw 5.50 Nm (4.06 lbf ft)
  • Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics IL PUMP pos. Description Type Quantity Torque Notes Oil drainage plug M16x1.5 19 Nm (14.01 lbf ft) Fastening oil sensor on clutch side 13 Nm (9.59 lbf ft)
  • Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics EAR SELECTOR pos. Description Type Quantity Torque Notes Gear retainer pawl fastener screw 12 Nm (8.85 lbf ft) Loctite dry loc 2040 Selector plate fastener screw 5.50 Nm (4.06 lbf ft)
  • Page 49 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics LUTCH COVER pos. Description Type Quantity Torque Notes Screw fastening Clutch Cover / inter- 13 Nm (9.59 lbf ft) mediate Clutch side cover...
  • Page 50 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch spring fastener screw 11 Nm (8.11 lbf ft) ATER PUMP pos. Description Type...
  • Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics pos. Description Type Quantity Torque Notes Fastener screw for Pump Cover / 13 Nm (9.59 lbf ft) Clutch side cover Screw fastening Pump Cover / 13 Nm (9.59 lbf ft)
  • Page 52 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RANKCASE pos. Description Type Quantity Torque Notes Bearing retainer fastener screw 10 Nm (7.38 lbf ft) Loctite 270 Piston oil jet fastener screw 5.50 Nm (4.06 lbf ft)
  • Page 53 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RANKCASE pos. Description Type Quantity Torque Notes Special calibrated screw for gearbox M9x1 18 Nm (13.28 lbf ft) lubrication Screw fastening flywheel side / 13 Nm (9.59 lbf ft)
  • Page 54 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics Crankcases are classified in two classes (1 or 2) depending on the diameter of the main bearing seat. The class is indicated on both crankcase halves, specifically, in the rear cylinder area on flywheel side crankcase halves and in the front cylinder area on clutch side crankcase halves.
  • Page 55 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics There are three crankshaft classes selectable for each bearing: • 4 - 5 - 6 for the flywheel side; • 7 - 8 - 9 for the clutch side;...
  • Page 56 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics RANKCASE CLASSES Specification Desc./Quantity Crankcase class A Centre-to-centre distance: 110.50 - 110.54 mm (4.3504 - 4.3519 in) Crankcase class B Centre-to-centre distance: 110.46 - 110.50 mm (4.3488 - 4.3504 in)
  • Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics Crankshaft class (crank pin) There are four different classes of crankshaft avail- able (0, 1, 2, 3), selected in relation to crank pin diameter.
  • Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Characteristics WHEN REFITTING, ALSO ENSURE THAT THE SEMI-BUSHINGS ARE ALL OF THE SAME CLASS. See also Removing the flywheel cover Recommended products chart...
  • Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS S-TOOLS PECIAL TOOLS email: info@motomatrix.co.uk...
  • Page 60 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Special tools PECIAL TOOLS Stores code Description 020709Y Engine support 020710Y Engine plate AP8140187 Engine support stand 020850Y Primary gear lock 020712Y...
  • Page 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Special tools Stores code Description 020714Y Dial gauge mounting 9100896 Clutch housing locking tool 020716Y Connecting rod locking 020894Y Pin snap ring fitting tool...
  • Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Special tools Stores code Description 020382Y Valve cotters removal tool 020896Y Bushing for valve removal 020720Y Timing tool 020376Y Adapter handle 020891Y Adapter 25 mm (0.98 in)
  • Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Special tools Stores code Description 020724Y Gear control rod roller cage punch 020726Y Extractor for bushings 020727Y Punch for bushings 020884Y 46 mm wrench for steering ring nut...
  • Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Special tools Stores code Description AP8140199 Tool panel 020898Y Dorsoduro 1200 graphics for tool support panels 8140426 Hooks for panel 020888Y Pliers for pre-fill pipe...
  • Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Special tools Stores code Description AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices AP8140146 Weight S-TOOLS - 65...
  • Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS MAIN AINTENANCE email: info@motomatrix.co.uk...
  • Page 67 Adequate maintenance is fundamental to ensure long-lasting, optimum operation and performance of your vehicle. To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are summarised in the table shown on the following page. Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to solve it.
  • Page 68 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance km x 1,000 Fork oil (2) Engine oil Light aiming Fork oil seals Flexible coupling (6) Clutch lever pin (7) Tyres - pressure/wear (5)
  • Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance • Turn the radiator forwards to act on the coils. • Unscrew and remove the two screws fixing coils to head cover.
  • Page 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance • Check the gap between the electrodes with a feeler gauge. CAUTION DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP. The gap between the electrodes should be 0.6 - 0.7 mm (0.023 - 0.027 in) Wear limit is achieved...
  • Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
  • Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Replace the sealing washer of the drainage plug (2).
  • Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance See also Replacement Air filter • Remove the fuel tank. • Unscrew and remove the ten screws. • Remove the filter box cover.
  • Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance • Unscrew and remove the four screws. • Remove the air-box cover. • Remove the filtering element. Checking the valve clearance The following operation can be carried out also with the engine fitted on the vehicle.
  • Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance Removing the head cover • Remove the bowl tappets and the ad- justment shims using a magnet. NOTE GREASE THE BOWL TAPPETS AND THE ADJUSTMENT SHIMS PROPERLY EACH TIME THEY ARE REMOVED.
  • Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Maintenance • Apply THREEBOND on the head cover perimeter along the gasket housing. • Apply THREEBOND on the head in the areas indicated in the figure.
  • Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS TROUBL ROUBLESHOOTING email: info@motomatrix.co.uk...
  • Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting TROUBLESHOOTING PROCEDURE IF THE EFI WARNING LIGHT ON THE INSTRUMENT PANEL TURNS ON OR IF THERE IS ABNORMAL ENGINE PERFORMANCE CAUTION...
  • Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 •...
  • Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting Engine The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION THE DIAGNOSIS INSTRUMENT MUST OPERATE CORRECTLY AND PGDS MUST BE UPDATED AT LEAST TO VERSION 9.0.0.
  • Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting If NORMAL is shown, go to 8; if TIP OVER is shown, go to 12 • 8. WITH THE SWITCH SET TO "RUN", WHAT DOES THE "RUN-STOP SWITCH" STATUS...
  • Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting PIN 42, "URGENT SERVICE" TURNS ON IN THE INSTRUMENT PANEL AND THE CON- TROL UNIT INDICATES ERRORS RELATED TO THE FRONT AND REAR THROTTLE BODY) YES, go to 3;...
  • Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting • 1. CHECK CONTINUITY OF WHITE/BLUE CABLE FROM PIN 14 OF THE CONTROL UNIT ON CABLE HARNESS SIDE TO PIN 3 OF THE BLACK CONNECTOR OF THE DIAGNO- YES, go to 2;...
  • Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting If there is continuity, go to MAIN INJECTION RELAY 17 CHECK; if there is not continuity, restore cable harness - END MAIN INJECTION RELAY 17 CHECK •...
  • Page 85 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Troubleshooting • 3. CHECK WITH CONNECTOR DISCONNECTED (6-ways black, inside the bow) ON THE SWITCH SIDE, PUSHING THE SWITCH, IF THERE IS CONTINUITY BETWEEN PIN 4 AND PIN 5 YES, go to 4;...
  • Page 86 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM email: info@motomatrix.co.uk...
  • Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Coil fixing screw 5.50 Nm (4.06 lbf ft) TE screw fastening regulator to M6x30 10 Nm (7.37 lbf ft)
  • Page 88 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Components arrangement 1. Engine speed sensor 2. Intake air pressure sensor 3. Intake air temperature sensor 4. Instrument panel ELE SYS - 88...
  • Page 89 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system 5. Engine control unit 6. Headlamp 7. Start-up relay 8. Coils 9. Spark plugs 10.Starter motor 11.Taillight 12.Auxiliary fuses 13.Main fuses and ABS fuses 14.Throttle grip position sensor...
  • Page 90 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Location on the vehicle: under the fuel tank, left side, front relay box, second relay starting from the front.
  • Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • 2 Rivets • 1 Black cable guide • 2 Littelfuse 30 A Fuses (ATO Series) • 12 Cable grommets (4 different types) •...
  • Page 92 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system 12.Speed sensor connectors: CENTRAL SECTION, TABLE D. 13.Auxiliary Fuses (rubber housing correct positioning and closing): FRONT SECTION, TABLE A. •...
  • Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLES B: FRONT CABLE HARNESS AR- RANGEMENT TABLE B1 • Main cable harness must be routed un- der throttle cables and brake pipes.
  • Page 94 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE C2 • Rubber clamp. TABLE C3 • Rubber clamp. TABLE D • 4.5x290 mm (0.18x11.42 in) Clamps TABLE E - Front speed / ABS sensor cable •...
  • Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE F - Front speed / ABS sensor cable 1. Hose clamps 2. 2.5x160 mm (0.01x6.30 in) Clamps 3. M4x6 TCB screw TABLE G - Front speed / ABS sensor cable 4.
  • Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE I - ABS pipes 6. 2.5x160 mm (0.01x6.30 in) Clamps TABLE J 7. 2.5x160 mm (0.01x6.30 in) Clamps Central part...
  • Page 97 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE A2 4.5x290 mm (0.18x11.42 in) Clamps TABLE A3 1. Rubber blocks 2. Nuts 3. Bushes 4. 4.5x290 mm (0.18x11.42 in) Clamps (must be...
  • Page 98 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE A6 9. Buffer 10. Bushes 11. Rubber blocks TABLE A7 12. 4.5x290 mm (0.18x11.42 in) Clamps 13. No. 3 short screws...
  • Page 99 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE A10 Ensure that the cable harness is correctly routed, as shown. TABLE B - INJECTORS 14. GREEN connector for front cylinder injector 15.
  • Page 100 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE D2 4.5x290 mm (0.18x11.42 in) Clamps TABLE E 16. Cable harness protection 17. 4.5x180 mm (0.18x7.08 in) Clamps TABLE F 18.
  • Page 101 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE H 4.5x290 mm (0.18x11.42 in) Clamps TABLES I: FRONT CYLINDER COIL CONNEC- TORS POSITION AND FASTENING TABLE I1 20. Mounting for the AMP SuperSeal connector 21.
  • Page 102 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLES J: LAMBDA CONNECTOR POSITION TABLE J1 TABLE J2 TABLES K TABLE K1: OVERVIEW WITH FILTER BOX BASE INSTALLED TABLE K2 22.
  • Page 103 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE L 25. Cable harness supports 26. 2.5x160 mm (0.01x6.30 in) Clamps TABLES M: FUEL PUMP CONNECTION POSI- TION TABLE M1...
  • Page 104 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE N 4.5x290 mm (0.18x11.42 in) Clamps TABLE O 27. Polarised relay 28. Cap TABLE P: OVERVIEW OF THE LEFT SIDE...
  • Page 105 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE Q 29. Cable grommets 30. 2.5x98 mm (0.01x3.86 in) Clamps 31. Cable grommet TABLES R TABLE R1 • Starter cable and ABS branch are rout- ed outside the metal cable grommet.
  • Page 106 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE S - Starter motor connector The starter motor connector cap is pierced. Grease connector with waterproof grease. 32. Chassis seal.
  • Page 107 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLES V TABLE V1 35. Stand switch cable: it must be routed under the clutch control support 36. 2.5x160 mm (0.01x6.30 in) Clamps TABLE V2 4.5x290 mm (0.18x11.42 in) Clamps...
  • Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE X Cable grommet. TABLE Y Rear stop switch cable arrangement. TABLE Z: OVERVIEW, LEFT SIDE TABLES AA TABLE AA1 Cable grommet.
  • Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE AA2 2.5x160 mm (0.01x6.30 in) Clamps TABLE AA3 Lambda probe correct installation. TABLE AA4 35. Screw 36. Cable grommet TABLE AA5 Lambda probe cable arrangement.
  • Page 110 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE AA6 Lambda probe cable arrangement. Back side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE- CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES"...
  • Page 111 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLES B - FRONT AND REAR WHEEL SPEED / ABS SENSOR FITTING TABLE B1 2.5x160 mm (0.01x6.30 in) Clamps TABLE B2 4.
  • Page 112 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLES C - NOTES ABOUT THE ROUTING OF THE TAILLIGHT CABLE HARNESS TABLE C1 7. 4.5x290 mm (0.18x11.42 in) Clamp 8.
  • Page 113 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system TABLE C2 4. 2.5x160 mm (0.01x6.30 in) Clamp 10. Taillight Cable harness TABLE C3 4. 2.5x160 mm (0.01x6.30 in) Clamp 11.
  • Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. COMPLETE HEADLAMP 4. FRONT LEFT TURN INDICATOR ELE SYS - 114 email: info@motomatrix.co.uk...
  • Page 115 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system 5. HIGH - LOW BEAM BULB 6. TAIL LIGHT BULB 7. HIGH BEAM LIGHT RELAY 8. LIGHT LOGIC RELAY 9. HORN 10.Left light switch...
  • Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system 43.- 44.ECU DIAGNOSIS 45.FALL SENSOR 46.SIDE STAND SWITCH 47.GEAR SENSOR 48.REAR CYLINDER PRESSURE SENSOR 49.FRONT CYLINDER PRESSURE SENSOR 50.REAR CYLINDER THROTTLE 51.FRONT CYLINDER THROTTLE...
  • Page 117 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Conceptual diagrams Checks and inspections GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION...
  • Page 118 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system CAUTION: THE CIRCUIT SHOULD NOT BE ENERGISED, OTHERWISE THE TEST IS IRRELE- VANT. GROUND CONNECTION check Check goal: this control is to check if a cable or a circuit is in contact with the vehicle ground (-) connection.
  • Page 119 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system not significant 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 120 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Dashboard In case of doubts in operation of the engine revs indication, it is possible to connect the vehicle to the diagnosis instrument and activate the engine revs indication choosing the function "Rpm indicator"...
  • Page 121 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system This is a 5-digit code, fixed for each vehicle. For these vehicles, the code is: 98789 If the code is incorrect, the following message is displayed: •...
  • Page 122 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system The test is performed only once when the key is set to ON. This error is signalled by the bulb icon, and the general warning light turns on as well.
  • Page 123 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Select the user interface language from this menu. • ITALIANO • ENGLISH • FRANCAIS • DEUTSCH • ESPAÑOL Service warning light reset VEHICLE SERVICING RESET This function is used to reset vehicle servicing.
  • Page 124 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Starter switch P0170 •...
  • Page 125 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Fuses SECONDARY FUSES (front left, above the wa- ter radiator) 1 - Light logic relay, Recovery logic relay, Stop, Horn, Daylight running lights, License plate light (10 A).
  • Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Shift the ECU and the protection. • Remove the ECU protection. • Disconnect the connector and remove the control unit.
  • Page 127 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system CONTROL UNIT - Diagnosis Function it controls the Ride by wire system, the injection/ ignition, the system safety checks and the self-di-...
  • Page 128 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Adjustable fuel supply Adjustable fuel correction 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 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Front cylinder average intake pressure (1) • Rear cylinder average intake pressure (2) • Engine rpm • Indicated average torque •...
  • Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • If shorted to positive: check the relay electrical specifications are correct by disconnecting it from the cable harness. If they are not correct, replace the relay; if OK, restore the cable harness (Blue/Pink cable) •...
  • Page 131 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • The BUFRSVXX.BIN file is saved in the diagnosis instrument memory card or in your PC hard disk, if you are using Piaggio Group Diagnostic Software combined to the diagnosis...
  • Page 132 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Battery voltage • Example value with key ON: 12.0 V • Example value with engine on: 14.2 V In case of recovery, this value is set by the control...
  • Page 133 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Speed sensor VEHICLE FRONT SPEED SENSOR FUNCTION:To indicate the vehicle speed by read- ing the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magne- toresistive sensor: a square-wave pulse is gener- ated with voltage approx.
  • Page 134 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed.
  • Page 135 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system REMOVAL LOCATION ON THE VEHICLE:on the swingarm, right side, under the chain tension screw. CONNECTOR LOCATION (if available): under the saddle, right side.
  • Page 136 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed.
  • Page 137 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Resistance at ambient temperature: 130 +/- 20 Ohm Pin-out: 1. Negative signal 2. Positive signal CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 138 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Twistgrip position sensor Removal • Remove the filter box. • Loosen the throttle cable nuts. • Unscrew and remove the two fixing screws.
  • Page 139 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • on the vehicle: left side, under the filter box • connector: on the sensor Electrical characteristics: • Not detected by a multimeter as they are contactless: read the voltage of the 4 tracks by the diagnosis instrument.
  • Page 140 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Throttle grip position sensor • Example value with key ON: 1107 mV • Example value with engine on: - Voltage corresponding to the potentiometer track A Throttle grip opening percentage •...
  • Page 141 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system are correct, replace the throttle grip sensor; if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring Blue front connector throttle grip position sensor - track B P0151 •...
  • Page 142 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system the cable ground insulation (from the throttle grip sensor connector or the control unit con- nector): if the cable is not ground insulated, restore the wiring. If it is ground insulated, and with the key set to ON, check that there is power supply for the potentiometer PIN A and that PIN C is connected to ground.
  • Page 143 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system sensor connector and the control unit is a few tenths of Ohm: if this is not the case, restore wiring. If the value is correct, replace the complete throttle grip sensor White rear connector throttle grip position (tracks C-D) P0155 •...
  • Page 144 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Intake pressure sensor Figure key • A - Rear • B - Front Function The pressure sensors (one at the front, one at the...
  • Page 145 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Example value with key ON: 1004 mbar • Example value with engine on: 735 mbar • NOTE: pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure •...
  • Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • If shorted to positive: excessive voltage has been detected at PIN 49. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 49.
  • Page 147 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system ted. The most frequent causes can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance.
  • Page 148 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the hole for pressure reading is clogged or sensor screw is loose).
  • Page 149 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Location: • on the vehicle: on the front cylinder, in- side the "V" • connector: on the sensor. Electrical characteristics: •...
  • Page 150 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 12 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
  • Page 151 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Air temperature sensor Function it tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti-...
  • Page 152 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector.
  • Page 153 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Location: • on the vehicle: exhaust end behind the rear head • connector: on the right side, at the back...
  • Page 154 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: STATUSES Lambda probe: Start-up_Lean_Rich_Fault due to rich value_Fault due to lean value •...
  • Page 155 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • If shorted to positive: disconnect the probe connector and check the sensor correct resist- ance: replace the sensor if not OK; if it is OK, restore the cable harness (Green/Red cable) •...
  • Page 156 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • An abnormal behaviour of the voltage at PIN 10 of the ENGINE connector has been detec- ted: the voltage, that should vary over time, keeps a constant value instead.
  • Page 157 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Pin out: • "+": supply • " ": ground DIAGNOSIS INSTRUMENT: PARAMETERS Front cylinder injection time • Example value with engine on: 1.9 ms Rear cylinder injection time •...
  • Page 158 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system injector connector (if there is voltage): if there is voltage, restore the filter box cable harness. If there is no voltage, replace the sensor •...
  • Page 159 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Low fuel: it is a resistance that if correctly supplied varies its electrical resistance if it is damped or not by petrol.
  • Page 160 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • If shorted to positive: excessive voltage has been detected at PIN 73 of the VEHICLE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 73 of the VEHICLE connector.
  • Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system 0.7 - 0.9 Ω at ambient temperature Pin out: 1. Power supply + Vbatt 2. Secondary circuit to ground 3. Activation from control unit...
  • Page 162 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation.
  • Page 163 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector.
  • Page 164 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Throttle body Function Sends to the injection control unit the throttle po- sition and activates the throttle according to the...
  • Page 165 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Example value with key ON: 5.5° • Example value with engine at idle: 2.1° With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°).
  • Page 166 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Rear throttle Potentiometer 2 (voltage) • Example value with key ON: 4226 mV • Example value with engine on: 4372 mV Key to throttle connectors figure: •...
  • Page 167 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Indicates whether the self-acquisition process through the diagnosis instrument has/has not been car- ried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero...
  • Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, rear throttle position P0125 •...
  • Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature. Error cause •...
  • Page 170 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
  • Page 171 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
  • Page 172 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
  • Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not...
  • Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Rear throttle minimum mechanical position self-acquisition P0182 •...
  • Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION.
  • Page 176 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
  • Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system PIN 64: gear indication: closed circuit (continuity); gear engaged: open circuit (infinite resistance). Gear engaged circuit resistance: 1st gear: 0.8 kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th...
  • Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Clutch lever sensor Function It tells the clutch lever position to the control unit. Operation / Operating principle If there is gear engaged but the clutch is pulled, i.e.
  • Page 179 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system the sensor. If the circuit is open, it means that the White/Purple cable from PIN 1 to PIN 56 of VEHICLE connector is shorted to ground: restore the cable harness.
  • Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system sensor; if the circuit is open, it means that the brown/green cable from sensor PIN 2 to VEHICLE connector PIN 70 is short circuit to ground: restore the cable harness...
  • Page 181 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system there is 5V voltage at PIN 2 (Pink/White cable). If there is not, check the Marelli control unit connector (PIN 65).
  • Page 182 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system correct activation: no error indications are displayed in case of lack of activa- tion CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
  • Page 183 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Location: • on the vehicle: right light switch. • connector: at the centre between air fil- ter box and water radiator.
  • Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Engine pinout key: Rear cylinder side spark plug coil control output PIN 1 Front cylinder side spark plug coil control output PIN 2...
  • Page 185 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Power ground connection 2 PIN 16 Engine speed sensor input (-) PIN 20 Input for rear throttle potentiometer 2 signal PIN 21...
  • Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Vehicle pinout key: Front cylinder injector control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine"...
  • Page 187 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Not used 4 High beam lights input...
  • Page 188 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Black-bodied instrument panel pinout key: 21 +Battery 22 Front left turn indicator activation 23 Front right turn indicator activation 24 Aerial 2...
  • Page 189 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system Can line Function It allows communication between the Marelli injection ECU and the instrument panel. Operation / operating principle CAN SYSTEM ADVANTAGES A CAN (controller Area network) line is a connection among the vehicle several electronic devices, organised as a computer network (Internet).
  • Page 190 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Electrical system • between PIN 26 and 27 of the instrument panel: approximately 120 Ohm Pin out: • Line L: Orange cable between Marelli control unit PIN 66 and the black-bodied connector PIN 27 of the instrument panel.
  • Page 191 Example: if the bike is equipped with ABS, the correct status we should find on the Navigator devices status page will be: Aprilia Traction Control present. While on a bike equipped with ABS and Navigator indication: Aprilia Traction Con- trol not present, update the control unit.
  • Page 192 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS ENG VE NGINE FROM VEHICLE email: info@motomatrix.co.uk...
  • Page 193 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle RONT CHASSIS pos. Description Type Quantity Torque Notes TCEI screw fastening shock absorb- M10x30 50 Nm (36.88 lbf ft)
  • Page 194 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle ENTRE FRAME pos. Description Type Quantity Torque Notes Flanged nut fastening side panels to 80 Nm (59 lbf ft)
  • Page 195 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle pos. Description Type Quantity Torque Notes TCEI screw fastening Pin to gearbox M6x16 12 Nm (8.85 lbf ft) lever and Gearbox Lever to knurled...
  • Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Disconnect the engine oil pressure sensor connector. • Disconnect the starter motor power supply cable. • For ABS version: Move the ABS con- trol unit and disconnect control unit connector.
  • Page 197 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Disengage the spring. • Unscrew and remove the three nuts from the front exhaust manifold • Disengage the spring joining central exhaust manifold to exhaust end.
  • Page 198 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Remove the front exhaust manifold, moving the central exhaust manifold. • Remove the central exhaust manifold. • Unscrew and remove the three nuts from the rear exhaust manifold.
  • Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Undo and remove the two screws and remove the pinion protection case. • Unscrew and remove the two clutch support screws.
  • Page 200 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Disconnect the gear in neutral sensor connector. • Slacken the gearing chain tension. • Unscrew and remove the screw; col- lect the washer and the spacer.
  • Page 201 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle Removing the engine from the vehicle • Carry out the operations described un- der Vehicle preparation. • Support the engine by means of belt and hoist.
  • Page 202 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Slide off the rear top pin and collect the washer. • Remove the two spacers. The thinner spacer is on the right.
  • Page 203 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Remove the bottom spacer on the right side. • Slide off the front pin and collect the washer.
  • Page 204 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Unscrew and remove the two screws of the ECU. • Move the ECU aside but keep it connected to the wiring harness.
  • Page 205 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Lift the throttle body but keep it con- nected to the wiring harness. • Disconnect the engine temperature sensor from the front cylinder.
  • Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Disconnect the throttle body and fasten it using an elastic band. • Unscrew and remove the screws, slid- ing out the front coils.
  • Page 207 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle • Working from the left side, tighten the three nuts. • Release the engine from the belt and the hoist.
  • Page 208 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine from vehicle See also Vehicle preparation Adjusting ENG VE - 208 email: info@motomatrix.co.uk...
  • Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS NGINE email: info@motomatrix.co.uk...
  • Page 210 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Use the special plate to duly support the engine during the servicing opera- tions. CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE EN-...
  • Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine 8. Tone wheel 9. Complete transmission gear shaft 10.Forks 11.Fork shaft 12.Spring 13.Pin for spring 14.Gear selector 15.Fork shaft 16.Fork 17.Gear selector drum 18.M8x1.25 threaded pin...
  • Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine 1. Main gear shaft Z=14 2. 2nd gear on primary Z=17 3. 3rd - 4th gear on secondary Z=20/22 4. 5th gear on primary Z=23 5.
  • Page 213 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine See also Splitting the crankcase halves • Slide off the desmodromic drum con- trol. • Remove the three gear selection forks.
  • Page 214 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Carefully rotate the engine support. • Carefully slide off the whole gear unit. • Repeat the removal operations but in reverse order.
  • Page 215 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Gear selector EAR SELECTOR pos. Description Type Quantity Torque Notes Gear retainer pawl fastener screw 12 Nm (8.85 lbf ft) Loctite dry loc 2040 Selector plate fastener screw 5.50 Nm (4.06 lbf ft)
  • Page 216 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Collect the washer. NOTE REPLACE THE WASHER ON EVERY SERVICING • Heat the screws of the gearbox selec- tor mounting plate.
  • Page 217 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Checking the gear selector Selector spring In the position shown, ensure that the gap between spring ends is +/- 0.4 mm (0.016 in), compared to the same gap measured at the corresponding teeth.
  • Page 218 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Gearbox Selector Shaft Removal • Place the left hand crankcase in a press and extract the roller cage with the specific tool.
  • Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Removing the starter motor • Disconnect the starter motor power supply cable. • Unscrew and remove the two screws and remove the starter motor.
  • Page 220 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Generator side GNITION pos. Description Type Quantity Torque Notes Spark plug 11 Nm (8.11 lbf ft) Freewheel Ring fastener screw 14 Nm (10.33 lbf ft)
  • Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the ten screws. • Remove the flywheel cover using the specific tool. Specific tooling 020712Y Handle for Flywheel cover removal •...
  • Page 222 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Magneto flywheel removal • Remove the flywheel cover. • Unscrew and remove the screw and remove the retention plate. • Heat the magneto flywheel with the specific heater.
  • Page 223 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the flywheel together with the freewheel. • Remove the start-up transmission gear. • Check dimensions of the supports of transmission gear on crankcase and cover: the limit is 12.005 mm (0.4726...
  • Page 224 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Heat the magneto flywheel with the specific heater. • Unscrew and remove the six screws. • Remove the bearing retainer and bear- ing from the magneto flywheel.
  • Page 225 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Insert the flywheel on the crankshaft. • Screw the screw together with the washer but without tightening. • Place the appropriate tool for locking the flywheel.
  • Page 226 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Clutch side ATER PUMP pos. Description Type Quantity Torque Notes Clutch side cover fastener screw 13 Nm (9.59 lbf ft) Fastener screw for Pump Cover / 13 Nm (9.59 lbf ft)
  • Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Drain the engine oil. • Detach clamp retaining water pump pipe. • Collect the gasket. Removing the clutch cover ENG - 227...
  • Page 228 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine LUTCH COVER pos. Description Type Quantity Torque Notes Screw fastening Clutch Cover / inter- 13 Nm (9.59 lbf ft) mediate Clutch side cover...
  • Page 229 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Disassembling the clutch LUTCH pos. Description Type Quantity Torque Notes Clutch spring fastener screw 11 Nm (8.11 lbf ft) • Remove the clutch-side cover.
  • Page 230 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the mushroom head clutch control rod. • Working on the flywheel side, push the clutch control rod so that it comes out on the other side.
  • Page 231 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the clutch hub nut. • Remove the washer to be chamfered. • Remove the clutch hub. •...
  • Page 232 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Collect the clutch housing. • Collect the spacer and the needle bearings. • Collect the special shim featuring two thicknesses.
  • Page 233 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine THE STEEL DISCS MUST SHOW NO SCORES OR TEM- PERING COLOUR. • Measure the thickness of the clutch plates at four positions, replace them if not complying with specifications.
  • Page 234 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the rotation locking pin from the oil pump control gear. Check the clutch bell for damage and wear that may result in clutch irregular operation. Deburr the teeth or replace the bell.
  • Page 235 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Checking the springs • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded;...
  • Page 236 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Place the washer correctly between the clutch housing and the hub. • Position the clutch hub. • Fit the clutch-side cover.
  • Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Tighten the nut and proceed to caulk. CAUTION BE CAREFUL WITH THE CUPPED RING FITTING SIDE; THE RING CONE SHALL BE DIRECTED TOWARDS THE ENGINE.
  • Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally. •...
  • Page 239 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Position the retainer ring. Heads EAD COVER pos. Description Type Quantity Torque Notes Special screw for fastening head 9 Nm (6.64 lbf ft)
  • Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 22 Nm (16.22 lbf ft) Threaded plug for water sensor seat M12x1.5...
  • Page 241 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine HEAD COVER FITTING • Installation operations apply to both head covers. • Ensure gasket is in good conditions. If required, change it and use a gasket having the same features.
  • Page 242 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the cap from flywheel cover. • Turn the crankshaft until the front cyl- inder piston reaches the TDC (com- bustion).
  • Page 243 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the decompression device housing. • Remove the counterweight and de- compression device with the relevant spring. • To refit, engage spring on decompres- sion device and preload it by one turn.
  • Page 244 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Front head removal • Remove the clutch assembly. • Unscrew and remove the screw and collect the washer and the internal spring.
  • Page 245 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the chain inter- mediate gear pin. • Pay attention to avoid damaging the O- ring. • Remove the primary gear following the explanation given on crankcase open- ing.
  • Page 246 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the external screw on the flywheel side. • Unscrew and remove the three bottom head fixing nuts.
  • Page 247 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Slide head off the stud bolts. • Remove the gasket between the head and the cylinder. • Rimuovere il pattino catena fisso.
  • Page 248 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Removing camshafts • Remove the head cover. • Unscrew and remove the two screws. • Remove the coolant fitting. See also Head cover removal •...
  • Page 249 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the camshafts with the gears. Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear.
  • Page 250 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the counterweight and de- compression device with the relevant spring. • To refit, engage spring on decompres- sion device and preload it by one turn.
  • Page 251 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the two screws. • Remove the chain tensioner and col- lect the gasket. • Remove the camshafts with the gears.
  • Page 252 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the primary gear following the explanation given on crankcase open- ing. • Remove the intermediate gear with chain. NOTE...
  • Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the three bottom head fixing nuts. • Unscrew and remove the four nuts, proceeding in stages and in a diagonal pattern.
  • Page 254 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the fixed chain slider. NOTE ON REASSEMBLY, PERFECTLY CLEAN THE MATING SURFACE OF THE SPECIAL SCREW RETAINING THE IDLE GEAR AND THE THREE TIMING GEARS AND RE- PLACE THE ALUMINIUM WASHER.
  • Page 255 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. Specific tooling 020382Y Tool for removing valve cotters fitted...
  • Page 256 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL.
  • Page 257 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Support the valve with two "V" blocks as shown and check the run-out with a dial gauge. If the run-out exceeds the specified limit, replace the valve.
  • Page 258 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Timing TIMING SYSTEM pos. Description Type Quantity Torque Notes Camshaft gear fastener nut M15x1 90 Nm (66.38 lbf ft) Timing drive gear fastener screw M24x1.5...
  • Page 259 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine pos. Description Type Quantity Torque Notes Camshaft retainer plate fastener torx M5 8.5 Nm (6.26 lbf ft) 3M SCOTCH GRIP screw...
  • Page 260 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Fit tool on crankshaft matching the fly- wheel key. • Tighten the screw on the crankshaft. • Turn crankshaft until the tool "V" is positioned at the front cylinder.
  • Page 261 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Locking torques (N*m) Nut fixing camshaft gears (pre-tightening) - M15x1 (4) 30 Nm (22.13 lbf ft) • Remove the two pins.
  • Page 262 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine 020720Y Timing tool Cylinder-piston assembly YLINDER pos. Description Type Quantity Torque Notes Chain tensioner fastener screw 13 Nm (9.59 lbf ft) Cylinder plate fastener screw 13 Nm (9.59 lbf ft)
  • Page 263 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine See also Front head removal Rear head removal Disassembling the piston • Remove the cylinder. • Take out the pin locking ring.
  • Page 264 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Lock the connecting rod using circlips. FOR SAFETY REASONS COVER THE CRANKCASE WITH A CLEAN CLOTH SO THAT THE PARTS DO NOT FALL IN- TO THE CRANKCASE.
  • Page 265 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions.
  • Page 266 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine PISTON RINGS • Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves. •...
  • Page 267 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Check for cracks on the piston and for compression on the piston sliding surface (seizing); Replace the piston if required.
  • Page 268 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine DISTRIBUTE Loctite 270 (high-strength) ON THE THREAD AND SCREW THE STUD BOLT ON THE CRANKCASE UNTIL THEY PROTRUDE BY 137 mm (5.39 in), THEN MAKE SURE THE Loctite HAS SET.
  • Page 269 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine See also Selecting the base gasket • Remove the tool and fully push cylinder on the stud bolts. Selecting the base gasket •...
  • Page 270 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Fit a dial gauge on the specific tool. • Set the dial gauge to zero on a refer- ence surface with a medium preload, e.g.
  • Page 271 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Crankcase - crankshaft RANKCASE pos. Description Type Quantity Torque Notes Bearing retainer fastener screw 10 Nm (7.38 lbf ft) Loctite 270 Piston oil jet fastener screw 5.50 Nm (4.06 lbf ft)
  • Page 272 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine RANKCASE pos. Description Type Quantity Torque Notes Engine speed sensor fixing screw 13 Nm (9.59 lbf ft) Loctite 243 Screw fastening flywheel side / 13 Nm (9.59 lbf ft)
  • Page 273 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Remove the oil filter. • Using a heating gun, heat the area shown in the figure then remove the crankshaft gear with a commercially available extractor.
  • Page 274 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Collect the O-ring. See also Removing the cylinder • Unscrew and remove the selector drum fastener screw. • Unscrew and remove the nine flywheel side M8 screws.
  • Page 275 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the two engine support nuts. • Open the crankcase halves. Removing the crankshaft RANKSHAFT pos. Description Type...
  • Page 276 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine pos. Description Type Quantity Torque Notes Connecting rod screw 15 + 30 Nm (11.06 + Lubricate the 22.13 lbf ft) + 50° ± 2°,...
  • Page 277 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine CHECK THE ENGINE OIL FILTER O-RING. LUBRICATION CHECK • Working on both crankcase halves, re- move and thoroughly clean the nozzle that lubricates the piston crown.
  • Page 278 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Inspecting the crankshaft components Crankshaft axial clearance check • The shaft axial clearance on the crank- case should be checked with a dial gauge mounted on the specific dial gauge support.
  • Page 279 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Installing • The orientation of the semi-bushings must match the specifications indica- ted in the drawing as closely as possi- ble.
  • Page 280 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Refitting the crankcase halves • Fit the strum box, if previously re- moved. • Tighten the two strum box fixing screws.
  • Page 281 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Tighten the two fixing pins. • Rotate the engine and the engine support into vertical position. • Working on the left side, place the elev- en M6 screws fixing the crankcase.
  • Page 282 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Tighten the two screws fixing the se- lector drum. • Fit a new O-ring in the seat. • Position the gear sensor and screw the two fixing screws.
  • Page 283 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Fit the special tool, tightly fastening the three screws securing the tool onto the crankcase. Specific tooling 020850Y Primary gear lock •...
  • Page 284 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Lubrication IL COOLING RADIATOR pos. Description Type Quantity Torque Notes TEFL screw fastening oil radiator M6x25 10 Nm (7.37 lbf ft)
  • Page 285 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Oil pump IL PUMP pos. Description Type Quantity Torque Notes Oil drainage plug M16x1.5 19 Nm (14.01 lbf ft) Fastening oil sensor on clutch side 13 Nm (9.59 lbf ft)
  • Page 286 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • By means of a calliper spanner lock out gear rotation and loosen the nut to re- move it. See also...
  • Page 287 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Unscrew and remove the two nuts fix- ing the protection. • Collect the protection. • Remove the oil pump. Inspection •...
  • Page 288 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Slide off the shaft with the cover. • Collect the lock pin from the shaft. • Remove the oil pump rotor.
  • Page 289 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine Installing NOTE PAY ATTENTION TO ALIGN THE REFERENCES ON STA- TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE.
  • Page 290 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Fit the spacer. • Fit the gear. • Place the washer. • By means of a calliper spanner lock out gear rotation and tighten the retaining nut.
  • Page 291 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Engine • Bend the chamfering tongue. • Refit the clutch. See also Assembling the clutch ENG - 291 email: info@motomatrix.co.uk...
  • Page 292 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS P SUPP OWER SUPPLY email: info@motomatrix.co.uk...
  • Page 293 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply Fuel pump UEL PUMP pos. Description Type Quantity Torque Notes TEFL screw fastening fuel pump M5x16 3 Nm (2.21 lbf ft)
  • Page 294 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply • Remove and empty the fuel tank, then remove the fuel pump fastening screws. • Partially slide out the fuel pump as shown.
  • Page 295 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply Diagram HROTTLE BODY pos. Description Type Quantity Torque Notes Intake union fastener screw 12 Nm (8.85 lbf ft) Loctite 242 Map sensor fixing screw 5.5 Nm (4.05 lbf ft)
  • Page 296 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply 1. Ride by Wire system control (throttle map) 2. Injection/ignition control 3. System safety checks 1 - Ride by Wire system control THROTTLE GRIP POSITION SENSOR The throttle grip is the part to which the throttle control cables arrive;...
  • Page 297 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply • Air temperature 3 - System safety checks The checks are structured in several levels: • Level 1 - sensor correct operation •...
  • Page 298 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply Removing the throttle body • To reach the throttle body you must re- move the filter box. • Working on both bodies, unscrew and remove the four screws and unscrew the filter support.
  • Page 299 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply • Working on both sides, remove the screws retaining the side brackets to intake fittings. • Remove the plates. •...
  • Page 300 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Power supply Using Navigator for injection system The complete list of all the parameters, status, errors, etc. is available at the home page of the website www.serviceaprilia.com in the search section: Parameters Navigator.
  • Page 301 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS SUSP USPENSIONS email: info@motomatrix.co.uk...
  • Page 302 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Wheel axle nut 80 Nm (59 lbf ft) TE flanged screw fastening front disc M8x20 30 Nm (22.13 lbf ft)
  • Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Remove the wheel axle fixing nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps.
  • Page 304 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Checking the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS.
  • Page 305 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value.
  • Page 306 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Front fork Diagram RONT FORK pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lbf ft) Screw (Pumping member pin fixing 30 Nm (22.13 lbf ft)
  • Page 307 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions TEERING pos. Description Type Quantity Torque Notes Headstock ring nut - pre-tightening M25x1 60 Nm (44.25 lbf ft) Unscrew after pre-...
  • Page 308 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Disassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. • Using the appropriate tool fasten the fork in the vice.
  • Page 309 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Place the fork vertically locking it in a vice by the specific tool. • Completely unscrew the plug. Specific tooling AP8140149 Protection for fitting operations •...
  • Page 310 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Remove the lock nut and the washer. • Remove the spring paying attention to drain the oil correctly. • Drain the oil into a container of suitable capacity to collect fluids.
  • Page 311 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim.
  • Page 312 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Using a hook spanner lock the pump- ing member pin • Remove the stem bottom screw. Specific tooling 020889Y Pumping member ring nut locking spanner •...
  • Page 313 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Check that the following components are in good conditions: • upper bushing; • lower bushing; • piston. If there are signs of excessive wear or damage, replace the affected component.
  • Page 314 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • dust gaiter; • O-Ring on the cap. Reassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
  • Page 315 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool.
  • Page 316 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Insert the pumping member pin in the stem. • Using a hook spanner lock the pump- ing member pin and tighten the fixing screw on the fork end to the prescribed torque.
  • Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Fit the spring. CAUTION BE CAREFUL WHEN INSERTING THE SPRING SINCE THE COMPRESSED SPIRAL PART MUST BE PLACED DOWN- WARDS.
  • Page 318 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Remove the specific tools. • Screw the cover in the sleeve to the prescribed torque. Filling oil • Place the sleeve upright in a vice fitted with protection shoes.
  • Page 319 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Headstock ring nut - pre-tightening M25x1 60 Nm (44.25 lbf ft) Unscrew after pre-...
  • Page 320 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Unscrew and remove the U-bolt four fixing screws. • Remove the U-bolt. • Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out.
  • Page 321 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Straighten the safety plate (1) on the counter-lock ring (2) and remove it from steering yoke pin. • Take the suitable tool for working on the steering ring nuts.
  • Page 322 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Fit the entire fork upper plate, adjusting with short taps with a rubber hammer • Fit the washer and tighten the upper plug to the specified tightening torque.
  • Page 323 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Assembling • Grease the lower and upper bearing rollers • Prefit the shim, dust gaiter and lower bearing on the steering yoke as shown in the figure.
  • Page 324 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Fit the specific upper seal ring with the lip placed upwards and the surface with the words downwards. • Fit it on the pin and place it on the upper rim of the headstock.
  • Page 325 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Rear EAR WHEEL pos. Description Type Quantity Torque Notes Lower self-locking nut fastening 50 Nm (36.88 lbf ft) Loctite 270 sprocket to sprocket carrier...
  • Page 326 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Fully slacken the gearing chain ten- sion. • Make the wheel move forward and re- lease the gearing chain from the sprocket.
  • Page 327 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Working from the left side, unscrew and remove the five nuts and remove the sprocket and the bolts. • Unscrew and remove the five screws and remove the anti-vibration buffer holder.
  • Page 328 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions • Replace both wheel bearings. ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. • Check the radial and axial clearance.
  • Page 329 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Suspensions Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper TCEI mounting screw M10x50 50 Nm (36.88 lbf ft) Lower TCEI mounting screw M10x80 50 Nm (36.88 lbf ft)
  • Page 330 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS CHAS HASSIS email: info@motomatrix.co.uk...
  • Page 331 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis Swinging arm WINGARM pos. Description Type Quantity Torque Notes Swingarm Pin adjustment bushing 12 Nm (8.85 lbf ft) Swingarm pin ring nut 60 Nm (44.25 lbf ft)
  • Page 332 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis • Slide off the rear calliper holding plate, keeping it linked to the brake pipe. CAUTION DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER REMOVING THE WHEEL.
  • Page 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis • Working from the left side, unscrew and remove the nut and collect the washer. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION.
  • Page 334 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis • Move the vehicle forward so as to check vertical oscillation of the chain in other positions too. clearance should remain constant at all wheel rotation phases.
  • Page 335 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSE AND/OR THE SEAL RINGS ARE MISSING OR DAMAGED, THE WHOLE CHAIN UNIT (PINION, SPROCKET AND CHAIN) SHOULD BE REPLACED.
  • Page 336 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis pos. Description Type Quantity Torque Notes TCEI screw fastening stand switch M5x16 6 Nm (4.42 lbf ft) Loctite 243 Exhaust XHAUST SYSTEM pos.
  • Page 337 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis • Disconnect the lambda probe. See also Tail guard Removing the exhaust manifold • Unscrew and remove the exhaust end fixing screw.
  • Page 338 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis Removing the exhaust manifold • Remove the engine oil radiator. • Disengage the spring. • Unscrew and remove the three nuts from the front exhaust manifold •...
  • Page 339 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis • Disengage the spring joining the cen- tral exhaust manifold to the rear ex- haust manifold. • Remove the front exhaust manifold, moving the central exhaust manifold.
  • Page 340 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis Removing the lambda sensor • To remove the lambda probe refer to exhaust end removal. See also Removing the tail pipe Engine oil cooler •...
  • Page 341 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Chassis • Working on the left side, unscrew and remove the screw from the front cylin- der. • Remove the seeger ring and slide off the pin.
  • Page 342 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS BRAK SYS RAKING SYSTEM email: info@motomatrix.co.uk...
  • Page 343 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. SYSTEM pos.
  • Page 344 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main fuse 6. ECU 7.
  • Page 345 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system • PIN 13 - F_GND - Front ABS sensor ground connection • PIN 14 - F_SIG - Front ABS sensor signal •...
  • Page 346 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 346 email: info@motomatrix.co.uk...
  • Page 347 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS CONTROL UNIT 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open)
  • Page 348 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
  • Page 349 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system - the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel; it is not possible to brake for an instant.
  • Page 350 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system By moving the selector to the right - pressing it briefly - the ABS system turns on and the warning light starts blinking.
  • Page 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system • the ABS warning light flashes (SL 750 Shiver ABS / Dorsoduro 750 ABS / Dorsoduro 1200 ABS) When the 5 km/h (3.11 mph) are exceeded: - if errors are not detected •...
  • Page 352 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system • C. +12V at PIN 4 with key ON 4. ARE THERE ANY ERRORS? (YES, go to 5; NO, go to 6) 5.
  • Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Characteristic Value/example Unit of Notes measure ment Possible indications are as follows: Norge / Stel- vio / ID by ECU.
  • Page 354 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit.
  • Page 355 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system ERRORS screen page This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO).
  • Page 356 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Caratteristica Valore/esempio Unità di Note misura (leggibile nella schermata ISO sulla riga Codice veicolo) e quanto rilevato dai PIN di identificazione...
  • Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Modulator MODULATOR REMOVAL • Remove the fairing lug. • Release clamp (1) and disconnect con- nector (2). • By unscrewing the nuts, remove and plug the brake oil pipes following this sequence: (3) - (4) - (6) - (5).
  • Page 358 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Rear brake calliper EAR BRAKE pos. Description Type Quantity Torque Notes Rear brake lever pin 10 Nm (7.37 lbf ft)
  • Page 359 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system Front brake calliper RONT BRAKE pos. Description Type Quantity Torque Notes Union with breather (fixing pipe to M10x1 25 Nm (18.44 lbf ft)
  • Page 360 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
  • Page 361 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system • In this case, the bleed process must be accompanied by further pedal strokes and with the bleed device connected (about 5 for each wheel circuit).
  • Page 362 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system BRAKE BLEEDING AFTER ABS CONTROL UNIT REPLACEMENT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it.
  • Page 363 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS DESCRIBED AT THE BEGINNING OF THE CHAPTER. • Check the stroke and the sensitivity of both the lever and the brake pedal.
  • Page 364 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy.
  • Page 365 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Braking system • Repeat this procedure on the remain- ing bleed valves of the system and close them all to the prescribed tight- ening torque.
  • Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS CLU SYS LUTCH SYSTEM email: info@motomatrix.co.uk...
  • Page 367 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Clutch system LUTCH PUMP pos. Description Type Quantity Torque Notes Clutch cylinder fastener 10 Nm (7.37 lbf ft) Union with breather and fixing pipe M10x1 25 Nm (18.44 lbf ft)
  • Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS COOL SYS OOLING SYSTEM email: info@motomatrix.co.uk...
  • Page 369 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system Circuit diagram OOLING SYSTEM pos. Description Type Quantity Torque Notes Electric fan fastener screw M4x45 3 Nm (2.21 lbf ft)
  • Page 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system • Unscrew and remove the three nuts on the opposite side, collecting the wash- ers. • Remove the electric fan collecting the spacers.
  • Page 371 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system • Slide off the sleeve and empty the sys- tem completely. Water pump ATER PUMP pos. Description Type Quantity Torque...
  • Page 372 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system Removal COVER REMOVAL • Drain off the cooling circuit completely. • Unscrew and remove the five water pump cover fixing screws.
  • Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system COMPLETE H2O PUMP REMOVAL • Remove the clutch cover. • Unscrew and remove the three H2O pump fixing screws. •...
  • Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system Coolant replacement • Release the clamp retaining the breather pipe to radiator. NOTE UPON REFITTING, ALWAYS REPLACE WITH A NEW CLAMP.
  • Page 375 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Cooling system • Lower radiator and disconnect the right electric fan. • Remove the radiator with the expan- sion tank. • To install the radiator, follow the operations explained above but in reverse order, and re- place all the clamps removed.
  • Page 376 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS BODYW ODYWORK email: info@motomatrix.co.uk...
  • Page 377 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes TCEI screw fastening instrument M6x20 10 Nm (7.37 lbf ft) panel mounting to fork yoke...
  • Page 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes TBEI screw fastening fork guard to M5x9 6 Nm (4.42 lbf ft) calliper mounting bracket...
  • Page 379 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes Screws fastening battery cover to 5x14 2.6 Nm (1.92 lbf ft) compartment TBEI screw fastening battery com- M5x9 6 Nm (4.42 lbf ft)
  • Page 380 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes TBEI screw fastening LH - RH covers M6x20 10 Nm (7.37 lbf ft)
  • Page 381 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork ADDLE MOUNTING pos. Description Type Quantity Torque Notes Upper LH TCEI screw fastening sad- M8x55 25 Nm (18.44 lbf ft) dle mounting to frame...
  • Page 382 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork Headlight assy. EADLAMP pos. Description Type Quantity Torque Notes TEFL screw fixing headlight mount- M6x16 10 Nm (7.37 lbf ft) ing to steering base...
  • Page 383 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Remove the instrument panel. • Working from the vehicle left side, un- screw and remove the pin, and collect the nut and the washer from the right side.
  • Page 384 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork Disassembling the lock LOCKS pos. Description Type Quantity Torque Notes Switch fastener shear head Manual screw TE screw fastening saddle lock / bat- M6x25 10 Nm (7.37 lbf ft)
  • Page 385 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork Taillight assy. AILLIGHT pos. Description Type Quantity Torque Notes TCEI license plate light fixing screw M5x25 6 Nm (4.42 lbf ft) TCEI rear turn indicator fixing screw 3 Nm (2.21 lbf ft)
  • Page 386 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork See also Tail guard • Disconnect the saddle opening cable and slide it out of the cable grommet. • Open the rear end of the license plate holder to be able to disconnect the tail- light connector.
  • Page 387 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork Footrest OOTRESTS pos. Description Type Quantity Torque Notes Upper screw fastening passenger M8x35 25 Nm (18.44 lbf ft) Loct. 243 footrests to frame side panels...
  • Page 388 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Remove the right footrest • Unscrew and remove both rear brake pump internal fixing screws. LEFT FOOTREST • Unscrew and remove the two external screws.
  • Page 389 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Unscrew and remove the front screw. • Unscrew and remove the water radia- tor screw. License plate holder • Remove the saddle.
  • Page 390 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Disconnect the saddle unlocking ca- ble. • Slide off the license plate holder to- wards the back. See also Seat...
  • Page 391 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork IR FILTER BOX pos. Description Type Quantity Torque Notes Cross head self-tapping screw fas- M5x20 3 Nm (2.21 lbf ft) tening covers / filter box...
  • Page 392 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Remove the headstock protection. • Disconnect the air temperature sensor. • Remove the two clamps from the blow- by system.
  • Page 393 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork Fuel tank UEL TANK pos. Description Type Quantity Torque Notes TCEI screw fastening filler cap flange M5x12 6 Nm (4.42 lbf ft)
  • Page 394 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork UEL PUMP pos. Description Type Quantity Torque Notes TEFL screw fastening fuel pump M5x16 3 Nm (2.21 lbf ft) Loctite 518...
  • Page 395 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Disconnect the fuel pump connector. • Disconnect the fuel pipe. • Unscrew and remove the four lower support screws. CAUTION...
  • Page 396 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Disconnect the two breather tubes on the right side. • Remove the tank. Instrument cluster support • Working on both sides, loosen the nuts and screws and remove everything.
  • Page 397 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Bodywork • Slide off the instrument panel from its support. • Disconnect the instrument panel con- nector. • Remove the instrument panel.
  • Page 398 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS email: info@motomatrix.co.uk...
  • Page 399 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. PRE DE DELIVERY email: info@motomatrix.co.uk...
  • Page 400 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts...
  • Page 401 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC 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 402 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency...
  • Page 403 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Pre-delivery • Remove the TCEI M6 X 50 screw which fastens the antivibration weight. • Fit the rubber ring in the hand guards.
  • Page 404 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO 1200 ABS - ATC Pre-delivery • Place the hand guards fastening them on the sides using TCEI M6 X 50 screw being careful when inserting the bush- ing.
  • Page 405 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. ABS: 343, 352 Air filter: 73, 391 Air temperature sensor: 151 Battery: 131 Brake: 358–360, 364, 365 Brake calliper: 358, 359 Brake fluid: 364 Brake pads: 359, 360 Brake pump: 365 Bulbs: Bushings:...
  • Page 406 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. Gearbox selector: 218 Handlebar: 305 Head cover: 75, 240, 241, 248 Headlight: 382 Identification: 12 Instrument panel: 120 Intake pressure sensor: 144 License plate holder: 389 Magneto flywheel: 222, 224, 251, 273 Maintenance: 9, 67 Maintenance Table: Mudguard:...
  • Page 407 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. Water pump: 371 Wiring diagram: 114 email: info@motomatrix.co.uk...

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