APRILIA DORSODURO FACTORY ABS 2011 Service Station Manual
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APRILIA DORSODURO FACTORY ABS 2011 Service Station Manual

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.
SERVICE STATION MANUAL
DORSODURO FACTORY ABS
email: info@motomatrix.co.uk
898998

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Summary of Contents for APRILIA DORSODURO FACTORY ABS 2011

  • Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. SERVICE STATION MANUAL 898998 DORSODURO FACTORY ABS 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: Safety Rules

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 FACTORY ABS Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
  • Page 10 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
  • Page 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: Vehicle Identification

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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. CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.
  • Page 13 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Engine ENGINE Specification Desc./Quantity Model M551M Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 over- head camshafts. No. of cylinders Total engine capacity 749.9 cm³...
  • Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Drive chain RIVE CHAIN Specification Desc./Quantity Type Endless (without master link) and with sealed links. No. of links Model 525 ZRPK Electrical system LECTRICAL SYSTEM Specification Desc./Quantity...

  • Page 15: Wheels And Tyres

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) Rear Oscillating swingarm with Sachs piggy-back single shock ab- sorber and adjustable spring preloading, wheelbase and hy- draulic compression and rebound damping.

  • Page 16: Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Supply UEL SYSTEM Specification Desc./Quantity Type Electronic injection (Multipoint) Throttle valve diameter Ø 52 mm (2.05 in) Fuel Premium unleaded petrol, minimum octane rating 95 (NORM) and 85 (NOMM) Tightening Torques Chassis...
  • Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics RONT FORK pos. Description Type Quantity Torque Notes Screws (fasten onto fork hubs) M6x40 12 Nm (8.85 lbf ft) Screw (Pumping member pin fixing 30 Nm (22.13 lbf ft) to the stem base) Upper cover...
  • Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics TERZO Pos. Descrizione Tipo Quantità Coppia Note Headstock ring nut - pre-tightening M25x1 30 Nm (22.13 lbf ft) Steering package settlement Headstock ring nut - tightening M25x1 12 Nm (8.85 lbf ft) Headstock nut - pre-tightening...
  • Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes TBEI screw fastening fork guard to M5x9 6 Nm (4.42 lbf ft) Loct. 243 calliper mounting bracket TBEI screw fastening mudguard to M5x9 4 Nm (2.95 lbf ft)
  • Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics ANDLEBAR pos. Description Type Quantity Torque Notes TCEI screw fastening counterweight M6x50 10 Nm (7.37 lbf ft) to handlebar end Stainless steel TCC screw fastening M8x25 25 Nm (18.44 lbf ft) upper clamp to lower clamp...
  • Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Pipe union fastening brake pipe to M10x1 25 Nm (18.44 lbf ft) pump Fastener for front brake pump on 10 Nm (7.37 lbf ft) handlebar TBEI screw fastening the brake tank...
  • Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics EADLAMP pos. Description Type Quantity Torque Notes TE screw fastening headlamp to M6x16 10 Nm (7.37 lbf ft) headlamp mounting and mudguard to steering base Fastener for front turn indicators 3 Nm (2.21 lbf ft) TCEI screw fastening headlamp...
  • Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics RONT BODYWORK pos. Description Type Quantity Torque Notes TBEI screw fastening front side pan- M5x9 4 Nm (2.95 lbf ft) els to tank TBEI screw fastening front side pan- M6x16 6 Nm (4.42 lbf ft)
  • Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 50 Nm (36.88 lbf ft) stems)
  • Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Central part RONT CHASSIS pos. Description Type Quantity Torque Notes TCEI screw fastening shock absorb- M10x30 50 Nm (36.88 lbf ft) er counterplate to RH frame bracket TC TORX screw fastening trellis M12x53 80 Nm (59 lbf ft)
  • Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics ENTRE FRAME pos. Description Type Quantity Torque Notes TCEI screws fastening side panels to M12x282 80 Nm (59 lbf ft) engine TCEI screw fastening lambda probe M4x10 3 Nm (2.3 lbf ft) plate to RH frame (pre-fit on RH side...
  • Page 27 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics OOTPEGS pos. Description Type Quantity Torque Notes Upper screw fastening passenger M8x35 25 Nm (18.44 lbf ft) footrests to frame side panels Lower TCEI screw fastening passen- M8x35 25 Nm (18.44 lbf ft) ger footrests to rider footrest mount-...
  • Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics TAND ASSEMBLY pos. Description Type Quantity Torque Notes Stand screw M10x1.25 10 Nm (7.37 lbf ft) Loctite 243 Thin nut M10x1.25 30 Nm (22.13 lbf ft) Loctite 243 Spring fixing pin 7.5 Nm (5.53 lbf ft)
  • Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics UEL PUMP pos. Description Type Quantity Torque Notes TEFL screw fastening fuel pump M5x16 6 Nm (4.42 lbf ft) IR FILTER BOX pos. Description Type Quantity...
  • Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics pos. Description Type Quantity Torque Notes SWP self-tapping screw M2.9x12 TCCR 3 Nm (2.21 lbf ft) Cross head self-tapping screw fas- M5x20 3 Nm (2.21 lbf ft) tening cover / filter box Cross head self-tapping screw fas- M5x20...
  • Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Coil fixing screw 13 Nm (9.59 lbf ft) TE screw fastening regulator to M6x30 10 Nm (7.37 lbf ft) frame CHAR - 31 email: info@motomatrix.co.uk...
  • Page 32 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Screw fastening ECU to filter box 2.5 Nm (1.47 lbf ft) base Starter relay fastener 3 - 4.2 Nm (2.21 - 3.1 lbf LOCKS pos.
  • Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Intake union fastener screw 12 Nm (8.85 lbf ft) Loctite 242 RBW control unit fastener screw 3.50 Nm (2.58 lbf ft) Loctite 242 Injector fastener screw...
  • Page 34 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics 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 Upper RH TCEI screw fastening sad- M8x60 25 Nm (18.44 lbf ft)
  • Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper TCEI mounting screw M10x50 50 Nm (36.88 lbf ft) Lower TCEI mounting screw M10x90 50 Nm (36.88 lbf ft) CHAR - 35 email: info@motomatrix.co.uk...
  • Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics XHAUST SYSTEM pos. Description Type Quantity Torque Notes SERPRESS self-locking nut fasten- 25 Nm (18.44 lbf ft) ing flange on head Primary Clamp (between front/rear 7 Nm (5.16 lbf ft) manifolds and central manifold) Silencer Clamp (between central...
  • Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics EAR BRAKE pos. Description Type Quantity Torque Notes Rear brake lever pin 25 Nm (18.44 lbf ft) Flanged TE screw fastening pump to M6x20 10 Nm (7.37 lbf ft) footrest mounting...
  • Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics AILLIGHT pos. Description Type Quantity Torque Notes TE screw fastening tail light to li- M6x45 10 Nm (7.37 lbf ft) cense plate mounting frame Fastener for rear turn indicators 3 Nm (2.21 lbf ft) Reflector fastener...
  • Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics EAR BODYWORK pos. Description Type Quantity Torque Notes Screws fastening battery cover to 4 Nm (2.95 lbf ft) compartment TBEI screw fastening battery com- M5x9 6 Nm (4.42 lbf ft) partment to saddle mounting...
  • Page 40 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics EAR BODYWORK pos. Description Type Quantity Torque Notes TBEI screw fastening license plate M5x9 6 Nm (4.42 lbf ft) mounting to mounting Fastener for license plate mounting 10 Nm (7.37 lbf ft) frame assembly to gusset plate - saddle lock...
  • Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) Engine EAD COVER...
  • Page 42 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 23 Nm (16.96 lbf ft) Threaded plug for water sensor seat M12x1.5 10 Nm (7.38 lbf ft) Loctite Drise AL 506 Head stud bolt fastener nut - pre- M10x1.25...
  • Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) CHAR - 43...
  • Page 44 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics TIMING SYSTEM pos. Description Type Quantity Torque Notes Camshaft gear fastener nut - pre- M15x1 30 Nm (22.13 lbf ft) tightening Camshaft gear fastener nut - tighten- M15x1 90 Nm (66.38 lbf ft) Timing drive gear fastener screw...
  • Page 45 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics pos. Description Type Quantity Torque Notes Cam tower / head fastener screws - 4.90 - 6.86 Nm (3.61 - pre-tightening 5.06) lbf ft Cam tower / head fastener screws - 9.81 - 12.75 Nm (7.24 - tightening...
  • Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) crankcase half Fastening oil filter union on clutch...
  • Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics EAR SELECTOR pos. Description Type Quantity Torque Notes Gear retainer pawl fastener screw 12 Nm (8.85 lbf ft) Selector plate fastener screw 5.50 Nm (4.06 lbf ft) Screw fastening Desmodromic se- 23 Nm (16.96 lbf ft) lector drum / Selector sprocket...
  • Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics LUTCH COVER pos. Description Type Quantity Torque Notes Fastener screw for Clutch Cover / 13 Nm (9.59 lbf ft) Clutch side cover Clutch fastener nut M24x1.5 180 Nm (132.76 lbf ft) ±...
  • Page 49 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch spring fastener screw 12 Nm (8.85 lbf ft) ATER PUMP pos. Description Type Quantity Torque Notes Clutch side cover fastener screw 13 Nm (9.59 lbf ft)
  • Page 50 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) Clutch Cover / clutch side crankcase half...
  • Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) Loctite 242 Tapered plug for crankshaft main...
  • Page 52 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics 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) clutch side crankcase halves Screw fastening flywheel side /...
  • Page 53 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Crankcase - crankshaft - connecting rod INTERNAL MARKING ON FIRST GENERATION CRANKCASES Crankcases are classified in two classes (1 or 2) depending on the diameter of the main bearing seat. The class is indicated on both crankcase halves, specifically, in the rear cylinder area on flywheel side crankcase halves and in the front cylinder area on clutch side crankcase halves.
  • Page 54 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics There are three crankshaft classes selectable for each bearing: • 4 - 5 - 6 for the flywheel side; • 7 - 8 - 9 for the clutch side; The class is stamped on the outer face of the crankshaft counterweight.
  • Page 55 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) See also Removing the flywheel cover...
  • Page 56 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Crankshaft class (crank pin) There are four different classes of crankshaft avail- able (0, 1, 2, 3), selected in relation to crank pin diameter.
  • Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics WHEN REFITTING, ALSO ENSURE THAT THE SEMI-BUSHINGS ARE ALL OF THE SAME CLASS. See also Removing the flywheel cover Selecting bushings There is only one dimension class for the connecting rod. As a result, the bushings used must be selected in accordance with the dimension class of the crank pin.
  • Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Characteristics Product Description Specifications AGIP PERMANENT SPEZIAL Recommended ENGINE COOLANT Ready mixed biodegradable coolant with "long life" technology and characteristics (red). Freezing protection up to -40° (-40° F).
  • 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 FACTORY ABS Special tools PECIAL TOOLS Stores code Description 020709Y Engine support 020710Y Engine plate AP8140187 Engine support stand 020711Y Engine pinion locking 020712Y Handle for Flywheel cover removal 020713Y Flywheel extractor S-TOOLS - 60...
  • Page 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description 020714Y Dial gauge mounting 020715Y Tone wheel removal 9100896 Clutch housing locking tool 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool AP8140302 tool for sealing ring fitting S-TOOLS - 61...
  • Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description 020718Y Camshaft gear alignment pin 020719Y Timing pin 020720Y Timing tool AP8140179 Valve spring compressor 020721Y Adaptor for valve removal 020722Y Guide for oil seal 020376Y...
  • Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description 020629Y 8 mm (0.31 in) guide 020412Y 15-mm Oil seal guide 020439Y 17-mm guide for oil seal 020263Y Sheath for fitting the driven pulley 020365Y 22 mm (0.87 in) guide 020364Y...
  • Page 64 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description 020483Y 30 mm guide 020441Y Oil seal punch 020358Y 37 x 40-mm adaptor 020357Y 32 x 35 mm adaptor 020359Y 42 x 47-mm adaptor 020360Y...
  • Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description 020723Y Jig for timing overhead camshafts 020724Y Gear control rod roller cage punch 020661Y Water pump overall seal replacement kit 020725Y Punch for water pump overall sealing 020885Y...
  • Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description AP8140180 Extractor for bushings 8140181 manometer for fuel - oil - compression pressure AP8140199 Tool panel 8202222 Generic adhesive film for panel 8140426 Hooks for panel 020880Y...
  • Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Special tools Stores code Description AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices AP8140146 Weight 020889Y Pumping member ring nut locking span- 020888Y Pliers for pre-fill pipe 020884Y...
  • Page 68 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 69: Maintenance Chart

    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 70: Spark Plug

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance km x 1,000 Light aiming Fork oil seals Flexible coupling ****** Tyres - pressure/wear (5) Wheels Bolts and nuts tightening Suspensions and setting Warning light indicating error on the instrument panel **** Fuel pipes *** Clutch wear...
  • Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance • Undo and remove the screw, remove the horn. • Turn the radiator forwards and lower it to act on the coil. • Undo and remove the screw.
  • Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance • Unscrew and remove the front spark plug. REAR SPARK PLUG • Lift the tank. • Unscrew and remove the rear coil fix- ing screw.

  • Page 73: Engine Oil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance The electrode gap should be between 0.6 ÷ 0.7 mm (0.023 ÷ 0.027 in). Otherwise, replace the spark plug. • Make sure the washer is in good con- ditions.
  • Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance • Shut off the engine. • Keep the vehicle upright with both wheels on the ground. • Check the correct oil level through the appropriate sight glass on the engine crankcase.

  • Page 75: Engine Oil Filter

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance Locking torques (N*m) Oil drainage plug - M16x1.5 19 Nm (14.01 lbf ft) • Replace the oil filter. • Fill up to the right engine oil level by adding recommended engine oil. See also Engine oil filter...
  • Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance • Remove the clamp and slide off the blow-by tube. • Remove the filter box cover. • Working on both ducts, turn the upper part of the intake ducts anticlockwise and remove it.

  • Page 77: Checking The Valve Clearance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance Checking the valve clearance The following operation can be carried out also with the engine fitted on the vehicle. • Remove both head covers. CAUTION WHENEVER THE HEAD COVER IS REMOVED, ALL FOUR RUBBER RINGS AND THE GASKET SHOULD BE REPLACED.
  • Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance • Replace calibrated pads with a pad thick enough to correct the valve clear- ance previously detected. • List of calibrated break pads: 1.
  • Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Maintenance • Apply THREEBOND on the head in the areas indicated in the figure. See also Removing the head cover MAIN - 79 email: info@motomatrix.co.uk...
  • Page 80 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 81 THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE CONTROL UNIT THROUGH NAVIGATOR BY SELECTING "SELF- DIAGNOSIS, APRILIA, DORSODURO, 750 i.e." • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
  • Page 82 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Troubleshooting Engine The engine does not start THE ENGINE DOES NOT START CAUTION NAVIGATOR SHOULD BE WORKING PROPERLY AND UPGRADED. CAUTION BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V;...
  • Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Troubleshooting • 11 - REPLACE THE MAIN INJECTOR RELAY (POLARISED) 41 - END • 12 - CHECK IF THERE IS VOLTAGE ON THE ORANGE/RED CABLE OF THE AUXILIARY INJECTION RELAY (POLARISED) 42.
  • Page 85 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Troubleshooting • 29 - VOLTAGE TO THE YELLOW/PINK CABLE OF THE RETENTION RELAY (START-UP LOGIC) 39 OK, go to 30; NOT OK, go to 31 •...
  • Page 86 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Troubleshooting • 44 - CHECK IF THERE IS VOLTAGE IN THE RED/BLACK CABLES ON THE CONTROL RELAY (START-UP LOGIC) 40 YES, go to 50; NO, go to 51 •...
  • Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Troubleshooting • 61 - REPLACE THE START-UP RELAY 36 - END • 62 - REPLACE THE STARTER MOTOR - END • 63 - RESTORE THE CABLE HARNESS - END •...
  • Page 88 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 89 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Coil fixing screw 13 Nm (9.59 lbf ft) TE screw fastening regulator to M6x30 10 Nm (7.37 lbf ft) frame ELE SYS - 89...
  • Page 90 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Screw fastening ECU to filter box 2.5 Nm (1.47 lbf ft) base Starter relay fastener 3 - 4.2 Nm (2.21 - 3.1 lbf Components arrangement ELE SYS - 90...
  • Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system 1. fall sensor 2. Intake air pressure sensor 3. Intake air temperature sensor 4. Instrument panel 5. Engine control unit 6. Headlamp 7.
  • Page 92 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Location on the wiring diagram: 38 • Location on the vehicle: under the fuel tank, right side, third relay starting from the front. MAIN INJECTION RELAY •...
  • Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Small black clamps 98 x 2.5 (3.86 x 0.01 in) • 1 10-cm (3.94 in) spiral for start-up cable • 1 Pick-Up divider cable harness (if fitted) Motorcycle division The wiring distribution is subdivided in three es- sential sections, as indicated in the figure.
  • Page 94 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE A - RECOVERY 1. 12V 30A Relay • Fasten cable harness with retaining straps as shown in the figure. TABLE B - FASTENING SWITCH CABLE HAR- NESSES •...
  • Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE D - Lay the cable as shown and fasten it with a 2.5x160 clamp TABLE E - Fasten with a 2.5x160 clamp Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND...
  • Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE B - CABLE HARNESS FOR RELAY UNIT The shortest cables must be connected to the three closest relays TABLE C To lay the auxiliary fuses box under the airbox: •...
  • Page 97 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE E 5. Cable guide already fitted on engine 6. Rubber cap TABLE F 4.5x180 (0.18x7.08) Clamps TABLE G Plastic cable guide holding the auxiliary fuses branch and the cylinder coil cable 1 (horizontal).
  • Page 98 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE H 4.5x290 (0.18x11.42) Clamp TABLE I 1. 12V / 30A Fan relay 2. Relay with ignition maintenance diode (serv- ice) 12V / 20A 3.
  • Page 99 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE L First of all connect the light switches connectors and the key switch inside the rubber cap and po- sition the latter as in the figure, then the Demand Master (BLUE tape) connector and then the "reg- ulator"...
  • Page 100 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE O1 • Clamp. TABLE P Engine attachment clamps that coil the main cable harness and the engine - battery ground connec- tion cable harness.
  • Page 101 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE S 15. Side stand switch output sheath 16. Battery compartment breather pipe 17. Cable grommet TABLE T The cables fastened to the engine ground must face downwards.
  • Page 102 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE Z Connector insertion on Demand and secondary lock closing TABLE ZA-ZB Tables with tips on filter box cable harness fitting. ELE SYS - 102 email: info@motomatrix.co.uk...
  • Page 103 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE ZC-ZD Tables with tips for fitting ground lead and start-up cable 22. Cable grommet 23. ABS cable harness connecting cable 24. Starter motor cable coiled with pigtail wire L=10 cm (3.93 in). 25.
  • Page 104 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE ZF Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard TABLE ZG When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in).
  • Page 105 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system TABLE ZH 27. Fasten the cable harness with a clamp. Insert the housing as shown in the figure. 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 106 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system General wiring diagram key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. COMPLETE HEADLAMP ELE SYS - 106 email: info@motomatrix.co.uk...
  • Page 107 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system 4. TAIL LIGHT BULB 5. TWIN HIGH-/LOW BEAM BULB 6. FRONT LEFT TURN INDICATOR 7. LOGIC RELAY WITH N.C. MATING 8. CLUTCH SWITCH 9.
  • Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system 42.FAN CONTROL RELAY 43.FUEL LEVEL SENSOR 44.FUEL PUMP 45.REAR CYLINDER COIL 46.FRONT CYLINDER COIL 47.REAR CYLINDER SPARK PLUG 48.FRONT CYLINDER SPARK PLUG 49.INTAKE AIR TEMPERATURE SENSOR 50.Water Temperature Sensor 51.LAMBDA PROBE...
  • Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system R Red Ro Pink V Green Vi Purple Conceptual diagrams Checks and inspections GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN"...
  • Page 110 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Check goal: this control is to check that there are not any circuit interruptions nor excessive resistance, for instance caused by rust, on the two terminals being inspected. Tester: set the tester on the "continuity"...
  • Page 111 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system 98789 If the code is incorrect, the following message is displayed: • INCORRECT CODE and the instrument panel goes back to the main menu. Otherwise, the following menu is displayed: •...
  • Page 112 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system DSB 06 - - Error cause • An oil sensor fault is signalled when it is detected that the sensor circuit is open or shorted to positive.
  • Page 113 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system At least one key must be programmed for the next start-ups. If no other key is inserted within 20 seconds or if there is no power or after the fourth key is programmed, the procedure finishes and all the functions of the vehicle and the instrument panel must be enabled (even if only one key has been programmed).
  • Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Lights list Front headlamp Characteristic Front daylight running light 12V - 6W H6 Low beam light 12 V - 50 W H4 High beam light 12 V - 60 W H4 Rear light...

  • Page 115: Control Unit

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Control unit MARELLI CONTROL UNIT Function It controls the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function.
  • Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Target idle rpm NAVIGATOR: ELECTRICAL ERRORS EEPROM Error P0601 - circuit not operational. Error cause • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status.

  • Page 117: Battery Installation

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Check the VEHICLE connector of the Marelli control unit, the filter box large connector and the throttle control unit connector: if not OK, restore. If OK, check continuity between the Marelli control unit and the throttle control unit connector from VEHICLE PIN 55 to PIN B7 and from PIN 56 to PIN A7: if not OK, restore.

  • Page 118: Speed Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system THE FIRST TIME THE ENGINE IS STARTED AFTER RECONNECTING THE BATTERY LEADS, WAIT 20 SECONDS BETWEEN THE MOMENT THE KEY IS SET TO "KEY ON" AND THE MOMENT THE STARTER BUTTON CAN BE PUSHED.
  • Page 119 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Speed sensor 5D91 the signal works irregularly: faulty sensor or signal interference. Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed.
  • Page 120 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system VEHICLE REAR SPEED SENSOR FUNCTION:To indicate the vehicle speed by read- ing the rear wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magne- toresistive sensor: a square-wave pulse is gener- ated with voltage approx.
  • Page 121 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system 5DA2 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; pos- sible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations. Troubleshooting: Check if the tone wheel is dirty, deformed or wrongly fixed.
  • Page 122 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Level in electrical circuit diagram: engine spe- ed sensor Location: • on the vehicle: inside the flywheel cov- • connector (if available): near the Mar- elli control unit Electrical characteristics: •...
  • Page 123 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Engine speed sensor P0336 - Synchronism lost Error cause • Displayed if the signal is not as the control unit expects, for example due to voltage fluctu- ations not correctly repeated.
  • Page 124 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system NAVIGATOR: PARAMETERS Left side throttle grip position sensor - track A example value: 1107 mV Voltage value of the left potentiometer track A Left side throttle grip position sensor - track B example value: 1107 mV Voltage value times 2 of the left potentiometer track B...
  • Page 125 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Error cause • If shorted to positive: excessive voltage has been detected at PIN 42 of the VEHICLE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 42 of the VEHICLE connector.
  • Page 126 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Right side Throttle Grip Position sensor - track C P0152- short circuit to positive / open circuit, short circuit to negative. Error cause •...
  • Page 127 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring. NAVIGATOR: LOGIC ERRORS Left side Throttle Grip Position (tracks A-B) P0154 - illogical signals. Error cause •...
  • Page 128 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system MOVING THEM (BLUE STAMP + BLUE BAND). THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED TO THE LEFT. THE CONNECTOR AND THE WHITE BAND SHOULD BE PLACED TO THE RIGHT.
  • Page 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system NAVIGATOR: PARAMETERS Front Cylinder Intake Pressure example value: 1003 mbar Pressure read by the front sensor. Rear Cylinder Intake Pressure example value: 1004 mbar Pressure read by the rear sensor.
  • Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • If the circuit is open, short circuit to negative, check filter box large connector, the Marelli control unit connector and the sensor connector. If not OK, restore. If everything is OK, and with key set to OFF, check if there is continuity between the VEHICLE PIN 34 of the Marelli control unit and the sensor connector PIN 3: if there is no continuity, restore the cable har- ness.
  • Page 131 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system front cylinder air pressure sensor P0107 - signal not valid. Error cause • According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activa- ted.
  • Page 132 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Troubleshooting • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean.
  • Page 133 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is below the estimated one (for example, smeared throttle body).
  • Page 134 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system example value: 75° C In case of recovery, this value is set by the control unit. Engine Temp. before Recovery example value: -40° C Value drawn from the signal read without taking into account any recovery: the value in the example refers to an open circuit.
  • Page 135 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system same as the engine temperature. Check also that the sensor electrical characteristics are ob- served: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector Air temperature sensor INTAKE AIR TEMPERATURE SENSOR...
  • Page 136 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 63 of the ENGINE connector.
  • Page 137 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system ambient. It does not require an external supply source but, in order to work properly, it should reach a high operating temperature: that is why there is a heating circuit inside.
  • Page 138 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system sponds to -25%. In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes it as a lean combustion condition and will try to enrich it. The value read will be 0.75: once this correction has been tried, the value shifts to 1.00 fixed and the Lambda probe error is signalled.
  • Page 139 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Shorted to positive: disconnect the probe connector and check the sensor correct resistance: replace the sensor if not OK; if it is OK, restore the cable harness. •...
  • Page 140 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Injector INJECTOR Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open.
  • Page 141 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. NAVIGATOR: ELECTRICAL ERRORS Front cylinder injector P0201 - shorted to positive / shorted to negative / open circuit.
  • Page 142 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system connector and check if there is voltage at PIN -: if there is voltage, restore the filter box cable harness. If there is no voltage, replace the sensor. •...
  • Page 143 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system 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 144: Throttle Body

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Navigator and check voltage at connector PIN 3: if there is voltage, restore the cable har- ness;...
  • Page 145 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system If during activation, the engine is started, the activation is not completed and the stop lights do not turn on. Every 150 key-ONs, however, the throttle valves are forced to activation. If start-up is attempted during this activation (which requires 3 seconds), the engine will not start.
  • Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Front / rear cylinder throttle correction Example value: 0.0° For example, if there is a hole in the intake manifold, the pressure read is different from the pressure estimated by the control unit and the system tries to reach an "estimated"...
  • Page 147 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Example value:short circuit to positive / open circuit, short circuit to negative Error cause • If shorted to positive: excessive voltage has been detected at PIN A5 of the throttle control unit.
  • Page 148 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • If shorted to positive: excessive voltage has been detected at PIN B5 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN B5 of the throttle control unit.
  • Page 149 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • shorted to negative: disconnect the throttle body connector, set the key to ON and check if PIN 3 is in continuity with the vehicle ground connection: if it is, there is a short circuit in the cable ground connection;...
  • Page 150 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • open circuit, overcurrent, excessive inside temperature: check the throttle body connector and the throttle control unit connector. If not OK, restore. If everything is OK, disconnect the throttle body connector (PIN 3) and the throttle control unit connector (C8) and check the circuit continuity between the two terminals;...
  • Page 151 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Check the throttle body connector as well as the throttle control unit connector. Check that cable resistance between the throttle body connector (PIN 1) and the throttle control unit (PIN 6A) is a few tenths of an Ohm.
  • Page 152 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Error cause • Throttle position, kept by the springs, not within the expected range (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting •...
  • Page 153 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • The throttle mechanical control may be damaged. Troubleshooting. • Replace the throttle body. Rear throttle Limp Home self-acquisition P0180 - test failed. Error cause •...
  • Page 154 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Delete errors hindering throttle self-learning. Rear throttle position error P0187 - misalignment between control and activation. Error cause • The throttle mechanical control may be damaged. Troubleshooting.
  • Page 155 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Instrument panel Error DSB 07 Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open.
  • Page 156 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Neutral sensor GEAR IN NEUTRAL SENSOR Function it tells the gear position to the control unit: if it is in neutral or in gear. Operation / Operating principle for gear in neutral, the circuit is closed to ground connection: then, via CAN, the control unit sends...
  • Page 157 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system control unit connector and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness; if OK, check the cable continuity between the sensor connector and ENGINE connector PIN 16: if there is no continuity, restore the cable harness.
  • Page 158 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Indication on Navigator always released: check the correct position of the cable terminals on the connector and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness;...

  • Page 159: Bank Angle Sensor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Side stand Example value:up/down Indication on Navigator always down: check the connector: if not OK, restore; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness;...
  • Page 160 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Example value: Normal / Tip over Indication on Navigator always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is no continuity, replace the sensor;...
  • Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system NAVIGATOR: ELECTRICAL ERRORS Cooling fan relay P0480 - shorted to positive / shorted to negative / open circuit. Error cause • If shorted to positive: excessive volt- age has been detected at PIN 54 of the VEHICLE connector.
  • Page 162 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system RUN/STOP switch Run / stop switch Function It tells the control unit if the driver wishes to enable engine start-up or to keep the engine running. Operation / Operating principle If the driver wants to shut off the engine or to dis- able engine start-up, the switch should be open,...
  • Page 163 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system is in good conditions and the continuity of the grey/yellow cable between the sensor in question and the VEHICLE connector PIN 26: if not OK, restore the cable harness; if OK, replace the Marelli control unit.
  • Page 164 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system PIN OUT ARELLI CONTROL UNIT Specification Desc./Quantity Key switch Vehicle connector: 12/29 Revolution sensor input (+) Engine connector: 9 Revolution sensor input (-) Engine connector: 23 Vehicle speed input Vehicle connector: 49...
  • Page 165 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNEC- TOR.
  • Page 166 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Throttle control unit PIN OUT THROTTLE CONTROL UNIT Specification Desc./Quantity 1A - Front throttle motor control (-) Front throttle body PIN: 5 2A - CAN L 3A - Voltage for front throttle potentiometers (+ 5 V) Front throttle body PIN: 2...
  • Page 167 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system Dashboard NOTE THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR.
  • Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system It allows communication between the Marelli injection control unit, the throttle control unit and the in- strument panel. Level in electrical circuit diagram:CAN line Pin-out: see wiring diagram NAVIGATOR: ELECTRICAL ERRORS U1602 CAN line without signals - Bus Off.
  • Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Electrical system • Check the filter box large connector and the throttle control unit connector: if not OK, restore; if OK, check the continuity of the two lines from the filter box large connector to the VEHICLE connector of the Marelli control unit: if not OK, restore the cable harness;...
  • Page 170 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 171 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle RONT CHASSIS pos. Description Type Quantity Torque Notes TCEI screw fastening shock absorb- M10x30 50 Nm (36.88 lbf ft) er counterplate to RH frame bracket TC TORX screw fastening trellis M12x53 80 Nm (59 lbf ft)
  • Page 172 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle ENTRE FRAME pos. Description Type Quantity Torque Notes TCEI screws fastening side panels to M12x282 80 Nm (59 lbf ft) engine TCEI screw fastening lambda probe M4x10 3 Nm (2.3 lbf ft)
  • Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle ENGINE pos. Description Type Quantity Torque Notes Flanged TE screw fastening pinion M10x1.25x25 50 Nm (36.88 lbf ft) Loctite 270 TCEI screw fastening Pin to gearbox M6x16 10 Nm (7.37 lbf ft) lever and Gearbox Lever to knurled...
  • Page 174 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle • Disconnect the engine temperature sensor connector. • Disconnect the engine oil pressure sensor connector. • Disconnect the starter motor power supply cable.
  • Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle • Move the breather pipe. • Disconnect the speed sensor connec- tor. • Unscrew and remove the three screws. • Remove the clutch control cylinder. •...
  • Page 176 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle • Undo and remove the three screws fix- ing the chain guide. • Remove the clutch pin. CAUTION UPON REFITTING, PROPERLY GREASE THE O-RING IN- DICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT.
  • Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle • Loosen the screw and slide off the gear transmission connecting rod keeping it linked to the gear shift lever through the rod.
  • Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 179 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle • Working on the left side, unscrew and remove the lower bolt. • Working on the right side, slightly slide off the lower bolt. •...
  • Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle • Working from the left side, tighten the three nuts. • Release the engine from the belt and the hoist. • Refit the pinion and restore the gearing chain clearance.
  • Page 181 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine from vehicle See also Vehicle preparation Adjusting ENG VE - 181 email: info@motomatrix.co.uk...
  • Page 182 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS NGINE email: info@motomatrix.co.uk...
  • Page 183 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Gearbox Diagram 1. Complete gear shaft and spring 2. Selector lock 3. Selector sprocket wheel 4. M5x16 Screw 5. Sprocket wheel pawl 6. Spring 7.
  • Page 184 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine 17.Gear selector drum 18.M8x1.25 threaded pin 19.Selector locking plate 20.Complete main gear shaft 21.TE flanged screw, M6x15 22.Complete index lever 23.Spring Gearbox shafts Gearbox shafts diagram key: 1.
  • Page 185 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine 10.Circlip 11.Transmission shaft 12.1st gear on primary Z=36 13.2nd gear on secondary Z=32 14.3rd gear on secondary Z=30 15.4th gear on secondary Z=28 16.5th gear on secondary Z=26 17.6th gear on secondary Z=25 18.Thrust washer...
  • Page 186 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Slide off the desmodromic drum con- trol. • Remove the three gear selection forks. CAUTION THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT.
  • Page 187 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Carefully slide off the whole gear unit. Refitting • Repeat the removal operations but in reverse order, make sure that the shim washer is fitted to the secondary shaft.
  • Page 188 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine EAR SELECTOR pos. Description Type Quantity Torque Notes Gear retainer pawl fastener screw 12 Nm (8.85 lbf ft) Selector plate fastener screw 5.50 Nm (4.06 lbf ft) Screw fastening Desmodromic se- 23 Nm (16.96 lbf ft) lector drum / Selector sprocket...

  • Page 189: Starter Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Gearbox Selector Shaft Removal • Place the left hand crankcase in a press and extract the roller cage with the specific tool. NOTE REPEAT THE SAME OPERATION FOR THE RIGHT HAND CRANKCASE HALF.
  • Page 190 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Removing the starter motor • Disconnect the starter motor power supply cable. • Undo and remove the four screws and remove the starter motor. Generator side ENG - 190 email: info@motomatrix.co.uk...
  • Page 191 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine GNITION pos. Description Type Quantity Torque Notes Spark plug 13 Nm (9.59 lbf ft) Freewheel Ring fastener screw 14 Nm (10.33 lbf ft) Loctite 242 Screw fastening Rotor - Crankshaft M12x1.25...
  • Page 192 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Removing the flywheel cover components • Remove the two pick-up fixing screws. • Remove the three stator fixing screws. CAUTION THE PICK-UP AND STATOR SHALL BE REMOVED SIMUL- TANEOUSLY AS THEY ARE PART OF THE SAME ELEC- TRICAL BRANCH.
  • Page 193 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Screw the anticlockwise bolt of the special tool on the external body. • Keeping the external body blocked and gripping the key, screw the anticlock- wise bolt so as to remove the flywheel from the crankshaft.
  • Page 194 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Freewheel removal • Heat the magneto flywheel with the specific heater. • Undo and remove the six screws. • Remove the freewheel from the mag- neto flywheel.
  • Page 195 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Place the appropriate tool for locking the flywheel. • Locking the flywheel in position, using the specific tool, tighten the screw on the crankshaft.
  • Page 196 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine 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) Clutch side cover Screw fastening Pump Cover /...
  • Page 197 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine pos. Description Type Quantity Torque Notes Fastening oil filler plug on Clutch cov- 2 Nm (1.48 lbf ft) Screw fastening fixing Plate / Clutch 5.50 Nm (4.06 lbf ft) control Mounting Screw fastening clutch control...
  • Page 198 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Disassembling the clutch LUTCH pos. Description Type Quantity Torque Notes Clutch spring fastener screw 12 Nm (8.85 lbf ft) • Remove the clutch side housing. •...
  • Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the mushroom head clutch control rod. • Remove the discs. • Remove the shim and the cup spring. • Fasten the clutch housing using the specific tool.
  • Page 200 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the clutch hub. • Retrieve the special washer between the clutch hub and the clutch housing. • Collect the clutch bell. •...

  • Page 201: Checking The Clutch Plates

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Checking the clutch plates • Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions. Maximum distortion allowed: 0.20 mm (0.0079 •...
  • Page 202 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Checking the clutch housing • Remove the clutch bell. • Remove the seeger ring. • Remove the oil pump control gear. UPON REFITTING, THE GEAR COLLAR MUST ALWAYS BE FACING THE CLUTCH BELL.
  • Page 203 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Checking the pusher plate Check the pressure plate and the bearing for dam- age and wear. If necessary, replace the parts. Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation.
  • Page 204 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Assembling the clutch • Fit the shim washer. • Fit the needle bearing and the spacer. • Fit the clutch bell. • Make sure that the oil pump control drive gear of the clutch bell engages correctly with the oil pump driven gear.
  • Page 205 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Position the clutch hub. • Fit the clutch cover. • Check that the measurement has not changed compared with the one car- ried out upon removal;...
  • Page 206 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Fit the lathed driven disc (3). • Fit the nitrided steel disc (4). • Fit the clutch discs. Start with the fric- tion material discs and alternate with steel discs.

  • Page 207: Removing The Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Removing the head cover The operations described below are valid for both heads. • Undo and remove the four screws and collect the rubber rings. •...

  • Page 208: Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Separate the cylinder from the head. • Collect the gasket. See also Removing the cylinder Cylinder head pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5...
  • Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine pos. Description Type Quantity Torque Notes Nut fastening Stud Bolts / Head 26 Nm (19.18 lbf ft) Bleed union fastener screw 6.5 Nm (4.79 lbf ft) Water bleed union (steel) 3.50 Nm (2.58 lbf ft) Loctite 243...

  • Page 210: Removing The Valves

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Removing the valves • When removing the valve, mark the components according to the position and the cylinder they belong to, in order to refit the components to their correct positions. •...
  • Page 211 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Release the valve springs. • Remove the valve spring fittings and the springs. • Remove the valves. Checking the overhead camshaft Check that the camshaft toothed wheel works properly: if it is damaged or does not move smoothly, replace both the timing chain and the camshaft toothed wheel.
  • Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • a: 35.13 / 35.17 mm (1.3831 / 1.3846 in); Limit: 35.00 mm (1.3779 in); • b: 28 mm (1.1023 in); • Fasten the camshaft in horizontal po- sition, as shown in the figure, and make it spin to check the eccentricity with a dial gauge;...

  • Page 213: Checking The Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Check the valve eccentricity: valve stem (3) maximum eccentricity allowed: 0.05 mm (0.00197 in) valve head (4) maximum eccentricity allowed: 0.05 mm (0.00197 in) Check that the fixing grooves (5) of the valve cot- ters are in proper conditions.
  • Page 214 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Timing TIMING SYSTEM pos. Description Type Quantity Torque Notes Camshaft gear fastener nut - pre- M15x1 30 Nm (22.13 lbf ft) tightening Camshaft gear fastener nut - tighten- M15x1 90 Nm (66.38 lbf ft) Timing drive gear fastener screw...
  • Page 215 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine pos. Description Type Quantity Torque Notes Special screw for fastening mobile / 19 Nm (14.01 lbf ft) Loctite 242 fixed shoes Cam tower / head fastener screws - 4.90 - 6.86 Nm (3.61 - pre-tightening 5.06) lbf ft...
  • Page 216 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the timing chain intermediate gear. • Slide off the timing chain from the crankshaft. NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
  • Page 217 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Undo and remove the fixed chain ten- sioner slider screw. • First remove the head in order to re- move it. REAR HEAD •...
  • Page 218 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Installing the chain tensioner Refit the removed timing system chain tensioner on the cylinder - head: • Fit the timing chain on the crankshaft and on the intermediate gear.
  • Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine If necessary, remove the timing system gears from the camshafts: • Place the camshaft with the timing sys- tem gear on a vice and protect the cams of the camshaft adequately.
  • Page 220 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Using the specific template, check the correct position of the cams. NOTE USE OF THE TEMPLATE: THIS TOOL IS PLACED ON THE CAMS WITHOUT THE CAM CAPS, USING THE PROFILE MARKED WITH THE NUMBER OF THE CYLINDER BEING USED, WITH THE MARKINGS FACING THE FLYWHEEL...
  • Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the camshaft, lock it on a vice with aluminium jaws, then tighten it to the prescribed torque. DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE ULTIMATE TIGHTENING TORQUE WITH THE SHAFT MOUNTED ON THE CYLINDER.
  • Page 222 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine 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) Removing the cylinder...
  • Page 223 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the gasket between the cylin- der and the crankcase. See also Chain removal Disassembling the piston • Remove the head and cylinder. •...
  • Page 224 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the top ring, the intermediate ring and the three oil scraper rings. See also Removing the cylinder head Removing the cylinder ENG - 224 email: info@motomatrix.co.uk...
  • Page 225 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions. • Check cylinder sliding surface for signs of friction and scratches. Also check the seal sur- faces for damages.
  • Page 226 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine PISTON RINGS • Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves. • Measure the piston ring side clearance and replace the piston and the piston rings all together if not complying with specifications.
  • Page 227 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Measure the pin outside diameter (a) and if not complying with specifica- tions, replace the pin. Pin outside diameter: 22.00 - 21.97 mm (0.8661 - 0.8650 in) Limit: 21.96 mm (0.8646 in) •...
  • Page 228 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine The piston rings are different and must be installed with the "N" marking at the top. • Fit the lower oil scraper ring on the pis- ton with the gap turned towards the exhaust side.
  • Page 229 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 230 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Tighten the three screws on the intake and discharge sides. • Screw the two head fixing screws lo- cated inside the timing chain compart- ment.
  • Page 231 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Tighten the intermediate gear pin once Loctite residues are thoroughly re- moved and a high-strength threadlock is applied on the thread. • Make sure that both timing chain slid- ers are correctly fitted.

  • Page 232: Installing The Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine 020714Y Dial gauge mounting • Rotate the crankshaft up to the TDC (the reversal point of the dial gauge ro- tation). • Lock the crankshaft at TDC using the specific tool.
  • Page 233 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Fit a new gasket between the cylinder and the head. • Couple the cylinder and the head. • Screw without tightening the two screws on the outlet side.
  • Page 234 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Apply THREEBOND on the head in the areas indicated in the figure. • For the remaining operations, follow the removal operations but in reverse order. Crankcase - crankshaft RANKCASE pos.
  • Page 235 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) clutch side crankcase halves Screw fastening flywheel side /...
  • Page 236 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Use a commercially available extractor to remove the crankshaft gear. • Remove the gearbox control rod, re- trieving the washer. ENG - 236 email: info@motomatrix.co.uk...
  • Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Undo and remove the screw fixing the speed sensor. • Remove the speed sensor with cau- tion. • Heat the screws of the gearbox selec- tor mounting plate.
  • Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Undo the two neutral sensor fastener screws. • Remove the neutral sensor. • Retrieve the sensor contact complete with spring. • If the pinion has been removed, refit, fastening with the special tool.
  • Page 239 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine The tone wheel is fixed with Loctite threadlock and must therefore be heated with a special hot air gun, taking particular care not to heat ex- cessively.
  • Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the pinion. • Remove the clutch control rod. • Working on the left hand side, undo and remove the nine M8 crankcase fastener screws.
  • Page 241 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the fuel vapour breather pipe mounting plate. CAUTION DURING REASSEMBLY, REMEMBER TO FIT THE FUEL VAPOUR BREATHER PIPE MOUNTING PLATE NEAR THE PINION.
  • Page 242 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Separate the crankcase halves by giv- ing short taps with a rubber mallet. • Open the crankcase halves. • Retighten the two screws to the engine mounting.
  • Page 243 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • If necessary, undo and remove the two screws fastening the rose pipe. • Remove the rose pipe. See also Removing the cylinder Magneto flywheel removal Removing the crankshaft RANKSHAFT...
  • Page 244 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Remove the crankshaft. See also Splitting the crankcase halves Inspecting the crankcase halves BEARINGS AND OIL SEAL CHECK Thoroughly clean the two sections of the crankcase, the ball bearings, the threads of the crankcase fixing screws and the bearing seats with a non-aggressive solvent.
  • Page 245 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine LUBRICATION CHECK • Working on both crankcase halves, re- move and thoroughly clean the nozzle that lubricates the piston crown. REPLACE THE SPRAY NOZZLE O-RING IF NECESSARY. •...
  • Page 246 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • To reduce the installation force neces- sary, score an incision approximately 0.5 mm (0.02 in) deep (without cutting into the steel shell) in each semi-bush- ing in the area indicated in the figure.
  • Page 247 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Assembling the connecting rod CAUTION TO FIT THE CONNECTING RODS, CHECK THE COUPLING TYPES INDICATED IN THE "CRANK- CASE- CRANKSHAFT CONNECTING ROD" SECTION, IN THE "CHARACTERISTICS" CHAPTER OF THE WORKSHOP MANUAL.
  • Page 248 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Apply black sealing paste (Threebond) on the left crankcase half. CAUTION BE CAREFUL NOT TO APPLY THREEBOND IN EXCESS AS IT MAY BLOCK OIL DUCTS THROUGH THE CRANKCASE HALVES.
  • Page 249 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Working on the left side, place the nine M6 screws fixing the crankcase. • Working on the left side, place the nine M8 screws fixing the crankcase.
  • Page 250 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Place the gear selector drum and check that it is correctly timed; thrust the desmo drum axially from the fly- wheel side so that the timing roller pro- trudes.
  • Page 251 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Tighten the pinion fixing nut using the special tool. Specific tooling 9100896 Clutch housing locking tool • Position the sensor contact together with the spring.
  • Page 252 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Position the plate together with the se- lector. • Tighten the three screws fixing the gear selector plate by applying Loctite medium-strength. •...
  • Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Position the washer and the crankshaft lock-nut. • Fit the special tool and fix it steadfastly to the crankcase by tightening the four fixing screws on the crankcase.

  • Page 254: Oil Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) crankcase half Fastening oil filter union on clutch...
  • Page 255 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Collect the shim washer. • Undo and remove the two screws fixing the oil pump. • Remove the entire pump. NEW GENERATION PUMP REMOVAL ENG - 255 email: info@motomatrix.co.uk...
  • Page 256 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Press the raised side of the safety washer using a screwdriver. • Lock the pump gear with a commercial hook spanner and unscrew the nut, collecting the safety washer.
  • Page 257 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Undo and remove the two screws fixing the oil pump. • Remove the entire pump. Inspection • Undo and remove the two fixing screws.
  • Page 258 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Slide off the shaft with the cover. • Collect the lock pin from the shaft. • Remove the oil pump rotor. • Remove the oil pump stator.
  • Page 259 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine Installing NOTE PAY ATTENTION TO ALIGN THE REFERENCES ON STA- TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE. IF REQUIRED, REPLACE THE STATOR / ROTOR UNIT. OLD GENERATION PUMP INSTALLATION •...
  • Page 260 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Fit the shim washer. • Fit the oil pump gear and fasten it through appropriate screw with corre- sponding washer. • By means of a commercial hook span- ner, lock the pump and tighten the screw to the prescribed torque.
  • Page 261 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • Tighten both oil pump fixing screws. • Fit the shim washer. • Fit the oil pump gear. • Fit the safety washer. •...
  • Page 262 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Engine • By means of a screwdriver, lift and bend the safety washer opposite the fitting tabs, until it rests on the nut. ENG - 262 email: info@motomatrix.co.uk...
  • Page 263 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 264: Fuel Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Power supply Fuel pump UEL PUMP pos. Description Type Quantity Torque Notes TEFL screw fastening fuel pump M5x16 6 Nm (4.42 lbf ft) Electrical characteristics: •...
  • Page 265 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Power supply Diagram HROTTLE BODY pos. Description Type Quantity Torque Notes Intake union fastener screw 12 Nm (8.85 lbf ft) Loctite 242 RBW control unit fastener screw 3.50 Nm (2.58 lbf ft) Loctite 242 Injector fastener screw...
  • Page 266 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 267 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Power supply • For medium-high throttle openings alpha/n • For temporary speed (speed change) alpha/n • The main parameters that correct the injection map are: •...
  • Page 268 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Power supply • Remove the upper plate. • Remove both bodies. UPON REFITTING , REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE.
  • Page 269 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Power supply • Working on the body in question, re- move the injector, slide off the clip and the injector itself. CAUTION NEVER UNDO THE SCREWS IN THE FIGURE Using Navigator for injection system The complete list of all the parameters- device status, errors, etc.- is available at the home page of the website www.serviceaprilia.com in the search section: Parameters Navigator.
  • Page 270 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 271: Removing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Wheel axle nut 80 Nm (59 lbf ft) Flanged TE screw fastening front M8x20 30 Nm (22.13 lbf ft) Loctite 243 disc...
  • Page 272 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Remove the wheel axle fixing nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps. • Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is exposed.
  • Page 273 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions Checking the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS.

  • Page 274: Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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. An excessive eccentricity is usually caused by worn or damaged bearings.
  • Page 275 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions Diagram RONT FORK pos. Description Type Quantity Torque Notes Screws (fasten onto fork hubs) M6x40 12 Nm (8.85 lbf ft) Screw (Pumping member pin fixing 30 Nm (22.13 lbf ft) to the stem base) Upper cover...

  • Page 276: Removing The Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions OPTION 01- Steering upper plate without a headstock cut. TEERING PTION pos. Description Type Quantity Torque Notes Headstock ring nut - pre-tightening M25x1 30 Nm (22.13 lbf ft) Steering package settlement...
  • Page 277 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Using the appropriate tool fasten the fork in the vice. Specific tooling AP8140149 Protection for fitting operations • Operating on the upper screw, unload the spring.
  • Page 278 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Using the specific tool, fixed to the pre- loading pipe, compress the spring. • Insert a spanner in the lock nut of the cover.
  • Page 279 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Remove the spring paying attention to drain the oil correctly. • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
  • Page 280 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller. • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem.
  • Page 281 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Remove the pumping member pin. Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem.
  • Page 282 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • lower bushing; • pumping member pin. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE.
  • Page 283 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • O-Ring on the cap. Reassembling the fork NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. • Lock the stem in a vice without dam- aging the surface.
  • Page 284 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool. Specific tooling AP8140189 Oil seal fitting tool for Ø...
  • Page 285 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Using a hook spanner lock the pump- ing member pin and tighten the fixing screw on the fork end to the prescribed torque.
  • Page 286 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Insert the washer that will be supported on the spring • Insert and hand tighten the nut on the pumping member pin •...
  • Page 287 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Pour the remaining oil. • Pump out oil a few times. • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
  • Page 288 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions TEERING PTION pos. Description Type Quantity Torque Notes Headstock ring nut - pre-tightening M25x1 30 Nm (22.13 lbf ft) Steering package settlement Headstock ring nut - tightening M25x1 12 Nm (8.85 lbf ft) Headstock cap...
  • Page 289 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Unscrew and remove the top bolt on the headstock and retrieve the washer. • Operating from both sides, loosen the screws fixing the stanchions to the up- per plate.
  • Page 290 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions TEERING RING NUT pos. Description Type Quantity Torque Notes Headstock ring nut - pre-tightening M25x1 30 Nm (22.13 lbf ft) Steering package settlement Headstock ring nut - tightening M25x1 12 Nm (8.85 lbf ft)
  • Page 291 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 292 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions Get the suitable tool for the tightening of the ring nut. Carry out the following operations: - carry out a first tightening of the ring nut to the indicated tightening torque for the settlement of the steering package.
  • Page 293 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Finish the nut tightening to the indica- ted tightening torque. TEERING UPPER PLATE pos. Description Type Quantity Torque Notes Headstock nut - pre-tightening M22x1 10 Nm (7.37 lbf ft) Loctite 243...
  • Page 294 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Install the upper bearing on the steer- ing tube as shown in the figure, with the conical part facing down. • After inserting, the bearing must slide freely on the steering column till match- ing with the steering bearing (of the steering) conic in the frame.
  • Page 295 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Pass with a brush on the seal ring to lay down potential grease storage. • Place the tightening ring nut with the rim placed downwards.

  • Page 296: Removing The Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions EAR WHEEL pos. Description Type Quantity Torque Notes Lower self-locking nut fastening 50 Nm (36.88 lbf ft) sprocket to sprocket carrier TCEI screw fastening flexible cou- M10x30 50 Nm (36.88 lbf ft) Loctite 270...
  • Page 297 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions • Unscrew and remove the nut on the wheel axle. • Collect the thrust washer and the right chain tensioner slider. • Working on the right side, hit the wheel axle lightly so as to take out the head from its housing.

  • Page 298: Checking The Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions See also Adjusting Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel.
  • Page 299 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Suspensions REAR wheel spindle • Use a dial gauge to check the wheel spindle eccentricity (1). Replace the wheel spindle if the eccentricity ex- ceeds the limit value (1).

  • Page 300: Shock Absorbers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 M10x90 50 Nm (36.88 lbf ft) Removing...
  • Page 301 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 302 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) Swingarm pin nut 90 Nm (66.38 lbf ft) TPSI screw fastening rear stand...
  • Page 303 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 304 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis • Working from the left side, unscrew and remove the nut and collect the washer. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION. SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS.
  • Page 305 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis tions too. clearance should remain constant at all wheel rotation phases. • If clearance is uniform but over 30 mm (1.18 in) or below 25 mm (0.98 in), ad- justment is necessary.
  • Page 306 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis LUBRICATE THE CHAIN ON A REGULAR BASIS, PARTICULARLY IF YOU DETECT DRY OR RUSTY PARTS. FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED.
  • Page 307 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis Exhaust XHAUST SYSTEM pos. Description Type Quantity Torque Notes SERPRESS self-locking nut fasten- 25 Nm (18.44 lbf ft) ing flange on head Primary Clamp (between front/rear 7 Nm (5.16 lbf ft) manifolds and central manifold) Silencer Clamp (between central...
  • Page 308 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis • Remove the saddle. • Undo and remove the two upper screws and collect the washers. • Remove the exhaust end backwards by sliding off the two brackets from the rubber rings in the upper section and the bracket from the chassis retainer in the lower part.
  • Page 309 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis exhaust manifold Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off.
  • Page 310 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Chassis Removing the lambda sensor • Unscrew and remove the fixing screw of the lambda probe connector brack- • Move the breather pipe and the bracket with the lambda probe connector fixed to it.
  • Page 311 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 312 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. SYSTEM pos. Description Type Quantity Torque...
  • Page 313 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main relay 6. ECU 7. Instrument panel 8.
  • Page 314 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system • PIN 16 - ISO_K - K line (diagnosis) • PIN 18 - KL30 - Power supply Foreword key: 1. Rear brake calliper 2.
  • Page 315 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever control 4. Rear system circuit BRAK SYS - 315 email: info@motomatrix.co.uk...
  • Page 316 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open)
  • Page 317 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
  • Page 318 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system Riding with an active ABS system • At engine start-up, the ABS warning light (5) on the instrument panel (4) turns on and remains on until the vehi- cle exceeds 5 km/h (3.1 mph).
  • Page 319 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system • the EFI warning light turns off and the word ABS on the display disappears (NA 850 Mana ABS). • the ABS warning light turns off (SL 750 Shiver ABS / Dorsoduro 750 ABS) - if at least one malfunction is detected •...
  • Page 320 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system • A. Cable continuity between PIN 8 of the ABS control unit connector and PIN 28 of the instrument panel. • B. Check connectors - refer to the operations described in the chapter If the previous checks are OK, the causes might be: •...
  • Page 321 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system NOTE: the "X" in the table identifies the con- nector pin is grounded. PARAMETERS screen page This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.)
  • Page 322 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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. ACTIVATION Characteristic Value/example...
  • Page 323 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system ERRORS Characteristic Value/example Unit of Notes measure ment Front speed sensor: 5D90 electric Electrical fault in sensor or cable harness malfunction Front speed sensor: 5D91 the signal Faulty sensor or signal interference works irregularly Front speed sensor: 5D92 the signal...
  • Page 324 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters. ADJUSTMENTS Characteristic Value/example Unit of Notes measure ment Coding (1) Used for re-coding the control unit or coding a new one.
  • Page 325 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 326 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system Rear brake calliper EAR BRAKE pos. Description Type Quantity Torque Notes Rear brake lever pin 25 Nm (18.44 lbf ft) Flanged TE screw fastening pump to M6x20 10 Nm (7.37 lbf ft) footrest mounting...

  • Page 327: Front Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) callipers) TEFL screw (Fixing calliper to fork M10x1.25...

  • Page 328: Rear Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Rear brake pads Removal •...
  • Page 329 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency. CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CON- DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
  • Page 330 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system Rear If there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from the brake pump and minimising calliper efficiency during braking.
  • Page 331 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Braking system Front brake pump RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Pipe union fastening brake pipe to M10x1 25 Nm (18.44 lbf ft) pump Fastener for front brake pump on 10 Nm (7.37 lbf ft)
  • Page 332 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 333 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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) Fastener for clutch pump on handle-...
  • Page 334 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 335: Circuit Diagram

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system Circuit diagram OOLING SYSTEM pos. Description Type Quantity Torque Notes Fan fastener screw 3 Nm (2.21 lbf ft) Flanged TE screw fixing LH side ra- M6x25 10 Nm (7.37 lbf ft) diator to trellis frame and radiator...

  • Page 336: Coolant Replacement

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system Coolant replacement • Remove the right side fairing. • Place a container of suitable capacity. • Loosen the screw, move the clamp and slide off the sleeve.

  • Page 337: Water Pump

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system Water pump 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) Clutch side cover Screw fastening Pump Cover /...
  • Page 338 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system • Unscrew and remove the anticlock- wise nut fixing the rotor. • Remove the rotor. • Unscrew and remove the rotor control gear fixing nut and act on the gear hex- agonal insert.
  • Page 339 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system • Tighten the three screws. • Fit the upper part of the tool. • Fully tighten the pin with the bolt. • Preventing the bolt from turning, tight- en the nut to that the lower part of the tool, onto which the shaft and integra-...
  • Page 340 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system • Fit a new shaft and integrated seal as- sembly using the specific tool. Specific tooling 020725Y Punch for water pump overall sealing •...
  • Page 341 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system • Fit the water pump cover, fastening the five screws. Removing the radiator • Drain off the cooling system. • Undo and remove the screw. •...
  • Page 342 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system • Undo and remove the screw, remove the horn. • Working on the left side of the vehicle, undo and remove the screw. •...
  • Page 343 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Cooling system • Loosen and move the clamp. • Slide off the pipe. • Release the clamp. • Slide off the pipe. • Undo and remove the screw and col- lect the washer.
  • Page 344 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 345 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 RONT MUDGUARD pos.
  • Page 346 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork pos. Description Type Quantity Torque Notes TBEI screw fastening mudguard to M5x9 4 Nm (2.95 lbf ft) stanchions Screw fastening number panel to 1 Nm (0.74 lbf ft) headlamp RONT BODYWORK...
  • Page 347 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes Screws fastening battery cover to 4 Nm (2.95 lbf ft) compartment TBEI screw fastening battery com- M5x9 6 Nm (4.42 lbf ft) partment to saddle mounting...
  • Page 348 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes TBEI screw fastening LH - RH covers M6x20 10 Nm (7.37 lbf ft) to silencer TBEI screw fastening tail fairing to M5x9 6 Nm (4.42 lbf ft)
  • Page 349 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 Upper RH TCEI screw fastening sad- M8x60 25 Nm (18.44 lbf ft)
  • Page 350 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork Headlight assy. EADLAMP pos. Description Type Quantity Torque Notes TE screw fastening headlamp to M6x16 10 Nm (7.37 lbf ft) headlamp mounting and mudguard to steering base Fastener for front turn indicators 3 Nm (2.21 lbf ft)
  • Page 351 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 352 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork Taillight assy. AILLIGHT pos. Description Type Quantity Torque Notes TE screw fastening tail light to li- M6x45 10 Nm (7.37 lbf ft) cense plate mounting frame Fastener for rear turn indicators 3 Nm (2.21 lbf ft) Reflector fastener...
  • Page 353 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Unscrew and remove the screw. • Undo and remove the three internal screws. • Working from both sides, undo and re- move the screw. •...
  • Page 354 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork Footrest OOTPEGS pos. Description Type Quantity Torque Notes Upper screw fastening passenger M8x35 25 Nm (18.44 lbf ft) footrests to frame side panels Lower TCEI screw fastening passen- M8x35 25 Nm (18.44 lbf ft)
  • Page 355 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Remove the right footrest • Undo and remove both rear brake pump internal fixing screws. LEFT FOOTREST • Undo and remove the two external screws.
  • Page 356 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Undo and remove the rear screw. • Remove the side fairing. License plate holder • Remove the saddle. • Remove the tail section. •...
  • Page 357 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Disconnect the saddle unlocking ca- ble. • Slide off the license plate holder to- wards the back. See also Seat Tail guard Air box BODYW - 357 email: info@motomatrix.co.uk...
  • Page 358 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork IR FILTER BOX pos. Description Type Quantity Torque Notes Cross head self-tapping screw fas- M5x20 3 Nm (2.21 lbf ft) tening separator / filter box SWP self-tapping screw M2.9x12 TCCR 3 Nm (2.21 lbf ft)
  • Page 359 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Remove the filter support partition. • Release the cable harness from the clamps. • Undo and remove the two screws after loosening the front and rear manifold clamps.
  • Page 360 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Lift the filter box and working on both cylinders, loosen and move the clamp and slide off the oil vapour recovery pipe. •...

  • Page 361: Fuel Tank

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Remove the filter box together with the throttle body, by lifting it up from be- hind. CAUTION COVER THE SLEEVE OPENINGS SO THAT NO FOREIGN BODIES COME IN.
  • Page 362 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork UEL TANK pos. Description Type Quantity Torque Notes TCEI screw fastening filler cap flange M5x16 3 Nm (2.21 lbf ft) Rear TE screw fastening tank M6x90 10 Nm (7.37 lbf ft) CAUTION...
  • Page 363 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Pay attention not to damage the immo- bilizer aerial. • Draw the tank backward as much as you can in order to avoid interferences in the front part when lifting the tank.
  • Page 364 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork OPTION 01 • If there is a "Y" joint, disconnect the tank breather pipe and when refitting it, place it according to the new standard following the refitting procedure.
  • Page 365 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Disconnect the fuel pump connector. • Remove the tank. CAUTION UPON REFITTING THE TANK, FOLLOW THE SAME STEPS BUT IN REVERSE ORDER. CONNECT AGAIN THE FUEL PIPES AND THE FUEL PUMP CONNECTOR.
  • Page 366 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Remove the three screws that fix the instrument panel. • Slide off the instrument panel from its support. • Disconnect the instrument panel con- nector.
  • Page 367 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Bodywork • Remove the radiator cover. Tail guard • Remove the saddle. • Remove the rear passenger grab han- dle (if present). • Working from both sides, undo and re- move the external screw.
  • Page 368 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. INDEX OF TOPICS email: info@motomatrix.co.uk...
  • Page 369 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. PRE DE DELIVERY email: info@motomatrix.co.uk...
  • Page 370 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection...

  • Page 371: Road Test

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS 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 372 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive:...
  • Page 373 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Pre-delivery Specific operations for the vehicle LEFT • Remove the left side chain protection • Fit a left bracket and a left chain pro- tection;...
  • Page 374 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Pre-delivery • Remove the shock absorber protection on the exhaust. • Fit a right bracket; fasten then with a TEFL M8x35 mm screw at the top and with a TCEI M8x35 mm screw at the bottom.
  • Page 375 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Pre-delivery • Remove the TCEI M6 X 50 screw which fastens the antivibration weight. • Fit the rubber ring in the hand guards. • Place the lower spacer on the rear view mirror hole.
  • Page 376 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. DORSODURO FACTORY ABS Pre-delivery • Place the upper spacer on the rear view mirror hole. • Fit the rear view mirror screwing the corresponding support column. NOTE PERFORM THE SAME PROCEDURE FOR BOTH HAND GUARDS PRE DE - 376 email: info@motomatrix.co.uk...
  • Page 377 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. ABS: 312, 320 Air filter: 75, 361 Air temperature sensor: 135 Battery: 117 Brake: 326–328, 331 Brake calliper: 326, 327 Brake pads: 327, 328 Brake pump: 331 Bulbs: Bushings: CAN line: 167...
  • Page 378 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys. Handlebar: 274 Head cover: 79, 207, 217, 233 Headlight: 350 Identification: 12 Instrument panel: Intake pressure sensor: 128 License plate holder: 356 Magneto flywheel: 192, 217, 243 Maintenance: 9, 69 Maintenance Table: Mudguard:...

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