APRILIA DORSODURO 2007 Service Station Manual

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SERVICE STATION MANUAL

854202

DORSODURO

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Summary of Contents for APRILIA DORSODURO 2007

Page 1 SERVICE STATION MANUAL 854202 DORSODURO...
Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual 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 SERVICE STATION MANUAL DORSODURO NOTE Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Page 4 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 BRAK SYS RAKING SYSTEM CLU SYS LUTCH SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 DORSODURO Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system.
Page 8 DORSODURO 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. ENGINE OR TRANSMISSION OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
Page 9 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Only use ORIGINAL APRILIA SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10 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 11 DORSODURO Characteristics Vehicle identification Write down the chassis and engine number in the specific space of this manual. The chassis number is handy when purchasing spare parts. CAUTION ALTERING IDENTIFICATION NUMBERS IS AN OFFENCE WHICH MAY RESULT IN SEVERE CRIMINAL CHARGES AND FINES. PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY This number consists of numbers and letters, as in the example shown below.
Page 12 DORSODURO Characteristics Specification Desc./Quantity Dry weight (without fuel) 196 kg (432 lb) Engine NGINE Specification Desc./Quantity Model M551M Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 over- head camshafts. Cylinder quantity overall cylinder capacity 749.9 cm³ (45.76 cu.in) Bore / stroke 92 x 56.4 mm (3.62 x 2.22 cu.in) Intake valve clearance...
Page 13 DORSODURO 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 ELECTRICAL SYSTEM Specification Desc./Quantity Battery 12V - 10 Ah Main fuses Auxiliary fuses 3A, 10A, 15A, 20A (Permanent magnet) Generator 13.5 V - 450 W at 6000 rpm PARK PLUGS...
Page 14 DORSODURO Characteristics USPENSIONS Specification Desc./Quantity Front Upside-down telescopic hydraulic fork. Stem diam. 43 mm (1.69 in) Travel 160 mm (6.3 in) Rear Oscillating swingarm and single adjustable hydraulic shock ab- sorber Wheel travel 155 mm (6.1 in) IZES Specification Desc./Quantity Size A 693.1 mm (27.29 in) Size B...
Page 15 DORSODURO Characteristics Supply UEL SYSTEM Specification Desc./Quantity Type Electronic injection (Multipoint) Throttle valves diameter Ø 52 mm (2.05 in) Fuel premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM) Tightening Torques FRAME ASSEMBLY Name Torque in Nm TCEI screw fixing Shock Absorber Counterplate to right chas- 50 Nm (36.88 lbf ft) sis bracket - M10x30 (1)
Page 16 DORSODURO Characteristics Name Torque in Nm Screw (fasten on Fork Hub caps) - M8x40 (4) 25 Nm (18.44 lbf ft) REAR SUSPENSION UNIT Name Torque in Nm TCEI screw - M10x50 (1) 50 Nm (36.88 lbf ft) Lower TCEI fixing screw - M10x80 (1) 50 Nm (36.88 lbf ft) ENGINE UNIT Name...
Page 17 DORSODURO Characteristics Name Torque in Nm Filler with bleed (Heng Tong) - M10x1 (2) 25 Nm (18.44 lbf ft) Self-tapping TE screw fixing Calliper - M10x1.25x55 (4) 50 Nm (36.88 lbf ft) Brake pipe to steering base retainer - M6x25 (1) 10 Nm (7.37 lbf ft) REAR BRAKE UNIT Name...
Page 18 DORSODURO Characteristics Name Torque in Nm TCEI screw fixing instrument panel support to fork plate - 10 Nm (7.37 lbf ft) M6x20 (2) TBEI screw fixing Mudguard to stems - M5x9 (4) 4 Nm (2.95 lbf ft) Screw fixing number plate to light (4) 1 Nm (0.74 lbf ft) TBEI screw fixing ignition lock cover to spacer - M5x9 (3) 4 Nm (2.95 lbf ft)
Page 19 DORSODURO Characteristics Name Torque in Nm Spark plug (2) 13 Nm (9.59 lbf ft) 872425 - Screw fixing Pencil to Eldor coil - M6 (2) * 5.50 Nm (4.06 lbf ft) 874554 - Screw fixing Pencil to Eldor coil - M6 (2) ** 5,50 Nm (4.06 lbf ft) Screw fixing camshaft retaining plate - torx M3 (8) 3 Nm (2.21 lbf ft) (Loctite 270)
Page 20 DORSODURO Characteristics Name Torque in Nm Freewheel ring fixing screw - M6 (6) 14 Nm (10.33 lbf ft) (Loctite 242) Screw fixing Rotor - Crankshaft - M12x1.25 (1) 120 Nm (88.51 lbf ft) Screw fixing Retaining Plate - M5 (1) 8 Nm (5.90 lbf ft) Clutch fixing nut - M24x1.5 (1) 180 Nm (132.76 lbf ft) (Caulk)
Page 21 DORSODURO Characteristics Name Torque in Nm Crosshead self-tapping screw fixing side cover / filter casing - 3 Nm (2.21 lbf ft) M5x20 (3) Crosshead self-tapping screw 5x10 (2) 3 Nm (2.21 lbf ft) Overhaul data Assembly clearances Cylinder - piston assy. The pistons are available in four size types (A, B, C, D) to be coupled to the four cylinder types (A, B, C, D).
Page 22 DORSODURO Characteristics • Two letters representing the main bushings and the primary wheelbase are written on the clutch side. • A letter indicating the main bushing type is written on the flywheel side. RANKCASE SELECTION TYPE Specification Desc./Quantity Crankcase type 1 Bushing seat diameter: 53.954 - 53.960 mm (2.1241 - 2.1244 Crankcase type 2 Bushing seat diameter: 53.960 - 53.966 mm (2.1244 - 2.1246...
Page 23 DORSODURO Characteristics Crankcase category Crankcase can be selected from two types (A or B) according to the centre to centre distance be- tween the primary reduction gears. The category can be checked out on clutch-side crankcase half, at the back. NOTE SHOULD THE CRANKCASE BE REPLACED, THIS IS SUP- PLIED WITH THE PRIMARY REDUCTION GEAR ALREADY...
Page 24 DORSODURO Characteristics BUSHINGS Specification Desc./Quantity Crankshaft type 1 Connecting rod type 1: half-bushings A (red) Crankshaft type 2 Connecting rod type 1: half-bushings B (blue) Connecting rod selection Not all weight types are available as spare parts; only the main two. Refer to the following table for your choice: CONNECTING RODS Specification...
Page 25 DORSODURO Characteristics CHAR - 25...
Page 26 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 27 DORSODURO 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 - 27...
Page 28 DORSODURO Special tools Stores code Description 020714Y Comparator support 020715Y Tone wheel removal 9100896 Clutch bell locking tool 020716Y Connecting rod locking 020717Y Piston ring driver AP8140302 tool for sealing ring fitting 020718Y Camshaft gear alignment pin S-TOOLS - 28...
Page 29 DORSODURO Special tools Stores code Description 020719Y Timing pin 020720Y Timing tool AP8140179 Valve spring compressor 020721Y Adaptor for valve removal 020722Y Guide for oil seal 020376Y Adapter handle 020629Y 8 mm (0.31 in) guide S-TOOLS - 29...
Page 30 DORSODURO Special tools Stores code Description 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 25-mm Guide 020483Y 30 mm guide S-TOOLS - 30...
Page 31 DORSODURO Special tools Stores code Description 020441Y Oil seal punch 020358Y 37 x 40-mm adaptor 020357Y 32 x 35 mm adaptor 020359Y 42 x 47-mm adaptor 020360Y 52 x 55-mm adaptor 020723Y Template for timing overhead camshafts S-TOOLS - 31...
Page 32 DORSODURO Special tools Stores code Description 020724Y Gear control rod roller cage punch 020725Y Punch for water pump overall sealing 020726Y Extractor for bushings 020727Y Punch for bushings AP8140180 Extractor for bushings 8140181 manometer for fuel - oil - compression pressure AP8140199 Tool panel...
Page 33 DORSODURO Special tools Stores code Description 8202222 Generic adhesive film for panel 8140426 Hooks for panel S-TOOLS - 33...
Page 34 INDEX OF TOPICS MAIN AINTENANCE...
Page 35 Adequate maintenance is fundamental to ensuring 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 should be reported without delay...
Page 36 DORSODURO Maintenance km x 1,000 Tyres - pressure / wear***** Wheels Bolts and nuts tightening Suspensions and setting Warning light indicating error on the instrument panel **** Fuel pipes *** Clutch wear Break pad wear Spark plug At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required. CAUTION ALWAYS REPLACE BOTH SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING.
Page 37 DORSODURO Maintenance • Turn the radiator forwards and lower it to act on the coil. • Undo and remove the screw. • Slide off the front coil. • Unscrew and remove the front spark plug. REAR SPARK PLUG MAIN - 37...
Page 38 DORSODURO Maintenance • Undo and remove the two tank front screws. • Lift the tank. • Undo and remove the rear coil fixing screw. • Slide off the rear coil. • Unscrew and slide off the rear spark plug. • Check the gap between the electrodes with a feeler thickness gauge.
Page 39 DORSODURO Maintenance • Once the washer is fitted, screw the spark plug carefully to avoid damaging the thread. • Tighten it using the spanner supplied in the toolkit, make each spark plug com- plete 1/2 a turn to press the washer. CAUTION TIGHTEN THE SPARK PLUG CORRECTLY, OTHERWISE THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE...
Page 40 DORSODURO Maintenance • Shut off the engine. • Keep the vehicle upright with the two wheels on the ground. • Check the correct oil level through the appropriate sight glass on the engine crankcase. MAX = maximum level. MIN = minimum level •...
Page 41 DORSODURO 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 Check Engine oil filter •...
Page 42 DORSODURO Maintenance • Remove the clamp and slide off the blow-by tube. • Remove the filter casing cover. • Working on both ducts, turn the upper part of the intake ducts anticlockwise and remove it. • Remove the filtering element. COVER THE INTAKE DUCTS WITH A CLEAN CLOTH SO THAT FOREIGN BODIES DO NOT GET INTO THE INLET DUCTS.
Page 43 DORSODURO 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 44 DORSODURO Maintenance • Replace calibrated pads with a pad thick enough to correct the valve clear- ance previously detected. • List of calibrated break pads: 1. Calibrated pad 2.60 2. Calibrated pad 2.65 3. Calibrated pad 2.70 4. Calibrated pad 2.75 5.
Page 45 DORSODURO Maintenance • Apply THREEBOND on the head in the areas indicated in the figure. See also Removing the head cover MAIN - 45...
Page 46 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 47 THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE CONTROL UNIT THROUGH AXONE (MINIMUM VERSION: 5.1.5) BY SELECTING "SELF-DIAGNOSIS, APRILIA, DORSODURO" • 3 - ARE CURRENT "ATT" or STORED "MEM" ERRORS SHOWN IN THE "ERRORS DIS- PLAY" SCREEN PAGE? YES, go to 4;...
Page 48 DORSODURO Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAILURE AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 49 DORSODURO Troubleshooting Engine The engine does not start THE ENGINE DOES NOT START CAUTION AXONE SHOULD BE WORKING PROPERLY AND UPGRADED TO THE 5.1.5 VERSION MINIMUM. CAUTION BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V; 2) THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED; 3) AUXILIARY FUSES ARE NOT DAMAGED AND ARE ADEQUATELY FITTED.
Page 50 DORSODURO 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. YES, go to 13; OK, go to 14 •...
Page 51 DORSODURO 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 • 30 - WITH THE RETENTION RELAY (START-UP LOGIC) 39 DISCONNECTED, KEEP THE STARTER BUTTON PRESSED AND CHECK IF THERE IS APPROX. 1-2V VOLTAGE IN THE YELLOW/RED CABLE OK, go to 32;...
Page 52 DORSODURO 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 • 45 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/PINK CABLE FROM THE RELAY TO THE ENGINE CONNECTOR (PIN 2) OK, go to 47;...
Page 53 DORSODURO Troubleshooting • 61 - REPLACE THE START-UP RELAY 36 - END • 62 - REPLACE THE STARTER MOTOR - END • 63 - RESTORE THE CABLE HARNESS - END • 64 - WHAT DOES THE "FALL SENSOR" STATUS ON AXONE (DEVICE STATUS/ICON "0/1"...
Page 54 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 55 DORSODURO Electrical system Components arrangement 1. Revolution sensor 2. Intake air pressure sensor 3. Intake air temperature sensor ELE SYS - 55...
Page 56 DORSODURO Electrical system 4. Instrument panel 5. Engine control unit 6. Front headlamp 7. Start-up relay 8. Coils 9. Spark plugs 10.Starter motor 11.Rear light 12.Auxiliary fuses 13.Main fuses 14.Throttle grip position sensor 15.Gear in neutral sensor 16.Revolution sensor - pick up 17.Engine temperature sensor 18.Throttle control unit 19.Lambda Probe...
Page 57 DORSODURO Electrical system • Location on the vehicle: under the saddle. AUXILIARY INJECTION RELAY • Location on the wiring diagram: 40 • Location on the vehicle: under the fuel tank, right side, third relay starting from the front. FAN CONTROL RELAY •...
Page 58 DORSODURO Electrical system 1. Front section 2. Central section 3. Rear section SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Carry out the checks described below once the electrical system is refitted, connectors recon- nected and clamps and retainers restored. •...
Page 59 DORSODURO Electrical system TABLE A - FRONT HEADLAMP 1. 12V 30A Relay • Fasten cable harness with retaining straps as shown in the figure. TABLE B - FASTENING SWITCH CABLE HARNESSES • Fasten switch cable harnesses with a rubber retainer. TABLE C - FASTENING GROUND LEAD / START-UP CABLE •...
Page 60 DORSODURO Electrical system TABLE D - FASTENING LIGHT SWITCH / IM- MOBILIZER CABLES • The clamp clasps the cables going out from the light switches and the immo- bilizer aerial cable going out from the key switch. Central part 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 61 DORSODURO Electrical system TABLE B - MAIN CABLE HARNESS LAYING • The cable harness must be laid behind the blow-by tube. Therefore, slide off the blow-by tube from the filter casing to be able to insert the cable harness. TABLE C1 - CABLE HARNESS LAYING Components described in tables C1 - C2 of this page must be laid under the airbox.
Page 62 DORSODURO Electrical system TABLE C2 - CABLE HARNESS LAYING • The cable going out from the generator must be laid behind the thermostatic valve. TABLE D - FASTENING THE CABLE HARNESS • Fasten the cable harness with clamps as shown in the figure. ELE SYS - 62...
Page 63 DORSODURO Electrical system TABLE E - FASTENING THE FILTER CASING CABLE HARNESS • Cable guide that fastens the cable har- ness to the air filter casing. TABLE F - FASTENING THE FUSES CABLE HARNESS / FRONT CYLINDER COIL 1. Cable guide that fastens the secondary fuses and front cylinder coil cable harnesses. •...
Page 64 DORSODURO Electrical system TABLE H - FASTENING THE FUSES CABLE HARNESS Cable guide that fastens the secondary fuses and front cylinder coil cable harnesses. TABLE I - FASTENING THE CABLE HARNESS Fasten the cable harness with a retaining strap. ELE SYS - 64...
Page 65 DORSODURO Electrical system TABLE J - FILTER CASING ELECTRICAL COM- PONENTS 1. Resistance module 2. Main injection relay 3. 12V / 30A relay TABLE K - BATTERY / ENGINE EARTHING CA- BLE HARNESS PATH TABLE L - LAMBDA PROBE • Place two clamps to fasten the cable harness to the chassis, as indicated: 1.
Page 66 DORSODURO Electrical system TABLE M1 - FILTER CASING CABLE HAR- NESS • Place both throttle valve position sen- sors. TABLE M2 - SENSORS • Place the two sensors. TABLE M3 - CLAMPS • Fasten cable harnesses with clamps. TABLE M4 - FILTER HOUSING •...
Page 67 DORSODURO Electrical system TABLE N - FASTENING THE CABLE HARNESS Fasten the cable harness with a clamp. TABLE O - ELECTRICAL COMPONENTS 1. Regulator connector 2. Rubber cap that hosts light switch and key switch connectors 3. Demand 1 Master Connector First, connect the light switch and the key switch connectors inside the rubber cap (2) and position it as shown in the figure;...
Page 68 DORSODURO Electrical system TABLE P - LEFT SIDE Fasten the cable harness with a retaining strap. TABLE Q - RIGHT SIDE Fasten the cable harness with retaining straps. TABLE R - MAIN CABLE HARNESS / BATTERY EARTHING Two retaining straps that clasp the main cable harness and the battery-engine earthing cable harness. ELE SYS - 68...
Page 69 DORSODURO Electrical system TABLE S - METAL CABLE GUIDES TABLE T - GROUND LEADS The cables fastened to the engine earthing must face downwards. 1. Main cable harness engine earthing on the left. 2. Battery ground lead on the right. ELE SYS - 69...
Page 70 DORSODURO Electrical system TABLE U - BATTERY CABLE HARNESS Two retaining straps that clasp the cable harness. 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 71 DORSODURO Electrical system TABLE C - BREATHER TUBES FASTENING Two cable guides and a clamp that fasten the breather pipe. TABLE C - LICENSE PLATE HOLDER CABLE HARNESS Retaining strap that fastens the cable harness. ELE SYS - 71...
Page 72 DORSODURO Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. RIGHT FRONT TURN INDICATOR 3. COMPLETE FRONT HEADLAMP 4. TAIL LIGHT BULB ELE SYS - 72...
Page 73 DORSODURO Electrical system 5. HIGH-/LOW-BEAM BULB 6. FRONT LEFT TURN INDICATOR 7. LIGHT LOGIC RELAY 8. CLUTCH SWITCH 9. HORN 10.LEFT LIGHT SWITCH 11.INSTRUMENT PANEL 12.RIGHT LIGHT SWITCH 13.OIL PRESSURE SENSOR 14.INSTRUMENT PANEL DIAGNOSIS 15.SIDE STAND SWITCH 16.ECU DIAGNOSIS 17.IMMOBILIZER AERIAL 18.KEY SWITCH 19.REAR LEFT TURN INDICATOR 20.REAR RIGHT TURN INDICATOR...
Page 74 DORSODURO Electrical system 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.ENGINE TEMPERATURE SENSOR 51.LAMBDA PROBE 52.PURGE VALVE (OPTIONAL) 53.REAR CYLINDER PRESSURE SENSOR 54.FRONT CYLINDER PRESSURE SENSOR 55.REAR CYLINDER INJECTOR 56.FRONT CYLINDER INJECTOR 57.EFG 1X THROTTLE CONTROL UNIT...
Page 75 DORSODURO Electrical system 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 76 DORSODURO Electrical system CAUTION: THE CIRCUIT SHOULD NOT BE ENERGISED, OTHERWISE THE TEST IS IRRELE- VANT. GROUND CONNECTION check Check goal: this control is to check if a cable or a circuit is in contact with the vehicle ground (-) connection.
Page 77 DORSODURO Electrical system • ECU DIAGNOSIS • INSTRUMENT PANEL ERRORS • ERROR CLEARING • VEHICLE SERVICING RESET • UPDATE • CHANGE KEYS • KM / MILES ECU DIAGNOSIS In this mode a chart is displayed showing potential errors in the control unit. IT IS NECESSARY REFER TO THE ERROR IN- DICATIONS GIVEN BY AXONE FOR THIS VE- HICLE.
Page 78 DORSODURO Electrical system An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. Troubleshooting The test is performed only once when the key is set to ON. This error is signalled by the bulb icon, and the general warning light turns on as well.
Page 79 DORSODURO Electrical system • MILES LANGUAGES Select the user interface language from this menu. • ITALIANO • ENGLISH • FRANCAIS • DEUTSCH • ESPAGNOL Service warning light reset VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check.
Page 80 DORSODURO Electrical system Rear light Characteristic Rear tail light / stop light Fuses AUXILIARY FUSES A - Coil, Light logic relay, Recovery logic relay, Stop, Horn, Tail lights, License plate light (10A). B - Low-beam / high-beam lights (15A). C - Live positive lead to EFG-1x control unit and to instrument panel, Instrument panel diagnosis (10 D - Instrument battery positive and EFG-1x control unit (15 A).
Page 81 DORSODURO Electrical system Connector location: • ENGINE connector: upper connector with control unit on the vehicle; a letter E is stamped on the control unit, to the right of the connector. • VEHICLE connector: lower connector with control unit on the vehicle; a letter V is stamped on the control unit, to the right of the connector.
Page 82 DORSODURO Electrical system • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status. ROM Error P0605- 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 83 DORSODURO Electrical system After installing the control unit and setting the key to ON, wait for 3 seconds, time during which the control unit detects the throttle valve position. Connect to Axone and check that the status for Throttle Self-learning is Carried out and the status for Throttle grip autodetection is Not carried out(this last status entails Urgent service being dis- played on the instrument panel).
Page 84 DORSODURO Electrical system Speed sensor VEHICLE SPEED SENSOR Function To indicate the vehicle speed by reading the sec- ondary transmission shaft rotation. Operation / Operating principle Hall-effect sensor: a square-wave pulse is gener- ated with voltage between 0 and approximately 0.3-0.4V.
Page 85 DORSODURO Electrical system nected, there is continuity on PIN 1 with the ground connection. If there is no continuity, set the key to OFF and check that there is continuity between ENGINE PIN 36 and PIN 1 of the sensor connector. If there is not, replace the control unit; if there is, check that there is voltage at PIN 3 coming from the control unit (approximately 5V): if there is no voltage, set the key to OFF and check that there is continuity between the ENGINE PIN 13 and PIN 3.
Page 86 DORSODURO Electrical system Engine rpm sensor ENGINE REVOLUTION SENSOR Function It informs crankshaft position and speed to the Marelli control unit. Operation / Operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position.
Page 87 DORSODURO Electrical system CAUTION IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT-CIRCUITED OR NO ERROR IS DIS- PLAYED, CHECK THE REVOLUTION SENSOR CONNECTOR AND THE MARELLI CONTROL UNIT CONNECTOR: IF NOT OK, RESTORE; IF OK, CHECK THE SENSOR ELECTRIC CHARACTERIS- TIC IS THE CORRECT ONE: IF IT IS NOT, REPLACE THE SENSOR.
Page 88 DORSODURO Electrical system CAUTION THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED. MARK OR CHECK THE CONNECTOR MARK- ING BEFORE REMOVING THEM (BLUE STAMP + BLUE BAND). THE CONNECTOR AND THE BLUE BAND SHOULD BE PLACED TO THE LEFT.
Page 89 DORSODURO Electrical system Throttle grip Example value:Slightly twisted_choked_fully twisted Throttle grip autodetection Example value: carried out/not carried out AXONE: PARAMETER ADJUSTMENT Throttle grip autodetection AXONE: ELECTRICAL ERRORS Left side throttle grip position sensor track A P0150- short circuit to positive / open circuit, short circuit to negative Error cause •...
Page 90 DORSODURO Electrical system • if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check the cable earth insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not earth insulated, restore the wiring.
Page 91 DORSODURO Electrical system by the Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 92 DORSODURO Electrical system • The value of the left side sensor (tracks A-B) does not coincide with the value of the right side sensor (tracks C-D). Troubleshooting • Replace the throttle grip sensor RESET PROCEDURE If the Marelli control unit or the throttle grip sensor is replaced, check the Throttle grip Autodetection with the diagnosis instrument: once the check is completed, make sure that the throttle grip Autode- tection status indicates: carried out.
Page 93 DORSODURO Electrical system 1. Supply 2. Ground connection 3. Output signal AXONE: 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. Front Cylinder estimated Intake Pressure Example value: 1003 mbar Pressure estimated by the control unit according to the throttle position.
Page 94 DORSODURO Electrical system • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 34 of the VEHICLE connector. Troubleshooting • If short circuit to positive, see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx.
Page 95 DORSODURO Electrical system • If the circuit is open, short circuit to negative, check the filter casing 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 5 of the Marelli control unit and the sensor connector PIN 3: if there is no continuity, restore the cable harness.
Page 96 DORSODURO Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, cut or wrongly connected pipe between sensor and throttle body or a hole in the intake manifold). Troubleshooting •...
Page 97 DORSODURO Electrical system • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean: there is an evident defect in the intake and pressure reading systems. Pressure too low at front cylinder manifold error P0217 - signal not valid.
Page 98 DORSODURO Electrical system • Resistance at 25°: 2.05 kOhm +/- 100 • Resistance at 60°: 575 Ohm +/- 15 • Resistance at 90°: 230 Ohm +/- 5 Ohm Pin-out: 1. Yellow brown: 0-5 V signal: PIN B1 2. Brown: PIN B2 ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS...
Page 99 DORSODURO Electrical system the vehicle ground connection: if it is correct, it means that the error cause is that the cable is short circuit to positive and it is necessary to restore the cable harness between the EN- GINE PIN 45 and the sensor PIN 1; if there is no continuity with the ground connection, check the sensor connector and the Marelli control unit connector.
Page 100 DORSODURO Electrical system • on the vehicle: on filter casing • on connector sensor: near the probes Electrical characteristics: • Resistance at 0°: 32.5 kΩ +/- 5% • Resistance at 25°: 10.0 kΩ +/- 5% Pin-out: 1. 0-5 V signal: PIN 1 2.
Page 101 DORSODURO Electrical system If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. • If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor; if resistance is correct, it means that the cable has ground connection: restore the cable harness.
Page 102 DORSODURO Electrical system 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) 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 103 DORSODURO Electrical system AXONE: ELECTRICAL ERRORS Lambda probe P0130 - shorted to positive. Error cause • Excessive voltage (battery voltage) has been detected at PIN 43 of the ENGINE connector. Caution: the 'lambda probe' parameter is not the real value that is read; a recovery value is displayed instead.
Page 104 DORSODURO Electrical system • Check circuit continuity from probe connector (PIN 1 and PIN 2) toward the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the ENGINE connector PIN 43 and PIN 60 and restore the cable harness.
Page 105 DORSODURO Electrical system is energised for 5 seconds and the grey/green cable of the injector is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation.
Page 106 DORSODURO Electrical system • If shorted to positive: excessive voltage has been detected at PIN 34 of the ENGINE con- nector. • If shorted to negative: no voltage has been detected. • If the circuit is open: an interruption has been detected. Troubleshooting •...
Page 107 DORSODURO Electrical system • Secondary circuit resistance: MOhm value range (with positive probe on coil). Pin-out: 1. Supply + batt V 2. Secondary circuit ground connection 3. Activation from control unit CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 108 DORSODURO Electrical system AXONE: ELECTRICAL ERRORS Lambda probe P0130 - shorted to positive / circuit, shorted to negative Error cause • If shorted to positive: excessive voltage has been detected at PIN 17 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 17 of the ENGINE connector.
Page 109 DORSODURO Electrical system Throttle body THROTTLE BODY Function To inform the throttle control unit the position of the two throttle valves and to drive them both. Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless; therefore, no electrical diagnosis is possible for the throttle body, only for the circuits connected to it.
Page 110 DORSODURO Electrical system The value in the example refers to engine conditions with key set to ON. Rear throttle Potentiometer 1 (voltage) Example value: 780 mV The value in the example refers to engine conditions with key set to ON. Rear throttle Potentiometer 2 (voltage) Example value: 3756 mV The value in the example refers to engine conditions with key set to ON.
Page 111 DORSODURO Electrical system • If shorted to positive: excessive voltage has been detected at PIN A6 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN A6 of the throttle control unit. Troubleshooting •...
Page 112 DORSODURO Electrical system • If shorted to positive: excessive voltage has been detected at PIN B6 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN B6 of the throttle control unit. Troubleshooting •...
Page 113 DORSODURO Electrical system • The throttle power supply is too low to carry out the autodetection test correctly (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • The throttle test is not carried out when the key is set to ON because the test could show unreal errors (because the voltage is too low).
Page 114 DORSODURO Electrical system • The throttle test is not carried out when the key is set to ON because the test could show unreal errors (because the voltage is too low). Voltage is detected by the Marelli control unit. Rear throttle control circuit P0186 Example value:short circuit to positive / short circuit to negative / open circuit, overcurrent, excessive internal temperature.
Page 115 DORSODURO Electrical system is a few tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the complete throttle body. Potentiometer 2 sensor, front throttle position P0123 - signal not valid. Error cause •...
Page 116 DORSODURO Electrical system • Signal not within the expected value drawn according to the values of the intake pressure. Troubleshooting • Check the parameter of the Potentiometer 2 Rear throttle (voltage) to get which signal the control unit receives and to compare it to the Potentiometer 2 Front throttle (voltage). Check the throttle body connector as well as the throttle control unit connector.
Page 117 DORSODURO Electrical system • Check if the throttle body and the intake duct are clean. If they are, replace the throttle body. Detection of front throttle valve Recovery conditions (air Tº,water Tº) P0163 - possible presence of ice. Error cause •...
Page 118 DORSODURO Electrical system Error cause • Position of the throttle stop not within the expected range (at each key ON). Troubleshooting. • Check if the throttle body and the intake duct are clean. If they are, replace the throttle body. Detection of the rear throttle Recovery conditions (air Tº, water Tº) P0183 - possible presence of ice.
Page 119 DORSODURO Electrical system Engine oil pressure sensor ENGINE OIL PRESSURE SENSOR Function: it indicates to the instrument panel if there is enough oil pressure (0.5 +/- 0.2 bar (7.25 +/- 2.9 PSI)) in the engine. Operation / Operating principle: normally closed switch.
Page 120 DORSODURO Electrical system Error DSB 08 Error cause • An oil sensor failure is signalled when, with engine running, it is detected that the sensor circuit is closed. This error is signalled by the bulb icon and the general warning light turns on as well. Troubleshooting •...
Page 121 DORSODURO Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: STATUSES Gear in neutral Example value:yes/no AXONE: NOTES •...
Page 122 DORSODURO Electrical system • Clutch pulled: closed circuit (continuity) • Clutch released: open circuit (infinite resistance) Pin-out: 1. Voltage 12V 2. Ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CONCEPTS OF ELEC- TRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELEC- TRICAL SYSTEM CHAPTER.
Page 123 DORSODURO Electrical system Side stand sensor SIDE STAND SENSOR Function It tells the side stand position to the control unit. Operation / Operating principle If the gear is engaged and the side stand is unfol- ded, and therefore the circuit is open, the control unit does not enable vehicle start-up or shuts off the engine if it is rotating.
Page 124 DORSODURO Electrical system Bank angle sensor FALL SENSOR Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: When the Marelli control unit detects this ground connection, it does not enable start-up or shuts off the engine.
Page 125 DORSODURO Electrical system not, it means that, with key set to ON, there is no 5V voltage at PIN 2: restore the cable harness whose pink/white cable will be shorted to ground Electric fan circuit ELECTRIC FAN CIRCUIT Function Radiator fan and coolant - Operation. Operation / Operating principle When the control unit detects a temperature of approx.
Page 126 DORSODURO Electrical system • If the circuit is open: interrupted circuit detected. Excessive voltage can only be detected after the fan relay gets ac- tivated. Troubleshooting • If shorted to positive: check the relay electrical specifications are correct by disconnecting it from the cable har- ness.
Page 127 DORSODURO Electrical system • connector: inside the rubber protection located between the water radiator and the fuel tank, to the right. Electrical characteristics: • STOP position: the circuit is open • RUN position: closed circuit (continui- Pin-out: 1. Yellow/grey cable: - 2.
Page 128 DORSODURO Electrical system Location: • on the vehicle: inside the filter casing • connector: on the control unit Pin-out: see the CONNECTORS section See also Throttle control unit Connectors PIN OUT ARELLI CONTROL UNIT Specification Desc./Quantity Key switch Vehicle connector: 12/29 Revolution sensor input (+) Engine connector: 9 Revolution sensor input (-)
Page 129 DORSODURO Electrical system Specification Desc./Quantity Start-up control output Engine connector: 2 Serial line K for diagnosis Vehicle connector: 10 Auxiliary injection relay control output Vehicle connector: 62 Front coil control output Engine connector: 17 Rear coil control output Engine connector: 19 Front injector control output Engine connector: 50 Rear injector control output...
Page 130 DORSODURO 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. Throttle control unit PIN OUT THROTTLE CONTROL UNIT Specification Desc./Quantity 1A - Front throttle motor control (-)
Page 131 DORSODURO Electrical system Specification Desc./Quantity 7B - Rear throttle reset signal input 8B - Battery power supply input 1C - Front throttle motor control (+) Front throttle body PIN: 3 2C - Ground connection 3C - Ground connection Front throttle body PIN: 6 4C - Ground connection Rear throttle body PIN: 6 5C - Ground connection...
Page 132 DORSODURO Electrical system Specification Desc./Quantity GREY BODY: Indicator reset PIN 16 GREY BODY: Oil sensor input PIN 17 GREY BODY: 750/1200 Selection PIN 18 GREY BODY: * PIN 19 GREY BODY: K Line PIN 20 BLACK BODY: + Battery PIN 21 BLACK BODY: Front left turn indicator activation PIN 22 BLACK BODY: Front right turn indicator activation...
Page 133 DORSODURO Electrical system Error cause • The injection ECU cannot send CAN signals; it receives signals from the instrument panel and the throttle control unit: the control unit may need replacing. Troubleshooting • Replace the Marelli control unit. CAN line to instrument panel, U1701 - no signal Error cause •...
Page 134 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 135 DORSODURO Engine from vehicle Vehicle preparation • Remove the air filter case. • Remove the coolant radiator. • Remove the exhaust system. • Place the optional under-sump and rear wheel service stands. • Undo and remove the screw and move the coil.
Page 136 DORSODURO Engine from vehicle • Undo and remove the screw and col- lect the washer. • Disconnect the ground leads. • Move the breather pipe. • Disconnect the speed sensor connec- tor. • Undo and remove the three screws. • Remove the clutch control cylinder.
Page 137 DORSODURO Engine from vehicle • Undo and remove the two screws. • Remove the chain guard. • 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 138 DORSODURO Engine from vehicle • Disconnect the side stand sensor con- nector. • Loosen the screw and slide off the gear transmission connecting rod keeping it linked to the gear shift lever through the rod. • Slacken the gearing chain tension. •...
Page 139 DORSODURO Engine from vehicle See also Air box Removing the radiator Removing the engine from the vehicle • Carry out the operations described un- der Vehicle preparation. • Support the engine by means of belt and hoist. • Working on the left side, unscrew and remove the two upper nuts.
Page 140 DORSODURO 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. • Collect the spacer on the opposite side. • Remove the lower pin and collect the washer.
Page 141 DORSODURO Engine from vehicle • Working on the right side, insert the three bolts with their washers. • Working on the right side, place the spacers on the three bolts between the engine block and the chassis. CAUTION THE SPACERS HAVE DIFFERENT SIZES. REFIT THEM IN THE SAME WAY THEY WERE BEFORE BEING REMOVED.
Page 142 DORSODURO Engine from vehicle See also Vehicle preparation Adjusting ENG VE - 142...
Page 143 INDEX OF TOPICS NGINE...
Page 144 DORSODURO 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. Pin for spring 8. Tone wheel 9. Complete transmission gear shaft 10.Forks 11.Fork shaft 12.Spring 13.Pin for spring 14.Gear selector...
Page 145 DORSODURO 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. Main gear shaft Z=14 2. 2nd gear on primary Z=17 3.
Page 146 DORSODURO 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 19.Circlip 20.Thrust washer 21.Thrust washer 22.Thrust washer 23.Floating bushing...
Page 147 DORSODURO 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. ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE. • Carefully rotate the engine support.
Page 148 DORSODURO 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. See also Splitting the crankcase halves Gear selector Removing the gear selector To remove the gear selector refer to the operations described under Crankcase opening.
Page 149 DORSODURO Engine Pawl Make sure that both pawl tips run free, without jamming Selector plate spring With a thickness gauge, check that the spring is not deformed by over-stretching. Starter motor Removing the starter motor • Disconnect the starter motor power supply cable.
Page 150 DORSODURO Engine Generator side Key: 1. Complete starter motor 2. Complete torque limiter 3. Starting ring gear 4. Freewheel flange 5. Freewheel 6. Complete rotor 7. Complete stator 8. Flywheel cover gasket 9. Flywheel cover 10.TCEI low head screw M6x30 11.TBIC screw M5x12 12.TE flanged screw 13.Cap...
Page 151 DORSODURO Engine 20.TE flanged screw 21.NGK R CR7EK spark plug 22.Reference dowel 23.TE flanged screw Removing the flywheel cover • Remove the flywheel cover inspection cap. • Unscrew and remove the ten screws (1 - 2). NOTE THE FLYWHEEL COVER SCREW (2) IS SHORTER THAN SCREWS (1).
Page 152 DORSODURO 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. Magneto flywheel removal •...
Page 153 DORSODURO 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. Specific tooling 020713Y Flywheel extractor •...
Page 154 DORSODURO 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. Installing the flywheel • Insert the woodruff key on the crank- shaft.
Page 155 DORSODURO Engine • Place the appropriate tool for locking the flywheel. • Locking the flywheel in position, using the specific tool, tighten the screw on the crankshaft. • Remove the special tool. Specific tooling 020713Y Flywheel extractor Locking torques (N*m) Screw fixing Rotor - Crankshaft - M12x1.25 (1) 120 Nm (88.51 lbf ft) •...
Page 156 DORSODURO Engine Removing the clutch cover • Undo and remove the side fixing screws. • Remove the clutch cover. It is advisable to remove only the clutch cover in order to replace the clutch discs. Should the com- plete clutch assembly be removed, remove the crankcase, clutch side.
Page 157 DORSODURO Engine Disassembling the clutch Key: 1. Complete clutch bell 2. Washer 3. Clutch hub 4. Clutch pressure plate 5. Clutch spring 6. Washer 7. TCEI screw M6 8. Spacer 9. Anti-juddering 10.Belleville spring 11.Anti-juddering 12.Nitrided driven disc 13.Lathed drive disc 14.Drive disc 15.Driven disc ENG - 157...
Page 158 DORSODURO Engine • Remove the clutch side crankcase half. • Undo and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and collect the washers and the clutch springs. • Remove the pressure plate.
Page 159 DORSODURO Engine • Lock the clutch bell using the specific tool. Specific tooling 9100896 Clutch bell locking tool • Unscrew and remove the clutch hub nut and collect the washer. • Remove the clutch hub. • Collect the special washer between the clutch hub and the bell. •...
Page 160 DORSODURO Engine • Collect the spacer and the needle bearings. • Collect the shim washer. 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 161 DORSODURO Engine MUSHROOM VALVE CHECK • Check if the valve slides freely, without jamming. • Blow compressed air into the valve and check that the lubricating oil passage holes open. Checking the clutch housing • Remove the clutch bell. • Remove the seeger ring.
Page 162 DORSODURO Engine Check the main driven gear for damage and wear and, if necessary, replace the main transmission driving gear and the clutch bell all together. Make sure there is not excessive noise during operation; if necessary, replace the main transmission driving gear and the clutch bell all together.
Page 163 DORSODURO 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 164 DORSODURO Engine • Place the clutch hub. • Fit the clutch cover. • Check that the measurement has not changed compared with the one car- ried out upon removal; tighten the clutch nut afterwards. If it has changed, rotate the crankshaft so that the oil pump control drive gear engages cor- rectly with the oil pump driven gear on the clutch bell.
Page 165 DORSODURO 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. • Position all friction material discs with their teeth aligned in one of the long slots of the clutch bell.
Page 166 DORSODURO 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. • Remove the head cover. Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 167 DORSODURO Engine • Separate the cylinder from the head. • Collect the washer. See also Removing the cylinder Cylinder head Key: 1. Complete cylinder head 2. Inlet valve 3. Outlet valve 4. External valve spring 5. Internal valve spring 6. Upper cap 7.
Page 168 DORSODURO Engine 9. Stud bolt 10.Water pipe fitting 11.TBEI screw 12.Joint 13.O-ring 14.Flanged nut M8X1.25 15.Flanged nut 16.Valve sealing ring 17.TE flanged screw 18.Lock nut M10x1.25 19.Water Temperature Sensor 20.Threaded cap M6X10 21.Threaded cap 22.TE flanged screw 23.To radiator Removing the overhead camshaft •...
Page 169 DORSODURO Engine • Remove the cam cap carefully so as not to go through it and damage the seats of the calibrated dowels. • Remove the camshafts with the gears. 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 170 DORSODURO Engine • Compress the valve springs with the specific tightening bow and with the spring compressing tool. Specific tooling AP8140179 Valve spring compressor 020721Y Adaptor for valve removal • Remove the cotters using a magnet. • Release the valve springs. •...
Page 171 DORSODURO Engine 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. CAMSHAFT LOBES • Check that they do not show blue col- ouring, pitting or scratches;...
Page 172 DORSODURO Engine Clean off any combustion residues from the valves. Check the seat (1) on the valve head with a ruler flush. The surface of the seat must not be concave; re- place the valve if necessary. Check the clearance between the stem and the valve guide: inlet: 0.013 - 0.040 mm (0.00051 - 0.00157 in);...
Page 173 DORSODURO Engine • Check there are no mineral deposits or rust in the head water cooled jacket; clean off if required. • Use a checking ruler and a thickness gauge positioned diagonally to the ruler to measure the cylinder head distortion. Maximum cylinder head distortion: 0.03 mm (0.0012 in) •...
Page 174 DORSODURO Engine 7. Shim washer 8. Right nut M15x1 9. Special screw 10.Safety washer 11.Sealing ring 12.Camshaft support 13.Torx screw M6X35 14.Timing system chain 15.Chain guide slider 16.Chain tightener rod 17.Camshaft - rear inlet 18.Camshaft - rear outlet 19.Left nut M15x1 20.Spacer screw Removing the chain tensioner •...
Page 175 DORSODURO Engine Chain removal • Remove the chain tensioner. • Remove the main pinion. • Remove the movable chain slider and release the fixed chain slider from the clamp. • Unscrew and remove the pin of the tim- ing chain intermediate gear paying at- tention not to damage the O-ring.
Page 176 DORSODURO Engine Removing the chain sliders • Remove the chain tensioner and the camshafts from the corresponding head. FRONT HEAD • First remove the clutch cover in order to remove the chain sliders from the front head. • Undo and remove the movable chain tensioner slider screw.
Page 177 DORSODURO Engine chain tensioner Removing the head cover Clutch side Magneto flywheel removal Checking the chain Check the timing chain for damage or stiffness while moving. If required, replace both the timing chain and the camshaft sprocket wheels. Check the timing chain guide for damage. If necessary, replace the parts. Installing the chain tensioner Refit the removed timing system chain tensioner on the cylinder - head:...
Page 178 DORSODURO Engine Cam timing Timing • Rotate the crankshaft until the front cylinder piston reaches the top dead centre. • Lock the crankshaft with the specific special tool Specific tooling 020720Y Timing tool If necessary, remove the timing system gears from the camshafts: •...
Page 179 DORSODURO Engine • Align the clearance recovery gear to the main timing system gear using the specific tool. Specific tooling 020718Y Camshaft gear alignment pin • 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 180 DORSODURO Engine Cam cap/head fixing screws - M6 (16) Pre-tight- ening: (4.90 - 6.86) Nm ((3.61 - 5.06) lbf ft) Tightening: (9.81 - 12.75) Nm ((7.24 - 9.40) lbf ft) CAUTION INSTALL THE CAMSHAFT TIGHTENING NUTS WITH THE MARK FACING UP. •...
Page 181 DORSODURO Engine Cylinder-piston assembly Key: 1. Cylinder - Piston 2. Piston 3. Compression ring 4. Oil scraper ring 5. Oil scraper ring 6. Pin 7. Pin stop ring 8. Gasket 9. Plate 10.TE flanged screw 11.Complete chain tensioner 12.TE flanged screw 13.Head-cylinder gasket 14.11.8X10 Pin ENG - 181...
Page 182 DORSODURO Engine Removing the cylinder • Remove the timing chain. • Undo and remove the two head fixing screws located inside the timing chain compartment. • Undo and remove the external screw. • Unscrew and remove the four nuts, working in a diagonal sequence and in stages.
Page 183 DORSODURO Engine Disassembling the piston • Remove the head and cylinder. • Take out the pin locking ring. • Lock the connecting rod using the spe- cific tool. • Slide off the pin and remove the piston. Specific tooling 020716Y Connecting rod locking •...
Page 184 DORSODURO Engine See also Removing the cylinder head Removing the cylinder 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 185 DORSODURO Engine • Clean off lime scales on the cylinder cooling slots. • Measure the cylinder bore at a dis- tance of 10 - 43 - 90 mm (0.39 - 1.69 - 3.54 in) from the head coupling sur- face; the highest value should be considered to estimate wear limits.
Page 186 DORSODURO Engine Top ring (1st slot): 0.030 - 0.065 mm (0.0012 - 0.0026 in) Intermediate ring (2nd slot): 0.020 - 0.055 mm (0.0008 - 0.0022 in) Oil scraper ring (3rd slot): 0.010 - 0.045 mm (0.0004 - 0.0018 in) • Fit the piston ring to the cylinder.
Page 187 DORSODURO Engine • Measure the pin housing diameter (b) and replace the piston if not complying with specifications. Pin housing diameter (b): 22.010 - 22.015 mm (0.8665 - 0.8667 in) • Calculate the clearance between pin and pin hole and, if not complying with specifications, replace both pin and piston.
Page 188 DORSODURO Engine • Fit the oil scraper ring on the piston, with its opening facing the exhaust side. • Fit the remaining sealing rings on the piston with a 90° offset one from the other. • Place a new locking ring on the piston. •...
Page 189 DORSODURO Engine • Before fitting the cylinder, place the chain sliders and the timing chain on the crankshaft; fit the timing chain on the crankshaft from the base side. NOTE BEFORE FITTING THE CYLINDER, CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER.
Page 190 DORSODURO Engine • Check that the intermediate gear pin lubrication holes are clean. • With a hook, hold the timing chain. • Fit the timing chain on the intermediate gear. • Slide in the pin together with a new O- Ring and a washer.
Page 191 DORSODURO Engine Selecting the base gasket • Place the specific special tool on the piston, which should have sealing rings and be fitted on the connecting rod. • Lock the special tool with the clamp. Specific tooling AP8140302 tool for sealing ring fitting •...
Page 192 DORSODURO Engine inder base gasket thickness, an ade- quate compression ratio can be main- tained • Remove the specific tool and the cyl- inder. Specific tooling 020720Y Timing tool ASE GASKET Specification Desc./Quantity Measured protrusion -0.10 / + 0.0 mm (- 0.0039 / 0.0000 in) Gasket 0.4 mm (0.0157 in) Measured protrusion 0.05 / 0.10 mm (0.0020 / 0.0039 in) Gasket 0.5 mm (0.0197 in)
Page 193 DORSODURO Engine • Screw without tightening the screw on the intake side. • Tighten the cylinder-head fixing screws to the prescribed torque. • Place the cylinder-head unit on the crankcase stud bolts. Installing the head cover CAUTION BEFORE REFITTING HEAD COVERS, CLEAN HEAD AND COVER SURFACES CAREFULLY. •...
Page 194 DORSODURO Engine Crankcase - crankshaft Key: 1. Upper bushing 2. Lower bushing 3. Ball bearing 25x62x17 4. Ball bearing 30x62x23.8 5. Ball bearing 25x42x9 6. Ball bearing 20x47x14 7. Roller casing 30x37x12 8. Roller casing 9. Washer 10.TSPEI screw M6x12 11.Sealing ring 12.Sealing ring 8x16x7 13.Sealing ring 14x22x5...
Page 195 DORSODURO Engine 20.TE flanged screw 21.Seeger ring for hole 22.Special screw 23.Washer Splitting the crankcase halves • Fit the special tool by fixing the four fix- ing screws steadfastly on the crank- case. • Using the special tool, unscrew and re- move the crankshaft locking nut and collect the washer.
Page 196 DORSODURO Engine • Using a commercial available extrac- tor, remove the crankshaft gear. • Remove the gear control rod and col- lect the washer. • Undo and remove the screw fixing the speed sensor. • Carefully remove the speed sensor. •...
Page 197 DORSODURO Engine • Undo and remove the three screws fix- ing the gear selector plate. • Remove the plate together with the se- lector • Undo and remove the two screws fixing the neutral sensor. • Remove the neutral sensor. ENG - 197...
Page 198 DORSODURO Engine • Collect the sensor contact together with its spring. • If the pinion has been removed, refit and lock it with a special tool. Specific tooling 9100896 Clutch bell locking tool The tone wheel is sealed with Loctite. Heat it with a suitable blower, paying special attention not to reach high temperatures.
Page 199 DORSODURO Engine • Undo and remove the gear selector drum fixing screw. • Remove the gear selector drum. • Remove the pinion. • Slide off the clutch control rod. ENG - 199...
Page 200 DORSODURO Engine • Working on the left side, undo and re- move the nine M8 screws fixing the crankcase. • Working on the left side, undo and re- move the nine M6 screws fixing the crankcase. • Remove the fuel breather clamping plate.
Page 201 DORSODURO Engine • Undo and remove the pin, tighten it again one turn to allow for crankcase clearance and check sealing. CAUTION PAY SPECIAL ATTENTION TO ENGINE AND ENGINE SUP- PORT STABILITY AND MAKE SURE THE ENGINE-TO- PLATE FIXING IS RELIABLE. •...
Page 202 DORSODURO Engine • Fix the two screws to the engine sup- port again. • If necessary, undo and remove the two screws fixing the strum box. • Remove the strum box. See also Removing the cylinder Magneto flywheel removal Disassembling the clutch ENG - 202...
Page 203 DORSODURO Engine Removing the crankshaft Key: 1. Complete crankshaft 2. Complete connecting rod 3. Connecting rod screw 4. Bushing half-shell 5. Main transmission gear 6. Woodruff Key 7. Water pump gear 8. Plain washer 9. Nut 10.Roller 11.Bushing • Slide off the crankshaft. See also ENG - 203...
Page 204 DORSODURO Engine 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. Clean the seal surfaces and check that they are not damaged.
Page 205 DORSODURO Engine • Replace the O-ring on the oil passage duct. Before refitting UPON REFITTING THE CRANKSHAFT, GREASE THE SHAFT BUSHING-CONNECTING ROD COUPLING. Inspecting the crankshaft components Crankshaft axial clearance check • The shaft axial clearance on the crank- case should be checked with a com- parator mounted on the specific com- parator support.
Page 206 DORSODURO Engine Installing the crankshaft • Place the left side crankcase half on the engine support adequately. • Place the crankshaft on the seat of the crankcase half with caution. Refitting the crankcase halves • Fit the strum box, if previously re- moved.
Page 207 DORSODURO Engine • Place the right crankcase half with the aid of a rubber hammer. • Tighten the two fixing pins. • Rotate the engine and the engine support into vertical position. • Working on the left side, place the nine M6 screws fixing the crankcase.
Page 208 DORSODURO Engine • Working on the left side, place the nine M8 screws fixing the crankcase. • Tighten all the crankcase fixing screws, both M6 and M8 type. • Slide in the clutch control rod. • Place the pinion. • Place the gear selector drum and check that it is correctly timed;...
Page 209 DORSODURO Engine • Tighten the gear selector drum fixing screw. • Position the tone wheel. • Tighten the tone wheel with the special tool. Use Loctite medium-strength for sealing. Specific tooling 020715Y Tone wheel removal • Tighten the pinion fixing nut using the special tool.
Page 210 DORSODURO Engine • Position the sensor contact together with the spring. • Place the neutral sensor and lubricate its seat to facilitate refitting. BE CAREFUL NOT TO DAMAGE THE O-RING WHEN IN- SERTING THE SENSOR IN ITS POSITION. • Tighten the two screws fixing the neu- tral sensor.
Page 211 DORSODURO Engine • Tighten the three screws fixing the gear selector plate by applying Loctite medium-strength. • Place the speed sensor with caution. • Tighten the speed sensor fixing screw. • Place the transmission control rod with the washer. • Remove the grease off the primary pin- ion tapered pins - crankshaft coupling surfaces .
Page 212 DORSODURO Engine • Fit the special tool and fix it steadfastly to the crankcase by tightening the four fixing screws on the crankcase. • Tighten the crankshaft gear lock-nut. Specific tooling 020711Y Engine pinion locking Lubrication Oil pump Removing • Lock the pump gear with the commer- cially available hook spanner and undo the screw;...
Page 213 DORSODURO Engine • Collect the shim washer. • Undo and remove the two screws fixing the oil pump. • Remove the entire pump. ENG - 213...
Page 214 DORSODURO Engine Inspection • Undo and remove the two fixing screws. • Using a thickness gauge check clear- ance between rotor and stator and re- place the rotor / stator unit if required. clearance between rotor and stator: 0.04 ± 0.10 mm (0.0016 in ±...
Page 215 DORSODURO Engine • Remove the oil pump rotor. • Remove the oil pump stator. CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAM- AGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTH- ER MARKS). Installing • Follow the oil pump removal opera- tions;...
Page 216 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 217 DORSODURO Power supply Fuel pump Key: 1. Complete fuel pump unit 2. Flange gasket 3. Fuel filter 4. Low self-locking nut 5. Fuel delivery pipe Electrical characteristics: • Resistance: 0.7 +/- 0.2 Ohm AXONE: ELECTRICAL ERRORS Fuel pump relay control P0230 Example value: shorted to positive / open circuit, shorted to negative.
Page 218 DORSODURO Power supply Ride by Wire RIDE BY WIRE Operating logic Those riding motorbikes do not require a specific throttle valve opening from their engines but actually a specific torque. The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control;...
Page 219 DORSODURO Power supply • Throttle valve with 2 return springs for the controlled minimum opening position. • DC electrical motor • Tinned double throttle position sensors with magnetic control (contactless) The throttle bodies do not require any maintenance and cannot be overhauled. In case of electric or mechanic malfunction, replace the whole unit.
Page 220 DORSODURO Power supply the position exclusively depending on the springs are not moved. The engine may shut off during the operation if it is running at idle speed and the gear is in neutral. D the malfunction may affect riding in safety, the warning light turns on, the message Urgent Service is displayed, the engine stops running.
Page 221 DORSODURO Power supply • Working on both bodies, undo and re- move the two plate screws. • Remove the plate. • Working on both bodies, undo and re- move the screw and detach the body. • Working on the body in question, re- move the injector, slide off the clip and the injector itself.
Page 222 DORSODURO Power supply Using axone 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: Axone Parameters. The same parameters- device status, errors, etc. -are grouped per type of component they refer to in the Electrical system chapter, Checks and Controls P SUPP - 222...
Page 223 INDEX OF TOPICS SUSP USPENSIONS...
Page 224 DORSODURO Suspensions Front Key: 1. Front wheel 3.5"x17" 2. Tubeless valve 3. Internal spacer 4. Bearing 5. Sealing ring 30x47x7 6. Seeger ring 7. Front wheel right external spacer 8. Front brake disc 9. Washer 25.2x36x1 10.Wheel pin nut 11.TE flanged screw M8x20 12.Front wheel pin 13.Front cover 120/70 ZR 17"...
Page 225 DORSODURO Suspensions • Undo the screws fixing the front pliers and slide them off the disc. • Remove the wheel pin fixing nut. • Collect the sealing washer. • Loosen the screws on the wheel pin clamps. • Tap the wheel pin with a rubber hammer so that the holes on the opposite side are exposed. •...
Page 226 DORSODURO Suspensions • Collect the spacer from the front wheel right side. Checking the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS, ESPECIALLY THOSE MENTIONED BELOW.
Page 227 DORSODURO Suspensions WHEEL PIN • Using a dial gauge, check the wheel pin eccentricity. If the eccentricity ex- ceeds the limit value, replace the wheel pin. Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value.
Page 228 DORSODURO Suspensions 1. Handlebar 2. Right light switch 3. Left light switch 4. Anti-vibration weight terminal 5. Anti-vibration weight 6. TCEI screw 7. Upper U-bolt 8. Screw 9. Handgrips 10.Right rear-view mirror 11.Left rear-view mirror 12.Throttle opening cable 13.Throttle closing cable 14.Right hand guard 15.Left hand guard 16.Bushing...
Page 229 DORSODURO Suspensions Diagram Key: 1. Complete right stem 2. Complete left stem 3. Sleeve 4. Spring 5. Preloading pipe 6. Right pumping member assembly 7. Left pumping member assembly 8. Sleeve cap 9. O-ring 10.Rubber ring 11.O-ring 12.Snap ring 13.Stem + right wheel holder 14.Stem + left wheel holder 15.Dust guard 16.Seeger ring...
Page 230 DORSODURO Suspensions 20.Sliding bushing 21.Special washer 22.Screw 23.TE flanged screw 24.Spring Centring 25.O-ring 26.O-ring 27.Washer 28.Ring 29.Spring regulator 30.Spring regulator plate Removing the fork legs • Remove the front wheel. • Support the fork stem and loosen the screws on the upper and then the lower plate.
Page 231 DORSODURO Suspensions • Being careful not to damage the fork stem when placing it in a vice, in verti- cal position, using the appropriate pro- tection. Specific tooling AP8140149 Protection for fitting operations • Unscrew the sleeve cap. • Drain the oil into a container of suitable capacity to collect fluids.
Page 232 DORSODURO Suspensions NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. • Drain the fork oil. • Place the fork stem on a work table in upright position. • Fit the special tool. Specific tooling AP8140147 Spacer tool With the help of a second operator: •...
Page 233 DORSODURO Suspensions • Loosen the nut. • Remove the sleeve cap carefully so as not to damage the rod when removing • Remove the spacer. See also Draining oil • Measure the distance between the nut and the thread to restore this setting if necessary.
Page 234 DORSODURO Suspensions • Remove the washer and the bushing. • Slide off the preloading pipe together with the spring centring. • Remove the spring. Let the oil depos- ited on the spring turns fully drip into the sleeve. • Be careful not to damage the fork stem when placing it in a vice, in horizontal position, using the appropriate protections.
Page 235 DORSODURO Suspensions • Remove the pumping member. • Remove the bottom cap. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • Do not damage the sleeve edge while doing this. • Remove the snap ring. •...
Page 236 DORSODURO Suspensions • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal. • Remove the ring and the dust guard. 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).
Page 237 DORSODURO Suspensions Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check the spring is in good conditions. Check that the following components are in good conditions: • upper bushing; • lower bushing; • pumping member. If there are signs of excessive wear or damage, replace the affected component.
Page 238 DORSODURO Suspensions • dust guard; • 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. • Protect the bearing tube end with ad- hesive tape.
Page 239 DORSODURO Suspensions • Fit the sleeve on the stem and with the specified tool fit the oil seal into posi- tion. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) holes AP8140146 Weight • Insert the snap ring in its position. •...
Page 240 DORSODURO Suspensions • Fit the pumping member with the bot- tom cap in the sleeve. • Tighten the screw fixing the pumping element on the fork end to the prescri- bed torque. Filling oil • Place the sleeve upright in a vice fitted with protection jaws.
Page 241 DORSODURO Suspensions Oil level (from sleeve rim, without the spring and with pumping member compressed) 147 mm (5.79 in) • Insert the spring, with the closest turns side facing downwards. • Fit the preloading pipe together with the spring centring. •...
Page 242 DORSODURO Suspensions • Insert the sleeve cap and screw the nut. • Tighten the sleeve cap. Steering bearing Key: 1. Folk lower plate 2. Screw SUSP - 242...
Page 243 DORSODURO Suspensions 3. Washer 4. Roller bearing 5. Sealing ring 6. Ring nut 7. Headstock cap washer 8. Headstock cap 9. TCEI screw 10.Cap 11.Rubber ring 12.Lower U-bolt 13.Fork upper plate 14.Spacer Adjusting play • Place the vehicle so that the front wheel is off the ground. •...
Page 244 DORSODURO Suspensions • Operating from both sides, loosen the screws fixing the fork stems to the up- per plate. • Undo and remove the two screws fixing the instrument panel support to the fork upper plate. • Slide off the fork upper plate by moving it towards the instrument panel. •...
Page 245 DORSODURO Suspensions Rear Key: 1. Chain with master link 2. Crown 3. Rear wheel 6"x17" 4. Rear wheel anti-vibration buffer 5. Rear cover 180/55 ZR 17" 6. Anti-vibration rubber buffer 7. Tubeless valve 8. Rear wheel spacer 9. Pin 10.Lower self-locking nut M10 11.Sprocket carrier assembly 12.Anti-vibration buffer spacer 13.Bearing 30x55x13...
Page 246 DORSODURO Suspensions 20.TCEI screw M10x30 21.Sealing ring 38x52x7 22.Master link Removing the rear wheel • Place the vehicle on its rear service stand. • Fasten the vehicle handlebar to the bench using belts. • To facilitate operations, it is advisable to remove the chain protection by un- doing the two screws.
Page 247 DORSODURO Suspensions • Working on the right side, hit the wheel pin lightly so as to take out the head from its housing. • Working on the left side, slide off the wheel pin together with the chain guide slider. •...
Page 248 DORSODURO Suspensions Checking the rear wheel CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS, ESPECIALLY THOSE MENTIONED BELOW. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless.
Page 249 DORSODURO Suspensions REAR WHEEL RIM • Using a dial gauge, check that the ra- dial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit val- An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim (2) if after replacing the bearings, the value is not within the specified limit.
Page 250 INDEX OF TOPICS CHAS HASSIS...
Page 251 DORSODURO Chassis Swinging arm Key: 1. Swingarm 2. Roller casing 3. Ball bearing 4. Internal spacer 5. Sealing ring 6. Seeger ring for hole 7. O-ring 8. Sealing ring 9. Swing arm pin 10.Adjustment bushing 11.Swingarm pin internal bushing 12.Swingarm pin ring nut 13.Rear wheel bolt nut 14.Rear wheel pin washer 15.Left chain guide slider...
Page 252 DORSODURO Chassis 19.Rear stand bushing 20.TSPEI screw 21.Chain guide slider 22.TBEI screw 23.Wheel pin nut 24.Chain guard 25.Special TBEI screw 26.Rear wheel pin 27.Washer 28.Clip 29.Rear mudguard 30.Sealing ring 31.Rubber ring 32.Front cap 33.Side cap 34.Rear cap Removing • Remove the exhaust system. •...
Page 253 DORSODURO Chassis • Undo and remove the two lower swing- arm screws. • Remove the cable guides. • Undo and remove the shock absorber lower screw and collect the nut. • Fasten the shock absorber to the chas- sis. • With the specific box-spanner, un- screw and remove the locking ring nut.
Page 254 DORSODURO Chassis • Working on the right side, unscrew and remove the swingarm bolt. UPON REMOVING THE REAR SWINGARM PAY ATTEN- TION NOT TO JAM THE GEARING CHAIN. See also Removing the rear wheel Drive chain Adjusting The vehicle is fitted with an endless chain, without master link. NOTE CARRY OUT THE MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VE- HICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTS APPLICATIONS.
Page 255 DORSODURO Chassis If you need to adjust chain tension after the check: • Place the vehicle on its OPTIONAL rear service stand. • Loosen the nut (1) completely. • Loosen both lock nuts (4). • Actuate on the set screws (5) and ad- just the chain backlash checking that the references (2 - 3) match on both sides of the vehicle.
Page 256 DORSODURO Chassis • Wash the chain with fuel oil or kerosene. Maintenance operations should be more frequent if there are signs of quick rust. Lubricate the chain at the intervals specified on the routine maintenance table and whenever necessary. • After washing and drying the chain, lubricate it with spray grease for sealed chains.
Page 257 DORSODURO Chassis 15.Washer 16.Rubber ring 17.Clip 18.Heat-protecting cover 19.Shock absorber protection 20.Heat-protecting cover 21.TE flanged screw 22.T-shaped bushing 23.TBEI screw 24.Washer 25.TCEI screw 26.Safety washer 27.Right clamp 28.Flange Removing the tail pipe • Loosen the clamp between the ex- haust end and the manifold. •...
Page 258 DORSODURO Chassis • 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. Removing the manifold - tail pipe • Remove the front exhaust manifold.
Page 259 DORSODURO Chassis FRONT • Unscrew and remove the two nuts on the head exhaust stud bolts. • Loosen the clamp. • Remove the exhaust manifold. REAR • Loosen the exhaust pipe between the manifold and the exhaust end. • Unscrew and remove the two nuts on the head exhaust stud bolts.
Page 260 DORSODURO Chassis • Unscrew and remove the lambda probe. CHAS - 260...
Page 261 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 262 DORSODURO Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. Rear brake calliper Key: 1. Brake pump with reservoir 2. Rear brake calliper 3. Rear brake lever 4. Rear brake lever pin 5.
Page 263 DORSODURO Braking system 15.TCEI screw 16.Stop switch 17.Rear brake pipe 18.Washer 19.Air bleed 20.Pins + Calliper springs 21.Rear pads-torque 22.REAR BRAKE DISC 23.TE flanged screw 24.Cable guide 25.Flanged TBEI screw 26.Clamp Front brake calliper Key: 1. Front left brake calliper 2.
Page 264 DORSODURO Braking system 7. Copper washer Front brake pads Removal • Turn the pins and remove both split pins. • Remove both pins. • Collect the anti-vibration springs. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Page 265 DORSODURO Braking system • Unscrew and remove the pin. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Page 266 DORSODURO Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid. •...
Page 267 DORSODURO Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid. •...
Page 268 INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
Page 269 DORSODURO Clutch system Key: 1. Clutch pump 2. Clutch lever 3. Cover 4. U-bolt 5. Clutch pipe 6. Oil pipe screw 7. Washer 10x14x1.6 8. Clutch control cylinder 9. Bleeding Kit 10.TSPEI screw 11.TSPEI screw 12.Stop switch 13.Rubber ring CAUTION IF CLUTCH LEVER TRAVEL OR CLUTCH DISENGAGEMENT ARE IRREGULAR, CHECK THE CLUTCH SYSTEM FOR AIR BUBBLES AND BLEED THE SYSTEM THROUGH VALVE (9).
Page 270 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 271 DORSODURO Cooling system Circuit diagram Key: 1. Radiator 2. Opening 3. Cap 4. Expansion tank 5. Expansion tank cap 6. Water pipe 7. Thermostat-radiator pipe 8. Radiator-pump pipe 9. Radiator filling pipe 10.Pipe 11.Valve-motor pump pipe 12.Bleed pipe 13.TE flanged screw 14.T-shaped bushing 15.Rubber ring 16.Thermostat valve unit...
Page 272 DORSODURO Cooling system 19.Fan unit 20.TCB Screw 21.Washer 22.T-shaped bushing 23.Rubber ring 24.Clic clamp 25.Clic clamp 26.Pipe clamp 27.TE flanged screw 28.Flanged TBEI screw 29.Flanged self- locking nut 30.Radiator support 31.Clic clamp 32.Clic clamp 33.From front cylinder 34.From rear cylinder 35.To rear cylinder Electric fan •...
Page 273 DORSODURO Cooling system • Place a container of suitable capacity. • Loosen the screw, move the clamp and slide off the sleeve. • Remove the cap. • Empty the system into the specific container. • Loosen the screw and move the clamp. •...
Page 274 DORSODURO Cooling system Water pump - overhaul COVER REMOVAL • Drain off the cooling circuit completely. • Undo and remove the five screws. • Remove the water pump cover. PUMP ROTOR REMOVAL • Remove the clutch-side cover. • Lock the pump shaft with a universal wrench on the hexagonal insert on the shaft. •...
Page 275 DORSODURO Cooling system Removing the radiator • Drain off the cooling system. • Undo and remove the screw. • Remove the filler. • Remove both clamps and slide off the corresponding pipes. • Disconnect the electric fan connector. • Undo and remove the screw, remove the horn.
Page 276 DORSODURO Cooling system • Working on the left side of the vehicle, undo and remove the screw. • Lower the radiator from the upper fixing side to the chassis and remove it by sliding it off toward the vehicle right- hand side.
Page 277 DORSODURO Cooling system • Release the clamp. • Slide off the pipe. • Undo and remove the screw and col- lect the washer. • Slide off the expansion tank. Thermostatic valve Traditional circuit, three-way thermostatic valve: 1. Hot water inlet from the heads. 2.
Page 278 INDEX OF TOPICS BODYW ODYWORK...
Page 279 DORSODURO Bodywork Headlight assy. • Operating from both sides, undo and remove the front frame fixing screw and collect the nut. • 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 280 DORSODURO Bodywork • Disconnect the front headlamp con- nector and remove the front headlight assembly. See also Instrument cluster support Taillight assy. • Remove the license plate support. • Undo and remove the four screws. • Undo and remove the screw. •...
Page 281 DORSODURO Bodywork • Working from both sides, undo and re- move the screw. • Disconnect the rear headlight connec- tors. • Remove the rear headlight. See also Tail guard Footrest RIGHT FOOTREST • Undo and remove the two external screws. •...
Page 282 DORSODURO Bodywork LEFT FOOTREST • Undo and remove the two external screws. • Loosen the gear shift lever rod screw. • Slide off the gear shift lever rod. • Remove the left footrest. Side body panels • Undo and remove the screw. •...
Page 283 DORSODURO Bodywork • Remove the side fairing. License plate holder • Remove the saddle. • Remove the tail section. • Undo and remove the three screws. • Disconnect the rear headlight connec- tor. • Release the rear headlight cable har- ness from the clamps.
Page 284 DORSODURO Bodywork • Slide off the license plate holder to- wards the back. See also Seat Tail guard Air box • Remove the air filter. • Slide off the electrical components fas- tened to the air filter casing. • Undo and remove the eight screws. •...
Page 285 DORSODURO 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. • Loosen the clamp to slide off the bleed pipe.
Page 286 DORSODURO Bodywork • Lift the filter casing and working on both cylinders, loosen and move the clamp and slide off the oil vapour re- covery pipe. • Working on the left side, disconnect the two control unit connectors. CAUTION THE CONNECTORS ARE MARKED BY THE LETTERS "V"...
Page 287 DORSODURO Bodywork • Remove the filter casing together with the throttle body, by lifting it up from behind. CAUTION COVER THE COUPLING OPENINGS SO THAT NO FOR- EIGN BODIES COME IN. Should the throttle body be removed, disconnect either the map sensor pipes or the inlet ducts; it is necessary to check the air system tightness.
Page 288 DORSODURO Bodywork TANK REMOVAL • Lift the fuel tank. • Unscrew and remove the rear screw. • Disconnect the fuel pipe. • Disconnect the tank breather pipe from the Y branch.. • Release the cable harness from the clamps . BODYW - 288...
Page 289 DORSODURO Bodywork • Disconnect the fuel pump connector. • Remove the fuel tank. Instrument cluster support • Working on both sides, loosen the nuts and screws and remove them. • Disconnect the connectors of arrow in- dicators, headlamps, ignition key lock and relay.
Page 290 DORSODURO Bodywork • Slide off the instrument panel from its support. • Disconnect the instrument panel con- nector. • Remove the instrument panel. Radiator cover • Working from both sides, undo and re- move the screw. • Remove the radiator cover. BODYW - 290...
Page 291 DORSODURO Bodywork 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. • Undo and remove the three screws. • Slide off the tail section backwards. BODYW - 291...
Page 292 INDEX OF TOPICS...
Page 293 PRE DE DELIVERY...
Page 294 DORSODURO Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
Page 295 DORSODURO 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. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 296 DORSODURO Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
Page 297 DORSODURO Pre-delivery OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP- PROVAL. LEFT • Remove the left side chain protection • Fit a left bracket and a left chain pro- tection; fasten then with a TEFL M8x35 mm screw at the top and with a TCEI M8x35 mm screw at the bottom NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE...
Page 298 DORSODURO 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. NOTE FINGER TIGHTEN THE SCREWS AND AFTERWARDS USE THE SPECIFIC WRENCH •...
Page 299 DORSODURO 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. • Place the hand guards fastening them on the sides using TCEI M6 X 50 screw being careful when inserting the bush- ing.
Page 300 DORSODURO 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 - 300...
Page 301 Air filter: 41, 287 Battery: 83 Brake: 262–264 Bulbs: Chain: 13, 174–177, 182, 254 Clutch: 24, 121, 155–157, 160–163, 177, 202, 269 Clutch lever: 121 Coolant: 272, 276 Engine oil: 39, 119 Fork: 228, 230, 231, 238 Fuel: 217, 287 Fuses: 80 Headlight: 279 Identification: 11...
Page 302 Tank: 276, 287 Transmission: 12 Tyres: 14 Warning lights:...

APRILIA DORSODURO 2007 Service Station Manual

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