APRILIA Caponord 1200 2016 Manual

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MANUALE STAZIONE DI SERVIZIO

2Q000020

Caponord 1200 - Caponord 1200 Rally

Summary of Contents for APRILIA Caponord 1200 2016

Page 1 MANUALE STAZIONE DI SERVIZIO 2Q000020 Caponord 1200 - Caponord 1200 Rally...
Page 2 Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
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 Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee...
Page 5 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 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8 Caponord 1200 - Caponord 1200 Rally Characteristics Rules OPTION 01 Caponord 1200 - Caponord 1200 Travel Pack OPTION 02 Caponord 1200 Rally 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 Caponord 1200 - Caponord 1200 Rally Characteristics TAKE PARTICULAR CARE NOT TO SPILL COOLANT ONTO HOT PARTS OR THE ENGINE AND EXHAUST SYSTEM; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. WHILE POISONOUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY AP- PEALING TO ANIMALS.
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 Caponord 1200 - Caponord 1200 Rally Characteristics • Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand or batch number facing outward (visible side). ELECTRICAL CONNECTORS Electric connectors must be disconnected as described below;...
Page 12 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 "SCHEDULED MAINTENANCE TABLE" IN THE SCHEDULED MAIN- TENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Page 13 Caponord 1200 - Caponord 1200 Rally Characteristics S: production plant (S= Scorzè); XXXXXX: serial number (6 digits); ENGINE NUMBER The engine number is printed on the base of the engine crankcase, left hand side. Engine No..... FRAME NUMBER The chassis number is stamped on the right side of the headstock.
Page 14 Caponord 1200 - Caponord 1200 Rally Characteristics Specification Desc./Quantity Clutch Multiple-disk, oil-bathed clutch with control on the left side of the handlebar Lubrication Wet crankcase. Pressure system regulated by a trochoidal pump with oil radiator. Air filter Sponge. Cooling Liquid EARBOX Specification Desc./Quantity...
Page 15 Caponord 1200 - Caponord 1200 Rally 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 Battery VTX14-BS 12 V - 12 Ampere/hour Main fuses Secondary fuses 7.5 A;...
Page 16 Telescopic fork "UPSIDE-DOWN" (upside-down stanchions) fork with stanchions with 43mm diameter, hydraulic braking dynamic adjustment during extension and compression (semi- active Aprilia Dynamic Damping technology) on left stanchion; and of spring preload on right stanchion, manually adjustable Travel 170 mm (6.69 in)
Page 17 Caponord 1200 - Caponord 1200 Rally Characteristics Specification Desc./Quantity tomated management (or manually on instrument panel) of spring preload via electro-hydraulic system. Wheel travel 150 mm (5.90 in) SIZES A Specification Desc./Quantity Size A 519 ± 2 mm (20.43 ± 0.07 in) Size B 129.2 mm (5.07 in) Brakes...
Page 18 Caponord 1200 - Caponord 1200 Rally Characteristics Specification Desc./Quantity (*) Only for 78 kW - PIRELLI ANGEL GT versions Front tyre 120/70 ZR17" (58W) Front tyre pressure rider only: 2.4 bar (240 kPa) (34.81 PSI) rider + passenger: 2.5 bar (250 kPa) (36.26 PSI) Rear tyre 180/55 ZR17"...
Page 19 Caponord 1200 - Caponord 1200 Rally Characteristics Front side RONT FORK pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lb ft) Screw (Piston fixing to the stem 30 Nm (22.13 lb ft) base) Upper cap 20 Nm (14.75 lb ft)
Page 20 Caponord 1200 - Caponord 1200 Rally Characteristics RONT FORK pos. Description Type Quantity Torque Notes Sensor upper cover screw M6x20 10 Nm (7.37 lb ft) Sensor lower cover screw M6x12 10 Nm (7.37 lb ft) Screw (Piston fixing to the stem 30 Nm (22.13 lb ft) base) Upper cover...
Page 21 Caponord 1200 - Caponord 1200 Rally Characteristics TEERING pos. Description Type Quantity Torque Notes Headstock ring nut - tightening M35x1 60 ± 12 Nm (44.25 ± 8.85 lb ft) Headstock cap 20 ± 4 Nm (14.75 ± 2.95 lb ft) SHC screw fastening fork stanchions M8x35 25 ±...
Page 22 Caponord 1200 - Caponord 1200 Rally Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Brake pump fixing screws 10 ± 1,5 Nm (7.37 ± 1.10 lb CHAR - 22...
Page 23 Caponord 1200 - Caponord 1200 Rally Characteristics ONTROLS HANDLEBAR pos. Description Type Quantity Torque Notes Upper U-bolt fixing screw M8x25 25 ± 3.75 Nm (18.44 ± 2.76 lb ft) Anti-vibration weight fastening screws 20 ± 4 Nm (14.75 ± 2.95 lb LUTCH CONTROL pos.
Page 24 Caponord 1200 - Caponord 1200 Rally Characteristics RONT WHEEL APONORD pos. Description Type Quantity Torque Notes Wheel axle M25 x 1.25 80 ± 12 Nm (59 ± 8.85 lb ft) Wheel nut M25 x 1.25 80 ± 12 Nm (59 ± 8.85 lb ft) Front brake disc fixing screws M8x20 30 Nm (22.13 lb ft)
Page 25 Caponord 1200 - Caponord 1200 Rally Characteristics RONT WHEEL APONORD ALLY pos. Description Type Quantity Torque Notes Wheel axle M25 x 1.25 80 ± 12 Nm (59 ± 8.85 lb ft) Wheel nut M25 x 1.25 80 ± 12 Nm (59 ± 8.85 lb ft) Front brake disc fixing screws M8x20 30 Nm (22.13 lb ft)
Page 26 Caponord 1200 - Caponord 1200 Rally Characteristics NSTRUMENT SUPPORT Pos. Description Type Quantity Torque Notes Instrument panel to trellis fixing screws M8x25 25 ± 5 Nm (18.43 ± 3.68 lb OOLING SYSTEM pos. Description Type Quantity Torque Notes Electric fan fastener screw M4x45 3 Nm (2.21 lb ft) CHAR - 26...
Page 27 Caponord 1200 - Caponord 1200 Rally Characteristics pos. Description Type Quantity Torque Notes Flanged TE screw fastening left Ra- M6x25 10 Nm (7.37 lb ft) diator to trellis Flanged TE screw fastening expan- M6x20 10 Nm (7.37 lb ft) sion tank OP FAIRING INDSHIELD pos.
Page 28 Caponord 1200 - Caponord 1200 Rally Characteristics UDGUARD pos. Description Type Quantity Torque Notes Lug fixing screw M6x20 10 Nm (7.37 lb ft) Control unit support fixing screw M6x35 10 Nm (7.37 lb ft) Front with rear lug fixing screw 3.9x14 2 Nm (1.47 lb ft) Front mudguard fixing screw...
Page 29 Caponord 1200 - Caponord 1200 Rally Characteristics RONT FAIRING pos. Description Type Quantity Torque Notes Deflector fixing screw M5x12 6 Nm (4.42 lb ft) Deflector fixing screw M5x16 6 Nm (4.42 lb ft) Central part CHAR - 29...
Page 30 Caponord 1200 - Caponord 1200 Rally Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Intake union fastener screw 12 Nm (8.85 lb ft) Loctite 242 Map sensor fixing screw 5.5 Nm (4.05 lb ft) Injector fastener screw 12 Nm (8.85 lb ft) Loctite 242 Injection Throttle Body fastener 12 Nm (8.85 lb ft)
Page 31 Caponord 1200 - Caponord 1200 Rally Characteristics IR FILTER BOX pos. Description Type Quantity Torque Notes Cross head self-tapping screw fas- M5x20 3 Nm (2.21 lb ft) tening covers / filter box Cross head self-tapping screw fas- M5x20 3 Nm (2.21 lb ft) tening blow-by tank Intake duct fixing screw 6 ±...
Page 32 Caponord 1200 - Caponord 1200 Rally Characteristics ENTRE FRAME pos. Description Type Quantity Torque Notes Flanged nut fastening side panels to 80 Nm (59 lb ft) engine EAT POST FRAME pos. Description Type Quantity Torque Notes Seat post fixing screw M8x35 35 ±...
Page 33 Caponord 1200 - Caponord 1200 Rally Characteristics 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 Flanged nut fastening Trellis to frame 80 Nm (59 lbf ft) side panels Flanged TE screw fastening chain M8x35...
Page 34 Caponord 1200 - Caponord 1200 Rally Characteristics UEL TANK pos. Description Type Quantity Torque Notes Plastic ring nut 20 ± 3 Nm (14.75 ± 2.21 lb Level indicator fixing screws M6x16 3 ± 0.45 Nm (2.21 ± 0.33 lb Saddle fixing M5 x 9.5 3 ±...
Page 35 Caponord 1200 - Caponord 1200 Rally Characteristics TAND pos. Description Type Quantity Torque Notes Central stand pre-soaked fixing screws M10x33 50 Nm (36.88 lb ft) Loctite 243 Plate fastening screws M8x30 25 ± 5 Nm (18.43 ± 3.68 lb Loctite 243 Stand screw 25 ±...
Page 36 Caponord 1200 - Caponord 1200 Rally Characteristics IDE STAND pos. Description Type Quantity Torque Notes Plate fastening screws M8x30 25 ± 5 Nm (18.43 ± 3.68 lb Loctite 243 Stand screw 25 ± 5 Nm (18.43 ± 3.68 lb Loctite 243 Stand nut M10x1.25 25 ±...
Page 37 Caponord 1200 - Caponord 1200 Rally Characteristics OPTION 02 XHAUST pos. Description Type Quantity Torque Notes TBEI silencer protection screws M6x16 5 Nm (3.69 lb ft) SHC silencer flange screws M8x25 18 ± 3.6 Nm (13.28 ± 2.66 lb ft) Resonator fixing clamp 4.5 ±...
Page 38 Caponord 1200 - Caponord 1200 Rally Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake lever pin 25 ± 3.75 Nm (18.44 ± 2.76 Loctite 243 lb ft) Microswitch fixing nuts 0.4 ± 0.08 Nm (0.29 ± 0.05 lb ft) Spring linking pin M5x7...
Page 39 Caponord 1200 - Caponord 1200 Rally Characteristics ANK COVER pos. Description Type Quantity Torque Notes Covers fastening screws M5x9 3 ± 0.60 Nm (2.21 ± 0.44 lb ADDLE pos. Description Type Quantity Torque Notes Saddle fixing screw M5x12 6 Nm (4.42 lb ft) CHAR - 39...
Page 40 Caponord 1200 - Caponord 1200 Rally Characteristics ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Covers fastener screw M5x20 6 Nm (4.42 lb ft) Compartment fixing screw M5x12 6 Nm (4.42 lb ft) AIRINGS pos. Description Type Quantity Torque Notes Fairing fastener screw M5x9 6 Nm (4.42 lb ft)
Page 41 Caponord 1200 - Caponord 1200 Rally Characteristics OTARY SENSOR pos. Description Type Quantity Torque Notes Reaction rod fixing nut 8 Nm (5.9 lb ft) Back side CHAR - 41...
Page 42 Caponord 1200 - Caponord 1200 Rally Characteristics SYSTEM pos. Description Type Quantity Torque Notes ABS ECU fastener screw M6x25 8-10 Nm (5.90-7.37 lb ABS ECU fastener nut 10 Nm (7.37 lb ft) EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper SHC mounting screw M10x50 50 Nm (36.88 lb ft)
Page 43 Caponord 1200 - Caponord 1200 Rally Characteristics EAR SUSPENSION A pos. Description Type Quantity Torque Notes Upper SHC mounting screw M10x50 50 Nm (36.88 lb ft) Lower SHC mounting screw M10x59 50 Nm (36.88 lb ft) OPTION 01 CHAR - 43...
Page 44 Caponord 1200 - Caponord 1200 Rally Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes ● Fastening screws flexible coupling Rear wheel axle M25x1.25 120 ± 18 Nm (88.50 ± 13.27 lb ft) Rear brake disc fixing screws M8x18 30 Nm (22.13 lb ft) OPTION 02 EAR WHEEL pos.
Page 45 Caponord 1200 - Caponord 1200 Rally Characteristics pos. Description Type Quantity Torque Notes Swingarm Pin adjustment bushing 12 Nm (8.85 lb ft) Swingarm pin ring nut 60 Nm (44.25 lb ft) Fork pin nut M20 x 1.5 90 Nm (66.38 lb ft) TPSI screw fastening rear stand M6x40 10 Nm (7.37 lb ft)
Page 46 Caponord 1200 - Caponord 1200 Rally Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Mudguard TEFL fixing screws on wheel ad- M6x16 10 ± 2 Nm (7.37 ± 1.47 lb Loctite 270 justment UGGAGE RACK pos. Description Type Quantity Torque Notes Luggage rack screw...
Page 47 Caponord 1200 - Caponord 1200 Rally Characteristics pos. Description Type Quantity Torque Notes Luggage rack fastener screw M8x25 25 Nm (18.44 lb ft) Luggage rack screw 5x14 3 Nm (2.21 lb ft) EAR BODYWORK pos. Description Type Quantity Torque Notes Tail fairing fastener screw M5x12 6 Nm (4.42 lb ft)
Page 48 Caponord 1200 - Caponord 1200 Rally Characteristics EAR LIGHTS pos. Description Type Quantity Torque Notes Turn indicator fixing screw M5x16 6 Nm (4.42 lb ft) Taillight screw M5x16 6 Nm (4.42 lb ft) License plate light nut 6 Nm (4.42 lb ft) IDE BAG HOLDER pos.
Page 49 Caponord 1200 - Caponord 1200 Rally Characteristics Engine EAD COVER pos. Description Type Quantity Torque Notes Special screw for fastening head 9 Nm (6.64 lb ft) cover Special screw for fastening head 9 Nm (6.64 lb ft) cover Oil breather fastener screw 5.50 Nm (4.06 lbf ft) Spark plugs 10-12 Nm (7.38-8.85 lb...
Page 50 Caponord 1200 - Caponord 1200 Rally Characteristics pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 22 Nm (16.22 lb ft) Threaded plug for water sensor seat M12x1.5 10 Nm (7.38 lb ft) Loctite Drise AL 506 Head stud bolt fastener nut - pre- M10x1.25 10 Nm (7.38 lb ft) Lubricate the...
Page 51 Caponord 1200 - Caponord 1200 Rally Characteristics YLINDER pos. Description Type Quantity Torque Notes Chain tensioner fastener screw 13 Nm (9.59 lb ft) Cylinder plate fastener screw 7.84-9.81 Nm (5.78-7.23 lb ft) Chain tensioner adjustment screw 5.50 Nm (4.06 lb ft) CHAR - 51...
Page 52 Caponord 1200 - Caponord 1200 Rally Characteristics TIMING SYSTEM pos. Description Type Quantity Torque Notes Camshaft gear fastener nut M15x1 90 Nm (66.38 lbf ft) Timing drive gear fastener screw M24x1.5 40 Nm (29.50 lbf ft) 3M SCOTCH GRIP 2353 Special screw for fastening mobile / 19 Nm (14.01 lbf ft) 3M SCOTCH GRIP...
Page 53 Caponord 1200 - Caponord 1200 Rally Characteristics pos. Description Type Quantity Torque Notes Decompression device fixing screw torx M8 28.5 Nm (21.02 lbf ft) 3M SCOTCH GRIP 2353 Fastener screw 5.50 Nm (4.06 lbf ft) 3M SCOTCH GRIP 2353 RANKSHAFT pos.
Page 54 Caponord 1200 - Caponord 1200 Rally 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 20 Nm (14.75 lbf ft) side crankcase half Oil filter...
Page 55 Caponord 1200 - Caponord 1200 Rally Characteristics EAR SELECTOR pos. Description Type Quantity Torque Notes Gear retainer pawl fastener screw 12 Nm (8.85 lb ft) Loctite dry loc 2040 Selector plate fastener screw 5.50 Nm (4.06 lb ft) 3M SCOTCH GRIP 2353 Screw fastening Desmodromic se- 20 Nm (14.75 lb ft)
Page 56 Caponord 1200 - Caponord 1200 Rally Characteristics LUTCH COVER pos. Description Type Quantity Torque Notes Screw fastening Clutch Cover / inter- 13 Nm (9.59 lbf ft) mediate Clutch side cover Clutch fastener nut M24x1 170 Nm (125.38 lbf ft) Chamfer Fastening oil filler plug on Clutch cov- 2 Nm (1.48 lbf ft) Screw fastening fixing Plate / Clutch...
Page 57 Caponord 1200 - Caponord 1200 Rally Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch spring fastener screw 11 Nm (8.11 lb ft) ATER PUMP pos. Description Type Quantity Torque Notes Clutch side cover fastener screw 13 Nm (9.59 lbf ft) CHAR - 57...
Page 58 Caponord 1200 - Caponord 1200 Rally 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 Nut fastening water pump drive gear 12 Nm (8.85 lbf ft)
Page 59 Caponord 1200 - Caponord 1200 Rally 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 270 Tapered plug for crankshaft main M8x1 15 Nm (11.06 lbf ft) bearing lubrication...
Page 60 Caponord 1200 - Caponord 1200 Rally Characteristics RANKCASE pos. Description Type Quantity Torque Notes Special calibrated screw for gearbox M9x1 18 Nm (13.28 lbf ft) lubrication Screw fastening flywheel side / 13 Nm (9.59 lbf ft) clutch side crankcase halves Screw fastening flywheel side / 29 Nm (21.39 lbf ft) clutch side crankcase halves...
Page 61 Caponord 1200 - Caponord 1200 Rally Characteristics Crankcases are classified in two classes (1 or 2) depending on the diameter of the main bearing seat. The class is indicated on both crankcase halves, specifically, in the rear cylinder area on flywheel side crankcase halves and in the front cylinder area on clutch side crankcase halves.
Page 62 Caponord 1200 - Caponord 1200 Rally 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 63 Caponord 1200 - Caponord 1200 Rally Characteristics RANKCASE CLASSES Specification Desc./Quantity Crankcase class A Centre distance: 110.50 - 110.54 mm (4.3504 - 4.3519 in) Crankcase class B Centre distance: 110.46 - 110.50 mm (4.3488 - 4.3504 in) See also Removing the flywheel cover Crankcase class (internal marking on second generation crankcases) Two different crankcase classes (A or B) are avail-...
Page 64 Caponord 1200 - Caponord 1200 Rally Characteristics * Connecting rod selection class. ** Crank pin selection class. *** Progressive traceability number and date. SHAFT CATEGORY Class Crank pin diameter (mm) 42.000 - 42.006 mm (1.65354 - 1.65377 in) 41.994 - 42.000 mm (1.65330 - 1.65354 in) 41.988 - 41.994 mm (1.65307 - 1.65330 in) 41.982 - 41.988 mm (1.65283 - 1.65307 in) See also...
Page 65 Caponord 1200 - Caponord 1200 Rally Characteristics See also Removing the flywheel cover CHAR - 65...
Page 66 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 67 Caponord 1200 - Caponord 1200 Rally Special tools PECIAL TOOLS Stores code Description 020709Y Engine support 020710Y Engine plate AP8140187 U-bolt for motor support 020850Y Primary gear lock 020712Y Handle for removing the flywheel cover 020713Y Flywheel extractor S-TOOLS - 67...
Page 68 Caponord 1200 - Caponord 1200 Rally Special tools Stores code Description 020714Y Dial gauge mount 9100896 Clutch bell stopper 020716Y Connecting stem lock 020894Y Pin snap ring fitting tool 020895Y Piston installation ring 020719Y Timing pin 020382Y Tool to extract valve cotters S-TOOLS - 68...
Page 69 Caponord 1200 - Caponord 1200 Rally Special tools Stores code Description 020896Y Bushing for valve removal 020720Y Timing tool 020376Y Adaptor handle 020891Y 25 mm (0.98 in) adapter 020362Y 12 mm guide 020724Y Punch cage with rollers gearbox control stem S-TOOLS - 69...
Page 70 Caponord 1200 - Caponord 1200 Rally Special tools Stores code Description 020726Y Bushing extractor 020727Y Bushing punch 020966Y Steering adjustment socket 020193Y Gauge for oil pressure check AP8140612 Fuel pressure gauge AP8140199 Tool storage panel S-TOOLS - 70...
Page 71 Caponord 1200 - Caponord 1200 Rally Special tools Stores code Description 8140426 Hooks for panel 020888Y Clamp for pre-load pipe 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion 020922Y Diagnostic tool 020957Y Key for upper fork nut 020958Y Fork cartridge protection S-TOOLS - 71...
Page 72 Caponord 1200 - Caponord 1200 Rally Special tools Stores code Description AP8140149 Guard for assembly operations AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight S-TOOLS - 72...
Page 73 INDEX OF TOPICS MAIN AINTENANCE...
Page 74 Caponord 1200 - Caponord 1200 Rally Maintenance Scheduled maintenance table NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
Page 75 Caponord 1200 - Caponord 1200 Rally Maintenance km x 1000 (mi x 1000) 1 (0.6) 10 (6.2) 20 (12.4) 30 (18.6) 40 (24.9) Clutch wear Brake pad wear Labour time - Caponord 1200 (minutes) Labour time - Caponord 1200 ADD (minutes) Labour time - Caponord Rally (minutes) SCHEDULED MAINTENANCE TABLE ONLY FOR THE ASIA/PACIFIC MARKET SCHEDULED MAINTENANCE TABLE...
Page 76 Caponord 1200 - Caponord 1200 Rally Maintenance Recommended products Piaggio Group recommends the products of its "Castrol Official Partner" for the scheduled maintenance of its vehicles. Use lubricants and liquids having specifications that are equivalent, or superior, to the recommen- ded products.
Page 77 Caponord 1200 - Caponord 1200 Rally Maintenance FRONT SPARK PLUGS • Working on the left side of the vehicle, unscrew and remove the screw. • Turn the radiator forwards to act on the coils. • Unscrew and remove the two screws fixing coils to head cover.
Page 78 Caponord 1200 - Caponord 1200 Rally Maintenance See also Fuel tank • Check the gap between the electrodes with a feeler gauge. CAUTION DO NOT ATTEMPT IN ANY WAY TO CHANGE THE DISTANCE BETWEEN THE ELECTRODES. The gap between the electrodes should be 0.6 ÷ 0.7 mm (0.024 ÷...
Page 79 Caponord 1200 - Caponord 1200 Rally Maintenance Engine oil Check Check the engine oil level frequently. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
Page 80 Caponord 1200 - Caponord 1200 Rally Maintenance OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT; BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW. • Use a cloth to wipe off any mud deposit on the area next to the filler plug (1). •...
Page 81 Caponord 1200 - Caponord 1200 Rally Maintenance • Unscrew and remove the cap to drain out the engine oil. • Unscrew and remove the engine oil fil- ter. • Fit a new engine oil filter. • Add engine oil up to the correct level. •...
Page 82 Caponord 1200 - Caponord 1200 Rally 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 REPLACE THE FOUR RUBBER INSERTS AND THE GASKET EACH TIME THE BIG END COVER IS REMOVED.
Page 83 Caponord 1200 - Caponord 1200 Rally Maintenance • Remove the bowl tappets and the ad- justment shims using a magnet. NOTE GREASE THE BOWL TAPPETS AND THE ADJUSTMENT SHIMS PROPERLY EACH TIME THEY ARE REMOVED. • Replace calibrated pads with a pad thick enough to correct the valve clear- ance previously detected.
Page 84 Caponord 1200 - Caponord 1200 Rally Maintenance • Apply THREEBOND to the head at the points indicated in figure. MAIN - 84...
Page 85 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 86 SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT THE DIAGNOSIS INSTRUMENT TO THE CONTROL UNIT SELECTING "APRILIA, CAPONORD 1200, FUEL INJECTION" • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
Page 87 Caponord 1200 - Caponord 1200 Rally 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 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 88 Caponord 1200 - Caponord 1200 Rally Troubleshooting Engine The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION THE DIAGNOSIS INSTRUMENT MUST FUNCTION CORRECTLY. CAUTION BEFORE STARTING THE TROUBLESHOOTING PROCEDURE, MAKE SURE THAT: 1) THE BATTERY VOLTAGE IS GREATER THAN 12V; 2) THE MAIN, 30 A FUSE IS INTACT AND INSERTED CORRECTLY;...
Page 89 Caponord 1200 - Caponord 1200 Rally Troubleshooting • 7. WHAT DOES THE "TIP-OVER SENSOR" STATE ICON ON THE DIAGNOSTIC TOOL DEVICE STATES PAGE INDICATE, ICON 0/1? If it indicates the NORMAL state, go to point 8, if it indicates TIP OVER, go to point 12 •...
Page 90 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 91 Caponord 1200 - Caponord 1200 Rally Electrical system LECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Coil fixing screw 5.50 Nm (4.06 lbf ft) TE screw fastening regulator to M6x30 10 Nm (7.37 lbf ft) frame Screw fastening ECU to filter box 3 Nm (2.21 lbf ft) base Speed sensor TBEI fixing screw...
Page 92 Caponord 1200 - Caponord 1200 Rally Electrical system 1. Engine speed sensor 2. Intake air pressure sensor 3. Intake air temperature sensor 4. Instrument panel 5. Engine control unit 6. Headlamp ELE SYS - 92...
Page 93 Caponord 1200 - Caponord 1200 Rally Electrical system 7. Start-up relay 8. Coils 9. Spark plugs 10.Starter motor 11.Taillight 12.Secondary fuses 13.Main fuses 14.Throttle grip position sensor 15.Neutral / gear sensor 16.Engine speed sensor - pick up 17.Engine temperature sensor 18.Battery 19.Lambda probe 20.Fall sensor (optional equipment)
Page 94 Caponord 1200 - Caponord 1200 Rally Electrical system 1. Engine speed sensor 2. Intake air pressure sensor 3. Intake air temperature sensor 4. Instrument panel 5. Engine control unit 6. Headlamp ELE SYS - 94...
Page 95 Caponord 1200 - Caponord 1200 Rally Electrical system 7. Start-up relay 8. Coils 9. Spark plugs 10.Starter motor 11.Taillight 12.Secondary fuses 13.Main fuses 14.Throttle grip position sensor 15.Neutral / gear sensor 16.Engine speed sensor - pick up 17.Engine temperature sensor 18.Battery 19.Lambda probe 20.Fall sensor (optional equipment)
Page 96 Caponord 1200 - Caponord 1200 Rally Electrical system • Location on the vehicle: under the left fairing, left side, next to auxiliary injection relay. FAN CONTROL RELAY • Location on the electrical circuit diagram: 43 • Location on the vehicle: under fuel tank, right side, next to rear cylinder head. HIGH BEAM LIGHTS RELAY •...
Page 97 Caponord 1200 - Caponord 1200 Rally Electrical system 2. Central section 3. Rear section SPECIAL CHECKS FOR THE CORRECT CONNECTION AND ROUTING OF CABLES (ALL VER- SIONS). It is extremely important that any security locks for the following connectors are properly connected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
Page 98 Caponord 1200 - Caponord 1200 Rally Electrical system 20. Check securing of positive cable on starter motor. Check whether the hood has a hole and that it is inserted well. 21. Check for correct routing and securing of the primary and ABS fuses under the saddle. 22.
Page 99 Caponord 1200 - Caponord 1200 Rally Electrical system Support. Support. Front 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" IN THE "ELEC- TRICAL SYSTEM INSTALLATION"...
Page 100 Caponord 1200 - Caponord 1200 Rally Electrical system TABLE A - HANDLEBAR CABLE ROUTING. Check the arrangement of the cables and route them through the plate and the cable grommet. Turning the handlebar all the way, both to the right and to the left, the cables must not be under ten- sion, but they must also not be too slack with the handlebar straight.
Page 101 Caponord 1200 - Caponord 1200 Rally Electrical system • Rubber clamps (long) • Rubber clamps (long) TABLE C - LEFT AND RIGHT LIGHT SWITCH. Ensure that on the Right Light Switch of the aDD version the "Heated Handgrips" and "Cruise" con- trols are present.
Page 102 Caponord 1200 - Caponord 1200 Rally Electrical system TABLE D - FRONT FORK T.MAP SENSOR. Install the T.MAP on the left stanchion. Check that the connector is secured well. The sheath must stay under the boot so that the cables are not visible.
Page 103 Caponord 1200 - Caponord 1200 Rally Electrical system • Large plastic clamps 4.5x280 mm (0.18x11.02 in) ELE SYS - 103...
Page 104 Caponord 1200 - Caponord 1200 Rally Electrical system Check that all the connectors are correctly se- cured. Pay particular attention to the rear shock absorber connector boot; it must be inserted 1-1.5 • Rubber clamp (short). Group the connectors of the various components and secure them using a clamp.
Page 105 Caponord 1200 - Caponord 1200 Rally Electrical system Keep the front headlamp cables out of the instru- ment panel support (they are marked with two turns of red tape). Position the connectors of the components as il- lustrated in the photo. TABLE F - DASHBOARD Check that the dashboard fastening lever is locked by the appropriate tab.
Page 106 Caponord 1200 - Caponord 1200 Rally Electrical system Check the presence of the clamp that holds the horn cables secure. • Small plastic clamp 2.5x160 mm (0.1x6.3 in). TABLE H - FRONT HEADLAMP Check that the relays are correctly fastened and that the ends are pulled out of the seats once the component is inserted.
Page 107 Caponord 1200 - Caponord 1200 Rally Electrical system • Large plastic clamp 4.5x280 mm (0.18x11.02 in). Position the key connector as illustrated in the photo and ensure that it is fastened well. • Large plastic clamp 4.5x280 mm (0.18x11.02 in). •...
Page 108 Caponord 1200 - Caponord 1200 Rally Electrical system • Large plastic clamp 4.5x280 mm (0.18x11.02 in). TABLE M - IMMOBILIZER AERIAL, FRONT LAMBDA AND FANS CONNECTOR POSITIONING Position the Immobilizer aerial connector as illus- trated in the photo and ensure that it is fastened well.
Page 109 Caponord 1200 - Caponord 1200 Rally Electrical system Position the Right Hand Fan connector as illustra- ted in the photo and ensure that it is fastened well. Before fitting the fairing, remove it from the support tab and secure it to the radiator hose with a clamp. •...
Page 110 Caponord 1200 - Caponord 1200 Rally Electrical system • Large plastic clamp 4.5x280 mm (0.18x11.02 in). Check that the relays are correctly fastened and that the ends are pulled out of their seats once the component is inserted. Check that all the connectors are correctly secured and positioned as illustrated in the photo.
Page 111 Caponord 1200 - Caponord 1200 Rally Electrical system CAUTION: Incorrect positioning of the sensor and/or tightening of this screw may cause the ABS to malfunction. • Plastic clamp 2.5x160 mm (0.1x6.3 in). ELE SYS - 111...
Page 112 Caponord 1200 - Caponord 1200 Rally Electrical system First cable grommet on the ABS sensor and on the brake line that connects the left caliper to the ABS ECU. This way it is ensured that the two securing points do not have relative movements and that the cable does not rub on the mudguard.
Page 113 Caponord 1200 - Caponord 1200 Rally Electrical system Route the front ABS Sensor cable between the cover and the frame as illustrated in the photo. Route the front ABS Sensor above the cable har- ness that goes to the instrument panel support. TABLE P - EVC / VCU CABLE ROUTING ELE SYS - 113...
Page 114 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the connector is correctly secured and that the cable is positioned as illustrated in the fig- ure. TAKE CARE not to pinch the cable with the securing of the expansion tank. Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND...
Page 115 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the connector with BLUE tape is se- cured will on the Demand with the BLUE label and that the grey Security Lock is closed. Check that the connector with WHITE tape is se- cured will on the Demand WITHOUT the label and that the grey Security Lock is closed.
Page 116 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the two Front Coil connectors are con- nected. Check that the yellow rubber parts are not pinched. • Large plastic clamp 4.5x280 mm (0.18x11.02 in). As illustrated in the figure, fasten the two Front Coil cables together using the appropriate cable grom- met.
Page 117 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the relay connectors are correctly fas- tened and that the ends are pulled out of their seats once the component is inserted. Check that the filter box temperature sensor is cor- rectly connected.
Page 118 Caponord 1200 - Caponord 1200 Rally Electrical system TABLE A1 - BATTERY GROUND CABLE ROUTING Check that the cable grommet secures: the ground cable, the relay cable and the two rear coil cables. • Cable grommet. To secure the cable on the engine block use the end closest to the label. ELE SYS - 118...
Page 119 Caponord 1200 - Caponord 1200 Rally Electrical system Secure the ground cable onto the engine block to- gether with the cable harness ground. CAUTION: INCORRECT SECURING OF THIS SCREW MAY CAUSE THE VEHICLE TO CATCH FIRE. TABLE A2 - ABS CONTROL UNIT CABLE Check that the rubber guard is mounted as illus- trated in the figure.
Page 120 Caponord 1200 - Caponord 1200 Rally Electrical system The ABS control unit cable must loop as illustrated in the figure and it must be secured with a large plastic clamp. • Large plastic clamp 4.5x280 mm (0.18x11.02 in). • Large plastic clamps 4.5x280 mm (0.18x11.02 in) TABLE A3 - STARTER MOTOR Position the positive cable as illustrated in the fig-...
Page 121 Caponord 1200 - Caponord 1200 Rally Electrical system • Large plastic clamp 4.5x280 mm (0.18x11.02 in). CAUTION: Incorrect routing of the Relay-Start- er motor cable and incorrect securing may cause the vehicle to catch fire. TABLE A4 - FRONT LAMBDA PROBE For correct routing the front lambda probe must go into the cable grommet mounted on the front en- gine head.
Page 122 Caponord 1200 - Caponord 1200 Rally Electrical system Pre-assembly of the cover on the frame, keep the clamp wide. • Large plastic clamp 4.5x280 mm (0.18x11.02 in). • Small plastic clamps 2.5x160 mm (0.1x6.3 in) TABLE C - FUEL TANK ELE SYS - 122...
Page 123 Caponord 1200 - Caponord 1200 Rally Electrical system TABLE D - LAMBDA CABLE ROUTING AND SWINGARM SENSOR POSITIONING, WHERE APPLICABLE The Rear Lambda Probe and Rotary Sensor ca- bles must go through the cable grommet as illus- trated in the figure. Check that the Lambda Probe connector is con- nected well and that the yellow rubber gasket is not pinched.
Page 124 Caponord 1200 - Caponord 1200 Rally Electrical system Where applicable check for correct connection of the aDD Rotary Sensor and the correct routing of the Lambda Probe cable as illustrated in the figure. TABLE E - GROUND CABLE ROUTING ON SAD- DLE MOUNTING •...
Page 125 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the cut in the corrugated tube on this section is facing downward so that the cables are not visible. TABLE G - REAR SHOCK ABSORBER HOSE ROUTING, WHERE APPLICABLE Insert the white connector and then the semi- transparent connector with the boot just inserted.
Page 126 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the cable passes inside the saddle mounting and that the rubber clamp is placed at about 30 mm (1.18 in) from the metallic reference. • 2 rubber clamps (short) combined to- gether.
Page 127 Caponord 1200 - Caponord 1200 Rally Electrical system Check for the presence of the clamp on this con- nector. • Large plastic clamp 4.5x280 mm (0.18x11.02 in). TABLE L - GEAR SENSOR Check the connections for: 1. Side stand (if fitted), 2.
Page 128 Caponord 1200 - Caponord 1200 Rally Electrical system Position the connectors 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 129 Caponord 1200 - Caponord 1200 Rally Electrical system CAUTION: Incorrect positioning of the sensor and/or tightening of this screw may cause the ABS to malfunction. • Cable grommets. • Cable grommet. ELE SYS - 129...
Page 130 Caponord 1200 - Caponord 1200 Rally Electrical system CAUTION: The GAP between the tone wheel and the ABS sensor must be between 0.3 - 2.00 mm (0.012 - 0.079 in). TABLE B - LICENSE PLATE HOLDER PRE-FITTING • Licence plate holder cable harness. Check that the drainage hole for the water from both turn indicators, both Front and Rear, is facing downward.
Page 131 Caponord 1200 - Caponord 1200 Rally Electrical system • Large plastic clamps 4.5x280 mm (0.18x11.02 in) Ensure that the two screws are tightened to torque and that two 30A fuses are present. CAUTION: Incorrect securing of the two screws on the starter relay (the one that joins the red cables) and incorrect cable routing may cause the vehicle to catch fire.
Page 132 Caponord 1200 - Caponord 1200 Rally Electrical system 1. Fall sensor connector. 2. Connector for USB socket. Connect the fall sensor onto the battery support as illustrated in the figure. Position the USB socket connector as illustrated in the figure. Check that the connector is connected well and that the yellow gasket is not pinched.
Page 133 Caponord 1200 - Caponord 1200 Rally Electrical system Check that the connector is inserted well and held fast with a clamp. • Large plastic clamp 4.5x280 mm (0.18x11.02 in). CAUTION: Incorrect mounting of the BAT- TERY-ABS FUSES wiring harness (circled in red) may cause the vehicle to catch fire.
Page 134 Caponord 1200 - Caponord 1200 Rally Electrical system key: 1. MULTIPLE CONNECTORS ELE SYS - 134...
Page 135 Caponord 1200 - Caponord 1200 Rally Electrical system 2. FRONT LEFT TURN INDICATOR 3. FRONT HEADLAMP 4. FRONT RIGHT TURN INDICATOR 5. HIGH BEAM LIGHTS RELAY 6. LIGHT RELAY 7. LEFT LIGHT SWITCH 8. HORN 9. BLUEDASH PRE-INSTALLATION 10. INSTRUMENT PANEL 11.
Page 136 Caponord 1200 - Caponord 1200 Rally Electrical system 40. MAIN FUSE 1 41. BATTERY 42. ELECTRIC FANS 43. ELECTRIC FANS RELAY 44. USB PORT 45. ECU DIAGNOSIS 46. AUXILIARY INJECTION RELAY 47. PRIMARY INJECTION RELAY 48. FUEL RESERVE SENSOR 1 (NTC) 49.
Page 137 Caponord 1200 - Caponord 1200 Rally Electrical system 78. REAR INJECTOR 2 (SYNERJET/EXTERNAL) 80. BLUEDASH (IF FITTED) 81. FOG LIGHT LED (IF FITTED) CAPONORD 1200 TRAVEL PACK ELE SYS - 137...
Page 138 Caponord 1200 - Caponord 1200 Rally Electrical system key: 1. MULTIPLE CONNECTORS ELE SYS - 138...
Page 139 Caponord 1200 - Caponord 1200 Rally Electrical system 2. FRONT LEFT TURN INDICATOR 3. FRONT HEADLAMP 4. FRONT RIGHT TURN INDICATOR 5. HIGH BEAM LIGHTS RELAY 6. LIGHT RELAY 7. LEFT LIGHT SWITCH 8. HORN 9. BLUEDASH PRE-INSTALLATION 10. INSTRUMENT PANEL 11.
Page 140 Caponord 1200 - Caponord 1200 Rally Electrical system 40. MAIN FUSE 1 41. BATTERY 42. ELECTRIC FANS 43. ELECTRIC FANS RELAY 44. USB PORT 45. ECU DIAGNOSIS 46. AUXILIARY INJECTION RELAY 47. PRIMARY INJECTION RELAY 48. FUEL RESERVE SENSOR 1 (NTC) 49.
Page 141 Caponord 1200 - Caponord 1200 Rally Electrical system 78. REAR INJECTOR 2 (SYNERJET/EXTERNAL) 79. - 80. BLUEDASH (IF FITTED) 81. FOG LIGHT LED (IF FITTED) Colour key: Ar Orange Az Light blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red...
Page 142 Caponord 1200 - Caponord 1200 Rally Electrical system key: 1. MULTIPLE CONNECTORS 2. FRONT LEFT TURN INDICATOR 3. FRONT HEADLAMP 4. FRONT RIGHT TURN INDICATOR 5. HIGH BEAM LIGHTS RELAY 6. LIGHT RELAY ELE SYS - 142...
Page 143 Caponord 1200 - Caponord 1200 Rally Electrical system 7. LEFT LIGHT SWITCH 8. HORN 9. BLUEDASH PRE-INSTALLATION 10. INSTRUMENT PANEL 11. HEATED HANDGRIPS (WHERE PROVIDED) 12. POWER SUPPLY FOR GPS 13. RIGHT LIGHT SWITCH 14. QUICK SHIFT 15. FRONT STOP SWITCH 16.
Page 144 Caponord 1200 - Caponord 1200 Rally Electrical system 45. ECU DIAGNOSIS 46. AUXILIARY INJECTION RELAY 47. PRIMARY INJECTION RELAY 48. FUEL RESERVE SENSOR 1 (NTC) 49. FUEL RESERVE SENSOR 2 (LEVEL) 50. FUEL PUMP 51. OIL PRESSURE SENSOR 52. INTAKE AIR TEMPERATURE SENSOR 53.
Page 145 Caponord 1200 - Caponord 1200 Rally Electrical system Ar Orange Az Light blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red Ro Pink V Green Vi Violet Conceptual diagrams Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC- TORS;...
Page 146 Caponord 1200 - Caponord 1200 Rally Electrical system control unit) use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector. CAUTION IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PER- FORMING EACH OF THE CHECKS INDICATED FOR TROU- BLESHOOTING.
Page 147 Caponord 1200 - Caponord 1200 Rally Electrical system Immobiliser All functions for adjustment, storage or reset of the immobiliser codes can be controlled by the Dealer, while some of the dashboard settings can be controlled even by the client. The user has the possibility to insert or modify the user code by using the control keys "A" (the highest one) and "B"...
Page 148 Caponord 1200 - Caponord 1200 Rally Electrical system Enter the old user code, if accepted, it is possible to enter the new user code. (functions can be checked out by the dealer) NOTE THE FUNCTIONS OF THE "STORAGE KEYS", "USER CODE RESET" AND "ODOMETER COD- ING", CAN BE DONE ONLY WHEN NO ELECTRICAL ERRORS ARE PRESENT.
Page 149 Caponord 1200 - Caponord 1200 Rally Electrical system After the storage of the second key it is requested to enter another key (if in possession) and the re- verse counting restarts. It is possible to store a maximum of four keys. At the end of the counting, the storage of the keys is complete.
Page 150 Caponord 1200 - Caponord 1200 Rally Electrical system System components Function detects the transponder code in the key and sends it to the instrument panel Level in electrical circuit diagram: Immobilizer Location: • on the vehicle: in the ignition switch as- sembly •...
Page 151 Caponord 1200 - Caponord 1200 Rally Electrical system Error code B0006 (INSIDE ERROR) There is a fault in the instrument panel. Troubleshooting Replace the instrument panel. Error code B0007 (INSUFFICIENT NUMBER OF MEMORISED KEYS) The number of stored keys is less than two. Dashboard In case of doubts in operation of the engine revs indication, it is possible to connect the vehicle to the diagnostics instrument and activate the engine revs indication choosing the function "Rpm indicator"...
Page 152 Caponord 1200 - Caponord 1200 Rally Electrical system Check the mapping of the control unit and reset the vehicle configuration. OIL SENSOR Error code B0001 (OIL SENSOR FAILURE) Oil motor low pressure alarm: This alarm occurs when the engine is off and the pressure of the engine oil is low. If during the following OFF-ON key switching, the fault is not immediately detected, the error is no longer displayed.
Page 153 Caponord 1200 - Caponord 1200 Rally Electrical system Check the cable harness of the CAN line. ENGINE TEMPERATURE Error code B0010 (ENGINE OVERTEMPERATURE) Error cause Engine temperature > 115 °C. Troubleshooting The error is no longer displayed when the temperature falls below 113 °C. If the error continues to be displayed also with low engine temperature, the failure is probably in the sensor that is shortcircuited or in the cable harness: perform the diagnosis by connecting to the engine control unit.
Page 154 Caponord 1200 - Caponord 1200 Rally Electrical system stage "1" (pin 1-2), stage "2" (pin 1-3), stage "3" (pin 2-3). • Take the measurement; The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted, obtained by touching the two lugs.
Page 155 Caponord 1200 - Caponord 1200 Rally Electrical system ESISTANCE MEASUREMENT Winding stage Ambient temperature (ohm) Afterwards heat stabilisation (ohm) Stage 1 0.15 - 0.20 0.18 - 0.23 Stage 2 0.15 - 0.20 0.18 - 0.23 Stage 3 0.15 - 0.20 0.18 - 0.23 Zero load voltage •...
Page 156 Caponord 1200 - Caponord 1200 Rally Electrical system OLD SHORT CIRCUIT CURRENT 2000 4000 6000 8000 RMS DC current (Arms) (average of the 3 stage 26 - 31 26 - 31 26 - 31 26 - 31 currents) Voltage on battery poles with engine speed always between 3000 - 5000 RPM •...
Page 157 Caponord 1200 - Caponord 1200 Rally Electrical system • shorted to positive / open circuit, shorted to negative. Error cause • If shorted to positive: excessive voltage has been detected at PIN 58; if the circuit is open, shorted to negative: voltage equal to zero has been detected. DIAGNOSTIC TOOL: LOGIC ERRORS Starter switch P0169 •...
Page 158 Caponord 1200 - Caponord 1200 Rally Electrical system Front headlamp Characteristic Front daylight running lights 2V - 5W W5WB x 2 Low beam light 12V - 55W H11 x 2 High beam light 12V - 55W H11 Additional headlamps Characteristic Supplementary headlamps Taillight Characteristic...
Page 159 Caponord 1200 - Caponord 1200 Rally Electrical system 8 - VCU positive live (15 A) (only Caponord 1200 Travel Pack) Spare fuses (7.5 - 10 - 15 A) MAIN FUSES - (under the saddle, remove the battery protection) A - Battery recharge, primary injection relay, live positive, permanent BlueDash positive (30 A) B - Permanent ABS control unit positive (20 A) C - USB jack, heated handgrips, anti-theft, GPS,...
Page 160 Caponord 1200 - Caponord 1200 Rally Electrical system • Unscrew and remove the control unit fixing screw. • Slide off the control unit from the mountings and remove it from the ve- hicle. ELE SYS - 160...
Page 161 Caponord 1200 - Caponord 1200 Rally Electrical system NOTE DURING THE REFITTING, PAY PARTICULAR ATTENTION TO FIX THE CONTROL UNIT IN THE MOUNTINGS. CONTROL UNIT - Diagnosis Function it controls the Ride by wire system, the injection/ignition, the system safety checks and the self-diagnosis function Level in electrical circuit diagram: Each level in which the main component involves the control unit...
Page 162 Caponord 1200 - Caponord 1200 Rally Electrical system • Person in charge for last programming / - Indicates the series number of the DIAGNOSTICS INSTRUMENT that has carried out the last control unit remapping • BOOT version / - • Control unit serial number (NIP) / - •...
Page 163 Caponord 1200 - Caponord 1200 Rally Electrical system DIAGNOSTICS INSTRUMENT: PARAMETERS • Engine revs (rpm) • Front throttle position (pot. 1) (°) • Rear throttle position (pot. 1) (°) • Front throttle position correction (°) • Rear throttle position correction (°) •...
Page 164 Caponord 1200 - Caponord 1200 Rally Electrical system • Reference Front Cylinder Intake Pressure (mbar) • Rear Cylinder Intake Pressure (mbar) • Reference Rear Cylinder Intake Pressure (mbar) • Battery voltage (V) • Exhaust butterfly valve target position (%) • Blue connector throttle grip position sensor - track A (mV) •...
Page 165 Caponord 1200 - Caponord 1200 Rally Electrical system • Operative/Inoperative (Rich)/Inoperative (Lean)/Inoperative (Start-up) Front cylinder value • Rich/Lean/Not detected Rear cylinder value • Rich/Lean/Not detected Engine status • Indefinite / Key ON / Running engine / Stopped / Power latch / Power latch 2 / Power latch finished Engine mode •...
Page 166 Button + (during ATC setting) • Pressed/Released Button - (during ATC setting) • Pressed/Released ATC (Aprilia Traction Control) • Present/Not present Exhaust butterfly valve • Indeterminate / Search / Self-cleaning / Operation / Failure / Home position search Performing ATC (on bend) •...
Page 167 Caponord 1200 - Caponord 1200 Rally Electrical system Cruise control + button • Pressed/Released Button - cruise control • Pressed/Released ACC (Aprilia Cruise Control) • Present/Not present Speedometer unit of measurement • kph / mph Vehicle configuration • Valid/Not valid EVC (Exhaust Valve Control) •...
Page 168 Caponord 1200 - Caponord 1200 Rally Electrical system • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status Error RAM P0604 • circuit not operational Error cause • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status Error ROM P0605 •...
Page 169 Caponord 1200 - Caponord 1200 Rally Electrical system • As the level 2 safety system (comparison between requested torque and calculated torque) has detected a fault, the control unit has reset engine (C gravity). The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting •...
Page 170 Caponord 1200 - Caponord 1200 Rally Electrical system manages the suspension system, exhaust butterfly valve and the self-diagnostics function Level in electrical circuit diagram: Each level in which the main component involves the control unit Location: • on the vehicle: on the front part on the right side •...
Page 171 Caponord 1200 - Caponord 1200 Rally Electrical system • Pressure sensor (mBar) • Temperature sensor (°C) • Front valve current (mA) • Rear valve current (mA) • Number of preload motor operations • Exhaust butterfly valve target position (%) • Exhaust butterfly valve upper travel limit •...
Page 172 Caponord 1200 - Caponord 1200 Rally Electrical system • Front suspension valve • Rear suspension valve • Exhaust butterfly valve • Preload motor DIAGNOSTICS INSTRUMENT: ADJUSTMENTS • Control unit reset • Preload motor travel limits search • Resetting the rotary sensor Preparation of the VCU After resetting and/or replacing the VCU the following operations must be carried out in the order de- scribed:...
Page 173 Caponord 1200 - Caponord 1200 Rally Electrical system Battery Function Battery YTX 14-BS, which must be activated and loaded. Level in electrical circuit diagram: Battery recharge Location: • on the vehicle: under the saddle • connector: on the battery Electrical specifications: 12 Ah Pin out: 1.
Page 174 Caponord 1200 - Caponord 1200 Rally Electrical system • If too high: check correct operation of the voltage regulator. • If too low: check voltage regulator connectors, engine - vehicle cable harness connector and the control unit connector (paying special attention to possible oxidation): if not OK, restore; if OK, check that Red/White cable resistance from the voltage regulator connector to the control unit connector is a few tenths of Ohm: if not OK, restore cable harness;...
Page 175 Caponord 1200 - Caponord 1200 Rally Electrical system 5D90 electric malfunction: Electrical fault in sensor or cable harness. Troubleshooting: Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector.
Page 176 Caponord 1200 - Caponord 1200 Rally Electrical system • Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel. Troubleshooting: • Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer.
Page 177 Caponord 1200 - Caponord 1200 Rally Electrical system Speed sensor 5DA0 electric malfunction:Electrical fault in sensor or cable harness. Troubleshooting:Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the yellow/brown cable between PIN 2 of the sensor on the cable harness side and PIN 11 of the ABS control unit connector.
Page 178 Caponord 1200 - Caponord 1200 Rally Electrical system • Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel. Troubleshooting: • Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer.
Page 179 Caponord 1200 - Caponord 1200 Rally Electrical system Pin-out: 1. Negative signal 2. Positive signal CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTICS INSTRUMENT: STATUSES Synchronised panel •...
Page 180 Caponord 1200 - Caponord 1200 Rally Electrical system Twistgrip position sensor Removal • Remove the filter box. • Loosen the throttle cable nuts. • Unscrew and remove the two fixing screws. • Disconnect the two connections and remove the throttle grip position sen- sor.
Page 181 Caponord 1200 - Caponord 1200 Rally Electrical system • A: Track A supply • B: Track A ground • C: Track A signal • D: Track B supply • E: Track B ground • F: Track B signal SLAVE connector (white) •...
Page 182 Caponord 1200 - Caponord 1200 Rally Electrical system • Example value with key ON: 0 mV • Example value with engine on: - With a released throttle grip, the value read should be 0%, whereas 100 % should be read with throttle grip fully twisted.
Page 183 Caponord 1200 - Caponord 1200 Rally Electrical system • If shorted to positive: excessive voltage has been detected at PIN 13 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 13 of the ENGINE connector Troubleshooting •...
Page 184 Caponord 1200 - Caponord 1200 Rally Electrical system check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring White rear connector throttle grip position sensor - track D P0153 •...
Page 185 Caponord 1200 - Caponord 1200 Rally Electrical system • inconsistent signal Error cause • Two illogical voltage signals have been detected at PIN 23 and 11 of the ENGINE connector (tracks A-B) Troubleshooting • Check the parameters of the white rear connector Throttle Grip Position Sensor - tracks C and D: if one of the two values clearly deviates from 600-1400 mV, it means that this po- tentiometer is defective.
Page 186 Caponord 1200 - Caponord 1200 Rally Electrical system Intake pressure sensor Figure key • A - Rear • B - Front Function The pressure sensors (one at the front, one at the rear) are fundamental for calculation of generated torque, for calculation of ambient pressure and for correct ignition timing during start-up.
Page 187 Caponord 1200 - Caponord 1200 Rally Electrical system • Example value with key ON: 1004 mbar • Example value with engine on: 735 mbar • NOTE: pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure •...
Page 188 Caponord 1200 - Caponord 1200 Rally Electrical system • If shorted to positive: excessive voltage has been detected at PIN 49. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 49. Troubleshooting •...
Page 189 Caponord 1200 - Caponord 1200 Rally Electrical system ted. The most frequent causes can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance. Troubleshooting • Check the Marelli control unit connector and the sensor connector; if not OK, restore. If everything is OK, check that resistance between ENGINE connector PIN 49 and sensor connector PIN 3 is a few tenths of an Ohm;...
Page 190 Caponord 1200 - Caponord 1200 Rally Electrical system • A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the hole for pressure reading is clogged or sensor screw is loose). Troubleshooting • Check the conditions of the intake manifold and cleanliness of the hole for reading the pres- sure: there is an evident defect in the intake and pressure reading systems.
Page 191 Caponord 1200 - Caponord 1200 Rally Electrical system Location: • on the vehicle: on the front cylinder, in- side the "V" • connector: on the sensor. Electrical characteristics: • Resistance at 25°: 2.05 kΩ ± 100 Ω • Resistance at 60°: 575 kΩ ± 15 Ω •...
Page 192 Caponord 1200 - Caponord 1200 Rally Electrical system • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 12 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 193 Caponord 1200 - Caponord 1200 Rally Electrical system Air temperature sensor Function it tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature)
Page 194 Caponord 1200 - Caponord 1200 Rally Electrical system • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 195 Caponord 1200 - Caponord 1200 Rally Electrical system FRONT CYLINDER LAMBDA PROBE Location: • on the vehicle: exhaust end behind the rear head • connector: on the right side, at the back of the filter box Electrical specifications • Heater circuit: 7-9Ω at Ambient temp. Pin out: 1.
Page 196 Caponord 1200 - Caponord 1200 Rally Electrical system In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time; 1.25 corre- sponds to -25%.
Page 197 Caponord 1200 - Caponord 1200 Rally Electrical system • shorted to positive Error cause • Excessive voltage (battery voltage) has been detected at PIN 9 and 38 of the ENGINE connector. Caution: the 'Oxygen sensor' parameter is not the real value that is read; a re- covery value is displayed instead.
Page 198 Caponord 1200 - Caponord 1200 Rally Electrical system • If shorted to positive: excessive voltage has been detected at PIN 44 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 44 of the ENGINE connector.
Page 199 Caponord 1200 - Caponord 1200 Rally Electrical system 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. The external injectors (Synerject) are always working, whereas the internal ones (Marelli, aka "high- pressure"...
Page 200 Caponord 1200 - Caponord 1200 Rally Electrical system Electrical specifications: • internal injectors (Marelli): 14.8 Ω ± 5% (at ambient temp.) • external injectors (Synerject): 12.0 Ω ± 5% (at ambient temp.) Pin out: 1. Fuel system 2. Negative from control unit DIAGNOSTICS INSTRUMENT:PARAMETERS Front cylinder injection time •...
Page 201 Caponord 1200 - Caponord 1200 Rally Electrical system relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. Internal rear cylinder injector • The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left side;...
Page 202 Caponord 1200 - Caponord 1200 Rally Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/green cable: if there is connection, restore the cable harness.
Page 203 Caponord 1200 - Caponord 1200 Rally Electrical system • If the circuit is open: check the connector on the component and the Marelli control unit connector: if not OK, restore. If OK, check cable continuity between the ENGINE PIN 53 and component PIN 2 and restore the cable harness.
Page 204 Caponord 1200 - Caponord 1200 Rally Electrical system Electrical characteristics: PIN 1-2: 0.5 - 1 ohm; PIN 3-4: you do not need to measure the component electrical resistance since it works correctly with suitable supply from the instrument panel only. Check correct operation as follows: connect in series a bulb of approxi- mately 2 W: it should turn on if the tank is in reserve, otherwise, it remains off.
Page 205 Caponord 1200 - Caponord 1200 Rally Electrical system Marelli control unit: if not OK, restore; if OK, check continuity of cable harness (Brown/Black cable) Coil Coils key: 1. Front cylinder central coil 2. Front cylinder side coil 3. Rear cylinder central coil 4.
Page 206 Caponord 1200 - Caponord 1200 Rally Electrical system 0.7 - 0.9 Ω at ambient temperature Pin out: 1. Power supply + Vbatt 2. Secondary circuit to ground 3. Activation from control unit DIAGNOSTICS INSTRUMENT:PARAMETERS Example value with key ON: Current ignition advance. Example value with engine on: Indicates the cylinder advance where combustion will take place.
Page 207 Caponord 1200 - Caponord 1200 Rally Electrical system • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 28 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 28 of the ENGINE connector.
Page 208 Caponord 1200 - Caponord 1200 Rally Electrical system • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 2 of the ENGINE connector.
Page 209 Caponord 1200 - Caponord 1200 Rally Electrical system Throttle body Function Sends to the injection control unit the throttle po- sition and activates the throttle according to the control unit Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless;...
Page 210 Caponord 1200 - Caponord 1200 Rally Electrical system • Example value with key ON: 5.5° • Example value with engine at idle: 2.1° With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°).
Page 211 Caponord 1200 - Caponord 1200 Rally Electrical system Rear throttle Potentiometer 2 (voltage) • Example value with key ON: 4226 mV • Example value with engine on: 4372 mV Key to throttle connectors figure: • A - Front cylinder throttle connector •...
Page 212 Caponord 1200 - Caponord 1200 Rally Electrical system Indicates whether the self-acquisition process through the diagnosis instrument has/has not been car- ried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero setting is carried out DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS CAUTION...
Page 213 Caponord 1200 - Caponord 1200 Rally Electrical system there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, rear throttle position P0125 •...
Page 214 Caponord 1200 - Caponord 1200 Rally Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature. Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 215 Caponord 1200 - Caponord 1200 Rally Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 216 Caponord 1200 - Caponord 1200 Rally Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab- normal resistance in one of the two circuits Troubleshooting •...
Page 217 Caponord 1200 - Caponord 1200 Rally Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab- normal resistance in one of the two circuits Troubleshooting •...
Page 218 Caponord 1200 - Caponord 1200 Rally Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 219 Caponord 1200 - Caponord 1200 Rally Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Rear throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 220 Caponord 1200 - Caponord 1200 Rally Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 221 Caponord 1200 - Caponord 1200 Rally Electrical system Neutral sensor Function It tells the gear position to the control unit, from the 1st gear to the 6th gear, and if the gear is neutral or riding. Operation / Operating principle The sensor has 2 circuits: one to indicate the en- gaged gear, whose resistance varies according to the gear engaged: in this way, the injection ECU,...
Page 222 Caponord 1200 - Caponord 1200 Rally Electrical system DIAGNOSTIC TOOL: ELECTRICAL ERRORS Gear sensor P0461 • short circuit to positive or open circuit/ short circuit to negative. Error cause • If open circuit, short circuit to positive: excessive voltage has been detected on PIN 72. If short circuit to negative: voltage equal to zero detected at PIN 72.
Page 223 Caponord 1200 - Caponord 1200 Rally Electrical system 1. Ground connection 2. Voltage 12V Electrical specifications: • Side Stand Up: closed circuit (continu- ity) • Side Stand Down: open circuit (infinite resistance) CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 224 Caponord 1200 - Caponord 1200 Rally Electrical system Electrical specifications: • Sensor in vertical position: open circuit (resistance: 62 kOhm) • Sensor inverted: closed circuit (con- tinuity) Pin out: 1. Voltage 5V 2. Ground connection 3. Signal CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE...
Page 225 Caponord 1200 - Caponord 1200 Rally Electrical system Electric fan circuit Function Radiator fan and coolant - Operation Operation / Operating principle When the control unit detects a temperature of ap- prox. 102 °C, it closes the fan control relay pickup circuit to ground Level in electrical circuit diagram: electric fan...
Page 226 Caponord 1200 - Caponord 1200 Rally Electrical system • short circuit to positive/ short circuit to negative / open circuit Error cause • If shorted to positive: excessive voltage has been detected at PIN 61 of the VEHICLE con- nector. If shorted to negative: no voltage has been detected. If the circuit is open: 5V voltage has been detected.
Page 227 Caponord 1200 - Caponord 1200 Rally Electrical system Pin out: 1 blue/green cable: ground connection 2 yellow/red cable: 5 V CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 228 Caponord 1200 - Caponord 1200 Rally Electrical system electric motor; however, the logic and control of the motor reside in the VCU (Caponord 1200 Travel Pack) or in the EVC (Caponord 1200). The motor is equipped with a built in potentiometer to control the position.
Page 229 Caponord 1200 - Caponord 1200 Rally Electrical system DIAGNOSTICS INSTRUMENT: ADJUSTMENTS Exhaust valve - Zero position search • After having pressed the enter button for the zero position search (the motor rotor must position itself as illustrated in the figure), shut off the vehicle and leave the keys in OFF, even in the event that the instruments indicate the opposite.
Page 230 Caponord 1200 - Caponord 1200 Rally Electrical system • The search for the opening travel limit (valve open) and the closing travel limit (valve closed) is carried out. During both normal operation and the self-cleaning cycle, the valve will only move within this range and without reaching the mechanical end stops, to prevent strain to the electric motor.
Page 231 Caponord 1200 - Caponord 1200 Rally Electrical system • If the potentiometer signal is out of threshold check for continuity between motor PIN 3 - EVC PIN C2 and between motor PIN 2 - EVC PIN A5 • If time is excessive: carry out the check procedure on the component and the EVC connec- tor.
Page 232 Caponord 1200 - Caponord 1200 Rally Electrical system • If the circuit is open, shorted to negative: carry out the check procedure on the component and the EVC connector. Disconnect the two connectors and check for continuity of the cable between potentiometer PIN 2 and EVC PIN A5 and restore the cable harness.
Page 233 Caponord 1200 - Caponord 1200 Rally Electrical system • If the potentiometer signal is out of threshold check for continuity between motor PIN 3 - VCU PIN F3 and between motor PIN 2 - VCU PIN B4 • If time is excessive: check the component connector and the VCU connector. Disconnect the two connectors and check the continuity of the cable between motor PIN 4 - VCU PIN L1 and between motor PIN 5 - VCU PIN L2.
Page 234 Caponord 1200 - Caponord 1200 Rally Electrical system • If the circuit is open, shorted to negative: check the component connector and the VCU connector. Disconnect the two connectors and check for continuity of the cable between potentiometer PIN 2 and VCU PIN B4 and restore the cable harness. If the cable harness is intact check component PIN 2 ground insulation: if insulation is not present, restore the cable harness;...
Page 235 Caponord 1200 - Caponord 1200 Rally Electrical system VCU PIN B4 and restore the cable harness. If the cable harness is intact replace the component. Cruise Control Button (IF APPLICABLE) Function Cruise Control is an electronic system that allows the desired speed to be set and kept constant even in the event of uphill and downhill sections without needing to act on the throttle control.
Page 236 Caponord 1200 - Caponord 1200 Rally Electrical system to ON and the indicator light will go back to flash- ing). Speed control is deactivated (indicator light flashing) if: - the rider accelerates more than 30 kph over the cruise speed; - the clutch is engaged;...
Page 237 Caponord 1200 - Caponord 1200 Rally Electrical system • Short to positive or ground found between VCU connector PIN A4 and light switch connector PIN 2 (Gr cable - ground). Troubleshooting • Check the Cruise Control power cable insulation from ground between the VCU connector PIN F4 and the light switch connector PIN 1 (Br/Bl cable).
Page 238 Caponord 1200 - Caponord 1200 Rally Electrical system • Check the Cruise Control power cable continuity and insulation from ground between the VCU connector PIN F4 and the light switch connector PIN 1 (Br/Bl cable). • Check the Cruise Control power cable continuity and insulation between the VCU connector PIN A4 and the light switch connector PIN 2 (Gr cable).
Page 239 Caponord 1200 - Caponord 1200 Rally Electrical system Pin out: Gr/N - Ground M/V - Brake released signal G/Vi - Brake pulled signal DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS VCU ERRORS Front brake switch short circuit error C1505 Error cause • Short circuit found between VCU connector PIN C2 and the switch connector output (M/bi) or between VCU connector PIN D2 and the connector switch output (G/Ro).
Page 240 Caponord 1200 - Caponord 1200 Rally Electrical system G4. Check that there is continuity between the cable harness side switch connector PIN 3 (M/Bi) and VCU PIN C2. If faults are found restore the cable harness. If the checks return positive results, check on the switch side connector that there is continuity between PIN 1 (G/Ro) and PIN 2 (Gr/N) to the pulled brake lever and infinite resistance with the lever re- leased.
Page 241 Caponord 1200 - Caponord 1200 Rally Electrical system G4. Check that there is continuity between the cable harness side switch connector PIN 3 (M/V) and VCU PIN E2. If faults are found restore the cable harness. • If the checks return positive results, check on the switch side connector that there is con- tinuity between PIN 1 (G/Vi) and PIN 2 (Gr/N) to the pulled brake lever and infinite resistance with the lever released.
Page 242 Caponord 1200 - Caponord 1200 Rally Electrical system • Excessive voltage or null voltage found between VCU PIN C1 and the cable harness side output (Az) of the switch connector. Troubleshooting • Disconnect the valve connector and check "-" PIN ground and power insulation: if insulation is not present, restore the cable harness;...
Page 243 Caponord 1200 - Caponord 1200 Rally Electrical system • Disconnect the rear suspension valve and the VCU. Check that the valve connector PIN 1 (R) is insulated from ground and power and also from PIN 2 (Green). Check that the valve connector PIN 2 (Green) is insulated from ground and power.
Page 244 Caponord 1200 - Caponord 1200 Rally Electrical system • Check the component connector and the VCU connector. Disconnect the two connectors and check for continuity of the cable between Valve "+" PIN and VCU PIN B1 and restore the cable harness. If the cable harness is intact replace the valve. + command output error rear suspension valve short circuit C1607 Error cause •...
Page 245 Caponord 1200 - Caponord 1200 Rally Electrical system Pin out: 1. Ground from VCU 2. Temperature signal output 3. Power from VCU 4. Pressure signal output DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS VCU ERRORS Pressure sensor short circuit error C1407 Error cause •...
Page 246 Caponord 1200 - Caponord 1200 Rally Electrical system • Excessive voltage is found or null voltage between sensor connector PIN 2 and VCU PIN Troubleshooting • Disconnect the sensor connector and check PIN 2 ground and power insulation. if insulation is not present, restore the cable harness;...
Page 247 Caponord 1200 - Caponord 1200 Rally Electrical system to maximise comfort and maintain the correct bike set up. Level in electrical circuit diagram: VCU (Vehicle Control Unit) Location: • On the vehicle: on the left side of the bike, fixed to the frame. •...
Page 248 Caponord 1200 - Caponord 1200 Rally Electrical system • If short circuit: check the continuity between sensor connector PIN 2 and VCU PIN B3. If there is no continuity, restore the cable harness. • If the circuit is open: check the sensor connector and the VCU connector. Disconnect the two connectors and check for continuity of the cable between sensor PIN 2 and VCU PIN B3 and restore the cable harness.
Page 249 Caponord 1200 - Caponord 1200 Rally Electrical system • If the checks return positive results replace the sensor. Recovery • Constant current on the shock absorber Preload motor (IF APPLICABLE) Function Monitors the rear monoshock preload in order to maintain optimum set up. Operation / Operating principle The rear monoshock spring preload is adjustable by means of an electrical device to 5 positions...
Page 250 Caponord 1200 - Caponord 1200 Rally Electrical system Pin out: 1. Preload motor negative 2. Preload motor positive 3. Ground from VCU 4. Encoder 2 5. Power from VCU 6. Encoder 1 DIAGNOSTICS INSTRUMENT: ADJUSTMENTS Preload motor travel limits • When the rear shock absorber preload hydraulic torque module is replaced, travel limit po- sition self-acquisition must be carried out.
Page 251 Caponord 1200 - Caponord 1200 Rally Electrical system • The motor does not move even when current greater than ~ 4 A passes through. Troubleshooting • Check the preload motor because it is very likely mechanically locked, otherwise replace the motor. Preload motor command circuit open error C1621 Error cause •...
Page 252 Caponord 1200 - Caponord 1200 Rally Electrical system • Failed movement of the preload motor after a time out of 50 seconds. Troubleshooting • Check the preload motor because it is very probably mechanically locked. If the motor is free, check the component connector and the VCU connector: disconnect the two connec- tors and check the continuity of the cable between motor PIN 1 - VCU PIN M2 VCU and between motor PIN 2 - VCU PIN M1.
Page 253 Caponord 1200 - Caponord 1200 Rally Electrical system B2:. CAN H line B3:. - B4:. - B5:. - B6:. - B7:. - B8:. Power from battery 2 C1. Exhaust valve engine "A" C2. Analogue ground connection C3. - C4. - C5.
Page 254 Caponord 1200 - Caponord 1200 Rally Electrical system B1:. Front solenoid valve positive B2:. Pump engine encoder 2 B3:. Rotary sensor signal 1 B4:. Exhaust valve potentiometer signal C1. Front solenoid valve negative C2. Front stop switch C3. Rotary sensor signal 2 C4.
Page 255 Caponord 1200 - Caponord 1200 Rally Electrical system Engine pinout key: Rear cylinder side spark plug coil control output PIN 1 Front cylinder side spark plug coil control output PIN 2 Rear throttle motor output (+) PIN 3 Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5 Analogue ground connection 1 PIN 6/17 Cylinder 2 injector control output PIN 8...
Page 256 Caponord 1200 - Caponord 1200 Rally Electrical system Track C hand grip input PIN 23 Front cylinder intake pressure sensor input PIN 24 Reference voltage output + 5 V: tracks A-C, front throttle and pressure sensor PIN 25/51 Reference voltage output + 5V: tracks B-D and rear throttle PIN 26 Rear cylinder central spark plug coil control output PIN 27 Front cylinder central spark plug coil control output PIN 28 Front throttle motor output (-) PIN 29...
Page 257 Caponord 1200 - Caponord 1200 Rally Electrical system Vehicle pinout key: Front cylinder 1 injector control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine" switch input PIN 58 Electric fan relay control output PIN 61 Reference voltage output + 5V: tracks B-D and rear throttle PIN 63 Neutral input PIN 64 Fall sensor input PIN 65...
Page 258 Caponord 1200 - Caponord 1200 Rally Electrical system Dashboard Grey-bodied instrument panel pinout key: 1. Live supply ELE SYS - 258...
Page 259 Caponord 1200 - Caponord 1200 Rally Electrical system 2. RH indicator switch 3. - 4. High beam warning light 5. - 6. Signal SELECT 3 (ENTER) 7. Signal SELECT 2 (DOWN) 8. Signal SELECT 1 (UP) 9. Fuel reserve warning light 10.
Page 260 Caponord 1200 - Caponord 1200 Rally Electrical system 22. Power from battery 3 23. - 24. Signal aerial "B" 25. Signal aerial "A" 26. CAN H line 27. CAN L line 28. ABS warning light 29. Sensors analogue ground connection 1 30.
Page 261 Caponord 1200 - Caponord 1200 Rally Electrical system ABS control unit pin out key: 1. Power ground connection 1 2. Power ground connection 2 3. Vehicle speed signal 4. Live supply 5. CAN H line 6. CAN L line 7. - 8.
Page 262 Caponord 1200 - Caponord 1200 Rally Electrical system • Communication speed: messages travel at a speed of 250 kbps (data arrive at nodes every 20 ms, i.e. 50 times/second). CAN PROTOCOL (CONT. NETWORK AREA) The communication protocol is CSMA/CD (Carrier Sense Multiple Access w/ Collision Detection). In order to transmit, every nod must first check that the BUS (the connection among all devices) is free before attempting to send a message with BUS (Carrier Sense).
Page 263 Caponord 1200 - Caponord 1200 Rally Electrical system • Replace the Marelli control unit. CAN line without signals U1602 • Bus Off. Error cause • No communication on CAN line (PIN 66 and/or PIN 80): problem on the whole network (for example, battery cut-off or short circuited or shorted to ground).
Page 264 Aprilia Traction Control present. In the event of a bike with an ABS system and indication of the diagnostics instrument of: Aprilia Traction Control not present, update the control unit.
Page 265 Caponord 1200 - Caponord 1200 Rally Electrical system instrument of ADD NOT PRESENT, upgrade the vehicle configuration by means of the spe- cific adjustment. CAN line to VCU U1732 - Intermittent signal or communication error - (Caponord 1200 Travel Pack) Error cause •...
Page 266 Caponord 1200 - Caponord 1200 Rally Electrical system • The VCU does not receive communication from the instrument panel. Troubleshooting • Check the continuity between VCU PIN K2 - instrument panel PIN 27 (black connector) and between VCU PIN J2 - instrument panel PIN 26 (black connector). The error switches au- tomatically to memorised status when communication between the two control units is restored.
Page 267 Caponord 1200 - Caponord 1200 Rally Electrical system • Failed synchronisation between VCU and the instrument panel on the sent/received data packets (for each packet sent the VCU increases its internal counter by 1, which resets at 15). Troubleshooting • Probably contact or interruption of the cable harness that must be checked: check the con- tinuity between VCU PIN K2 - instrument panel PIN 27 (black connector) and between VCU PIN J2 - instrument panel PIN 26 (black connector).
Page 268 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 269 Caponord 1200 - Caponord 1200 Rally 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 Flanged nut fastening Trellis to frame 80 Nm (59 lbf ft) side panels Flanged TE screw fastening chain...
Page 270 Caponord 1200 - Caponord 1200 Rally Engine from vehicle ENTRE FRAME pos. Description Type Quantity Torque Notes Flanged nut fastening side panels to 80 Nm (59 lb ft) engine ENGINE pos. Description Type Quantity Torque Notes Flanged TE screw fastening pinion M10x1.25 50 Nm (36.88 lbf ft) Loctite 270...
Page 271 Caponord 1200 - Caponord 1200 Rally Engine from vehicle pos. Description Type Quantity Torque Notes TCEI screw fastening Pin to gearbox M6x16 12 Nm (8.85 lbf ft) lever and Gearbox Lever to knurled shaft LH lock nut for ball joint 10 Nm (7.37 lbf ft) RH lock nut for ball joint 10 Nm (7.37 lbf ft)
Page 272 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Slide out bushing and O-ring from gearbox secondary shaft. • Disengage the spring. • Unscrew and remove the three nuts from the front exhaust manifold ENG VE - 272...
Page 273 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Disengage the spring joining the cen- tral exhaust manifold to the rear ex- haust manifold. • Remove the front exhaust manifold, moving the central exhaust manifold. • Unscrew and remove the catalytic con- verter mounting screw •...
Page 274 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Unscrew and remove the three screws. • Remove the clutch control cylinder. • Lock the plunger using a clamp. • Undo and remove the two screws and remove the pinion protection case. •...
Page 275 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Disconnect the side stand sensor con- nector. • Disconnect the gear in neutral sensor connector. • Slacken the gearing chain tension. • Unscrew and remove the screw; col- lect the washer and the spacer. •...
Page 276 Caponord 1200 - Caponord 1200 Rally 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. Removing the engine from the vehicle • Carry out the operations described un- der Vehicle preparation.
Page 277 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Unscrew and remove the rear coil fix- ing screws. • Slide out the rear coils. • Slide off the rear top pin and collect the washer. • Remove the two spacers. The thinner spacer is on the right.
Page 278 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Slide off the rear bottom pin and collect the washer. • Remove the bottom spacer on the right side. • Slide off the front pin and collect the washer. • Remove the bottom spacer on the right side.
Page 279 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Unscrew and remove the screw. • Release the ground points. • Unscrew and remove the two screws of the ECU. • Move the ECU aside but keep it connected to the wiring harness. •...
Page 280 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Lift the throttle body but keep it con- nected to the wiring harness. • Disconnect the engine temperature sensor from the front cylinder. • Disconnect the alternator connectors. ENG VE - 280...
Page 281 Caponord 1200 - Caponord 1200 Rally Engine from vehicle • Disconnect the throttle body and fasten it using an elastic band. • Unscrew and remove the screws, slid- ing out the front coils. • Lower the engine and take it out of the chassis.
Page 282 Caponord 1200 - Caponord 1200 Rally 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.
Page 283 Caponord 1200 - Caponord 1200 Rally Engine from vehicle See also Vehicle preparation Adjusting ENG VE - 283...
Page 284 INDEX OF TOPICS NGINE...
Page 285 Caponord 1200 - Caponord 1200 Rally Engine • Use the special plate to duly support the engine during the servicing opera- tions. CAUTION TAKE PARTICULAR CARE TO ENSURE THAT THE EN- GINE AND ENGINE MOUNTING ARE STABLE AND EN- SURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE.
Page 286 Caponord 1200 - Caponord 1200 Rally Engine 8. Complete transmission gear shaft 9. Forks 10.Fork shaft 11.Gear selector 12.Fork shaft 13.Fork 14.Gear selector drum 15.M8x1.25 threaded pin 16.Selector locking plate 17.Complete main gear shaft 18.TE flanged screw, M6x15 19.Complete index lever 20.Spring 21.Nut 22.Threaded pin...
Page 287 Caponord 1200 - Caponord 1200 Rally Engine 2. 2nd gear on primary Z=17 3. 3rd - 4th gear on secondary Z=20/22 4. 5th gear on primary Z=23 5. 6th gear on primary Z=24 6. Thrust washer 7. Circlip 8. Thrust washer 9.
Page 288 Caponord 1200 - Caponord 1200 Rally Engine See also Splitting the crankcase halves • Extract the desmodromic control. • Remove the three gear selection forks. CAUTION THE FORK FOR THE PRIMARY SHAFT IS SMALLER THAN THAT OF THE SECONDARY SHAFT. THE FORKS FOR THE SECONDARY SHAFT ARE THE SAME.
Page 289 Caponord 1200 - Caponord 1200 Rally Engine • Carefully rotate the engine support. • Carefully slide off the whole gear unit. • Repeat the removal operations but in reverse order. VERIFICATION OF PINION FASTENING ON SECONDARY SHAFT Perform the following procedure in order to check the hole for fastening the pinion onto the gearbox's secondary shaft.
Page 290 Caponord 1200 - Caponord 1200 Rally Engine • If the external diameter of the counter- sink is equal to or less than 15.50 mm, rework the threading with a male M10 x 1.25. Use a manual male finisher or a low input machine series male. •...
Page 291 Caponord 1200 - Caponord 1200 Rally Engine Gear selector EAR SELECTOR pos. Description Type Quantity Torque Notes Gear retainer pawl fastener screw 12 Nm (8.85 lb ft) Loctite dry loc 2040 Selector plate fastener screw 5.50 Nm (4.06 lb ft) 3M SCOTCH GRIP 2353 Screw fastening Desmodromic se-...
Page 292 Caponord 1200 - Caponord 1200 Rally Engine Disassembling the clutch Collect the washer. NOTE REPLACE THE WASHER ON EVERY SERVICING • Heat up the gearbox selector support plate screws. • Unscrew the three gearbox selector plate fastening screws and remove them..
Page 293 Caponord 1200 - Caponord 1200 Rally Engine Checking the gear selector Selector spring In the position shown, ensure that the gap between spring ends is +/- 0.4 mm (0.016 in), compared to the same gap measured at the corresponding teeth. Pawl Make sure that both pawl tips run free, without jamming...
Page 294 Caponord 1200 - Caponord 1200 Rally 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. Specific tooling 020724Y Punch cage with rollers gearbox con- trol stem...
Page 295 Caponord 1200 - Caponord 1200 Rally Engine Removing the starter motor • Disconnect the starter motor power supply cable. • Unscrew and remove the two screws and remove the starter motor. ENG - 295...
Page 296 Caponord 1200 - Caponord 1200 Rally Engine Generator side GNITION pos. Description Type Quantity Torque Notes Spark plug 11 Nm (8.11 lb ft) Freewheel Ring fastener screw 14 Nm (10.33 lb ft) 3M SCOTCH GRIP 2353 Screw fixing rotor - Crankshaft - (12 M12x1.25 130 Nm (95.88 lb ft) mm - 0.47 in)
Page 297 Caponord 1200 - Caponord 1200 Rally Engine Removing the flywheel cover • Remove the flywheel cover inspection cap. • Unscrew and remove the ten screws. • Use the appropriate tool to remove the flywheel cover. Specific tooling 020712Y Handle for removing the flywheel cov- •...
Page 298 Caponord 1200 - Caponord 1200 Rally 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 299 Caponord 1200 - Caponord 1200 Rally Engine • Screw the special tool's left-handed pin onto the outer body. • Keeping the outer body locked in place with a socket wrench, screw in the left- handed pin so that the flywheel is ex- tracted from the crankshaft.
Page 300 Caponord 1200 - Caponord 1200 Rally Engine • Retrieve the wrench from the crank- shaft. Freewheel removal • Remove the flywheel. • Remove the freewheel gear. • Heat the magneto flywheel with the specific heater. • Unscrew and remove the six screws. •...
Page 301 Caponord 1200 - Caponord 1200 Rally Engine Installing the flywheel • Apply the wrench to the crankshaft. • Insert the starter's transmission gear, after having coated it with a layer of grease. • Insert the flywheel on the crankshaft. • Screw the screw together with the washer but without tightening.
Page 302 Caponord 1200 - Caponord 1200 Rally Engine Specific tooling 020713Y Flywheel extractor • Position the retention plate. • Tighten the screw. Clutch side ATER PUMP pos. Description Type Quantity Torque Notes Clutch side cover fastener screw 13 Nm (9.59 lbf ft) Fastener screw for Pump Cover / 13 Nm (9.59 lbf ft) Clutch side cover...
Page 303 Caponord 1200 - Caponord 1200 Rally Engine pos. Description Type Quantity Torque Notes Water pump support plug M6x10 6.5 Nm (4.79 lbf ft) 3M SCOTCH GRIP 2353 • Unscrew and remove the thirteen screws in a cross pattern (the two screws also retaining the water pump cover are longer than the other eleven ones).
Page 304 Caponord 1200 - Caponord 1200 Rally Engine Removing the clutch cover LUTCH COVER pos. Description Type Quantity Torque Notes Screw fastening Clutch Cover / inter- 13 Nm (9.59 lbf ft) mediate Clutch side cover Clutch fastener nut M24x1 170 Nm (125.38 lbf ft) Chamfer Fastening oil filler plug on Clutch cov- 2 Nm (1.48 lbf ft)
Page 305 Caponord 1200 - Caponord 1200 Rally Engine Removing the clutch cover alone is only recom- mended when replacing the clutch plates. When removing the entire clutch assembly, removing the clutch side cover is recommended. However, removing the entire clutch assembly is possible by removing the clutch cover alone.
Page 306 Caponord 1200 - Caponord 1200 Rally Engine • Remove the clutch-side cover. • Unscrew and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and retrieve the washers and the clutch springs.
Page 307 Caponord 1200 - Caponord 1200 Rally Engine • Remove the clutch control rod. • Fasten the clutch housing using the specific tool. Specific tooling 9100896 Clutch bell stopper • Unscrew and remove the clutch hub nut. • Remove the washer to be chamfered. ENG - 307...
Page 308 Caponord 1200 - Caponord 1200 Rally Engine • Remove the clutch hub. • Collect the washer between the clutch hub and the housing. • Collect the clutch housing. • Retrieve the spacer and the roller bear- ings. ENG - 308...
Page 309 Caponord 1200 - Caponord 1200 Rally Engine • Collect the special shim featuring two thicknesses. 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 310 Caponord 1200 - Caponord 1200 Rally Engine Checking the clutch housing • Remove the clutch bell. • Remove the seeger ring. • Remove the oil pump's drive gear. DURING REASSEMBLY, THE COLLAR OF THE GEAR MUST ALWAYS BE FACING THE CLUTCH BELL. •...
Page 311 Caponord 1200 - Caponord 1200 Rally Engine Checking the pusher plate Check the thrust plate and the bearing for damage 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 312 Caponord 1200 - Caponord 1200 Rally Engine Assembling the clutch • Fit the shim washer. • Fit the needle bearing and the spacer. • Fit the clutch housing. • Make sure that the oil pump control drive gear of the clutch housing engag- es correctly with the oil pump driven gear.
Page 313 Caponord 1200 - Caponord 1200 Rally Engine • Position the clutch hub. • Fit the clutch-side cover. • Check that the measurement has not changed compared with the one car- ried out upon removal; tighten the clutch nut afterwards. If the projection has changed, rotate the crankshaft to correctly engage the engine oil pump drive gear on the clutch housing with...
Page 314 Caponord 1200 - Caponord 1200 Rally Engine • Insert the cupped ring (1). CAUTION MAKE SURE THE DISC RING IS INSERTED FACING THE RIGHT DIRECTION; THE RING'S CONE MUST BE FACING THE ENGINE. • Fit the lathed driven disc (2). •...
Page 315 Caponord 1200 - Caponord 1200 Rally Engine Installing the clutch cover CLUTCH-SIDE COVER OIL SEAL INSTALLATION • For controlled driving of the oil seal, take a 0.5 mm (0.020 in) thick washer, having an inside diameter of 12 mm (0.47 in) and outside diameter of 20 mm (0.79 in). •...
Page 316 Caponord 1200 - Caponord 1200 Rally Engine Heads EAD COVER pos. Description Type Quantity Torque Notes Special screw for fastening head 9 Nm (6.64 lb ft) cover Special screw for fastening head 9 Nm (6.64 lb ft) cover Oil breather fastener screw 5.50 Nm (4.06 lbf ft) Spark plugs 10-12 Nm (7.38-8.85 lb...
Page 317 Caponord 1200 - Caponord 1200 Rally Engine pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 22 Nm (16.22 lb ft) Threaded plug for water sensor seat M12x1.5 10 Nm (7.38 lb ft) Loctite Drise AL 506 Head stud bolt fastener nut - pre- M10x1.25 10 Nm (7.38 lb ft) Lubricate the...
Page 318 Caponord 1200 - Caponord 1200 Rally Engine HEAD COVER FITTING • Installation operations apply to both head covers. • Ensure gasket is in good conditions. If required, change it and use a gasket having the same features. • Fit the cover. •...
Page 319 Caponord 1200 - Caponord 1200 Rally Engine • Remove the cap from flywheel cover. • Turn the crankshaft until the front cyl- inder piston reaches the TDC (com- bustion). • Unscrew and remove the eight cam tower screws working in a diagonal se- quence and in stages.
Page 320 Caponord 1200 - Caponord 1200 Rally Engine • Remove the decompression device housing. • Remove the counterweight and de- compression device with the relevant spring. • To refit, engage spring on decompres- sion device and preload it by one turn. •...
Page 321 Caponord 1200 - Caponord 1200 Rally Engine Front head removal • Remove the clutch assembly. • Unscrew and remove the screw and collect the washer and the internal spring. • Unscrew and remove the two screws. • Remove the chain tensioner and re- trieve the gasket.
Page 322 Caponord 1200 - Caponord 1200 Rally Engine • Unscrew and remove the chain inter- mediate gear pin. • Pay attention to avoid damaging the O- ring. • Remove the primary gear following the explanation given on crankcase open- ing. • Remove the mobile chain slider.
Page 323 Caponord 1200 - Caponord 1200 Rally Engine • Unscrew and remove the external screw on the flywheel side. • Unscrew and remove the three bottom head fixing nuts. • Unscrew and remove the four nuts, proceeding in stages and in a diagonal pattern.
Page 324 Caponord 1200 - Caponord 1200 Rally Engine • Slide head off the stud bolts. • Remove the gasket between the head and the cylinder. • Rimuovere il pattino catena fisso. Front head check • Using a round scraper, clean off any carbon deposits in the combustion chamber. CAUTION DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK PLUG THREADS OR THE VALVE SEATS.
Page 325 Caponord 1200 - Caponord 1200 Rally Engine Removing camshafts • Remove the head cover. • Unscrew and remove the two screws. • Remove the coolant fitting. See also Head cover removal • Remove the cap from flywheel cover. • Rotate the crankshaft until the rear cyl- inder piston reaches the TDC.
Page 326 Caponord 1200 - Caponord 1200 Rally Engine • Remove the camshafts complete with the gears. Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES •...
Page 327 Caponord 1200 - Caponord 1200 Rally Engine • Remove the counterweight and de- compression device with the relevant spring. • To refit, engage spring on decompres- sion device and preload it by one turn. • Install the counterweight and engage the preloaded device to it.
Page 328 Caponord 1200 - Caponord 1200 Rally Engine • Unscrew and remove the two screws. • Remove the chain tensioner and re- trieve the gasket. • Remove the camshafts complete with the gears. See also Removing camshafts Magneto flywheel removal • Unscrew and remove the two chain slider screws.
Page 329 Caponord 1200 - Caponord 1200 Rally Engine • Remove the primary gear following the explanation given on crankcase open- ing. • Remove the intermediate gear with chain. NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Page 330 Caponord 1200 - Caponord 1200 Rally Engine • Unscrew and remove the three bottom head fixing nuts. • Unscrew and remove the four nuts, proceeding in stages and in a diagonal pattern. • Slide head off the stud bolts. • Remove the gasket between the head and the cylinder.
Page 331 Caponord 1200 - Caponord 1200 Rally Engine • Remove the fixed chain slider. NOTE ON REASSEMBLY, PERFECTLY CLEAN THE MATING SURFACE OF THE SPECIAL SCREW RETAINING THE IDLE GEAR AND THE THREE TIMING GEARS AND RE- PLACE THE ALUMINIUM WASHER. Rear head check •...
Page 332 Caponord 1200 - Caponord 1200 Rally Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. Specific tooling 020382Y Tool to extract valve cotters 020896Y Bushing for valve removal • Remove the cotters using a magnet. •...
Page 333 Caponord 1200 - Caponord 1200 Rally Engine • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL. VALVE STEM DEVIATION Lift up the valve approx.
Page 334 Caponord 1200 - Caponord 1200 Rally Engine Support the valve with two "V" blocks as shown and check the run-out with a dial gauge. If the run-out exceeds the specified limit, replace the valve. Characteristic Valve stem run-out 0.05 mm (0.0020 in) Position the dial gauge at a right angle to the valve head face and measure the eccentricity.
Page 335 Caponord 1200 - Caponord 1200 Rally Engine Spring check Carry out a measurement and a visual inspection of the valve springs for damage, distortion or loss of tension. Measure the spring length at release position. Valve springs: minimum wear limit (1) 43.8 mm (1.724 in).
Page 336 Caponord 1200 - Caponord 1200 Rally Engine Timing TIMING SYSTEM pos. Description Type Quantity Torque Notes Camshaft gear fastener nut M15x1 90 Nm (66.38 lbf ft) Timing drive gear fastener screw M24x1.5 40 Nm (29.50 lbf ft) 3M SCOTCH GRIP 2353 Special screw for fastening mobile / 19 Nm (14.01 lbf ft)
Page 337 Caponord 1200 - Caponord 1200 Rally Engine pos. Description Type Quantity Torque Notes Camshaft retainer plate fastener torx M5 8.5 Nm (6.26 lbf ft) 3M SCOTCH GRIP screw 2353 Decompression device fixing screw torx M8 28.5 Nm (21.02 lbf ft) 3M SCOTCH GRIP 2353 Fastener screw...
Page 338 Caponord 1200 - Caponord 1200 Rally Engine • Fit tool on crankshaft matching the fly- wheel key. • Tighten the screw on the crankshaft. • Turn crankshaft until the tool "V" is positioned at the front cylinder. • Tighten the two pins of the tool. •...
Page 339 Caponord 1200 - Caponord 1200 Rally Engine Locking torques (N*m) Nut fixing camshaft gears (pre-tightening) - M15x1 (4) 30 Nm (22.13 lb ft) • Remove the two pins. • Unscrew and remove the eight fixing screws and remove the cam tower. •...
Page 340 Caponord 1200 - Caponord 1200 Rally Engine • Repeat the fastening operations of the camshafts to the rear head. • Release the crankshaft from the spe- cific special tool. • Rotate the crankshaft in the riding di- rection until the rear cylinder piston reaches the top dead centre (270°).
Page 341 Caponord 1200 - Caponord 1200 Rally Engine YLINDER pos. Description Type Quantity Torque Notes Chain tensioner fastener screw 13 Nm (9.59 lb ft) Cylinder plate fastener screw 7.84-9.81 Nm (5.78-7.23 lb ft) Chain tensioner adjustment screw 5.50 Nm (4.06 lb ft) Removing the cylinder •...
Page 342 Caponord 1200 - Caponord 1200 Rally Engine • Take out the pin locking ring. • Lock the connecting rod using the spe- cific tool. • Slide out the pin, using the assembly tool pin, and remove the piston. Specific tooling 020716Y Connecting stem lock 020894Y Pin snap ring fitting tool •...
Page 343 Caponord 1200 - Caponord 1200 Rally Engine • Remove the upper ring, the second ring and the oil ring. Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions. •...
Page 344 Caponord 1200 - Caponord 1200 Rally 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;...
Page 345 Caponord 1200 - Caponord 1200 Rally Engine Top ring (1st slot): with new engine 0.030 - 0.065 mm (0.0012 - 0.0026 in). Wear limit: 0.075 mm (0.0029 in) Intermediate ring (2nd slot): with new engine 0.020 - 0.055 mm (0.0008 - 0.0022 in). Wear limit 0.065 mm (0.0026 in) Oil scraper ring (3rd slot): with new engine 0.010 - 0.175 mm (0.0004 - 0.0069 in).
Page 346 Caponord 1200 - Caponord 1200 Rally 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 347 Caponord 1200 - Caponord 1200 Rally Engine • The piston rings are different and must be installed with the marking at the top. • Fit the lower oil scraper ring on the pis- ton with the gap turned towards the exhaust side.
Page 348 Caponord 1200 - Caponord 1200 Rally Engine See also Selecting the base gasket • Remove the tool and fully push cylinder on the stud bolts. Selecting the base gasket • Temporarily, fit the piston to the cylinder, without base or head gasket. ENG - 348...
Page 349 Caponord 1200 - Caponord 1200 Rally Engine • Fit a dial gauge on the specific tool. • Zero the dial gauge on a reference sur- face with an average preload of 5 mm (0.2 in), for example. Maintaining the zero position, mount the tool on the cyl- inder and secure it with two nuts (10 Nm - 7.38 lb ft), as shown in the figure.
Page 350 Caponord 1200 - Caponord 1200 Rally Engine Crankcase - crankshaft RANKCASE pos. Description Type Quantity Torque Notes Bearing retainer fastener screw 10 Nm (7.38 lbf ft) Loctite 270 Piston oil jet fastener screw 5.50 Nm (4.06 lbf ft) Loctite 242 Tapered plug for crankshaft main M8x1 15 Nm (11.06 lbf ft)
Page 351 Caponord 1200 - Caponord 1200 Rally 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 / 29 Nm (21.39 lbf ft) clutch side crankcase halves...
Page 352 Caponord 1200 - Caponord 1200 Rally Engine • Procure a steel bushing with the same measures as shown in the figure. • Install the bushing on the right end of the crankshaft before proceeding with the installation of the extractor for the gear removal.
Page 353 Caponord 1200 - Caponord 1200 Rally Engine • Remove the head-cylinder assem- blies. • Remove the gear sensor loosening the two fixing screws. • Collect the O-ring. See also Removing the cylinder • Unscrew and remove the selector drum fastener screw. •...
Page 354 Caponord 1200 - Caponord 1200 Rally Engine • Unscrew and remove the eleven fly- wheel side M6 screws. • Turn the engine into horizontal position. • Unscrew and remove the two engine support nuts. • Open the crankcase halves. ENG - 354...
Page 355 Caponord 1200 - Caponord 1200 Rally Engine Removing the crankshaft RANKSHAFT pos. Description Type Quantity Torque Notes Crankshaft primary gear fastener nut M24x1.5 300 Nm (221.27 lbf ft) Anticlockwise nut Connecting rod screw 15 + 30 Nm (11.06 + Lubricate the 22.13 lbf ft) + 50°...
Page 356 Caponord 1200 - Caponord 1200 Rally Engine 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. CAUTION TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE.
Page 357 Caponord 1200 - Caponord 1200 Rally Engine • Replace the O-Rings on oil ducts. 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 dial gauge mounted on the specific dial gauge support.
Page 358 Caponord 1200 - Caponord 1200 Rally 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 359 Caponord 1200 - Caponord 1200 Rally 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. Installing the crankshaft •...
Page 360 Caponord 1200 - Caponord 1200 Rally Engine • Apply black sealing paste (Threebond) on the left crankcase half. CAUTION TAKE CARE NOT TO MAKE EXCESSIVE USE OF THREE- BOND AS THIS COULD PREVENT THE OIL FROM PASS- ING BETWEEN THE GUARDS. •...
Page 361 Caponord 1200 - Caponord 1200 Rally Engine • Working on the left side, place the elev- en M6 screws fixing the crankcase. • Working on the left side, place the nine M8 screws fixing the crankcase. • Tighten all the crankcase fixing screws, both M6 and M8 type.
Page 362 Caponord 1200 - Caponord 1200 Rally Engine • Position the gear sensor and screw the two fixing screws. • Refit both head-cylinder assemblies. • Position the crankshaft gear. • Fit the special tool, tightly fastening the three screws securing the tool onto the crankcase.
Page 363 Caponord 1200 - Caponord 1200 Rally Engine Lubrication IL RADIATOR pos. Description Type Quantity Torque Notes Fastening nipple to oil radiator M16x1.5 18 Nm (4.05 lb ft) Oil radiator tubes fastening M16x1.5 15 Nm (11.06 lb ft) Fastening nipple to engine M16x1.5 42 Nm (30.97 lb ft) ENG - 363...
Page 364 Caponord 1200 - Caponord 1200 Rally 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 20 Nm (14.75 lbf ft) side crankcase half Oil filter...
Page 365 Caponord 1200 - Caponord 1200 Rally Engine • By means of a calliper spanner lock out gear rotation and loosen the nut to re- move it. See also Disassembling the clutch • Collect the washer. • Collect the gear. • Collect the spacer.
Page 366 Caponord 1200 - Caponord 1200 Rally Engine • Unscrew and remove the two nuts fix- ing the protection. • Collect the protection. • Remove the oil pump. 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 necessary.
Page 367 Caponord 1200 - Caponord 1200 Rally 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. CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAM- AGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTH- ER MARKS).
Page 368 Caponord 1200 - Caponord 1200 Rally 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. • Fit the oil pump. •...
Page 369 Caponord 1200 - Caponord 1200 Rally Engine • Fit the spacer. • Fit the gear. • Place the washer. • By means of a calliper spanner lock out gear rotation and tighten the retaining nut. ENG - 369...
Page 370 Caponord 1200 - Caponord 1200 Rally Engine • Bend the chamfering tongue. • Refit the clutch. See also Assembling the clutch Blow-by The Blow By system allows for oil vapours to be recycled. The law requires that these gas and oil vapours cannot be released into the atmosphere for environmental reasons.
Page 371 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 372 Caponord 1200 - Caponord 1200 Rally Power supply Fuel pump Removing CAUTION PAY ATTENTION DURING THE REMOVAL AND INSTALLATION PHASES OF THE FUEL PUMP SINCE TI COULD GET DAMAGED. • Remove and empty the tank first. • Unscrew and remove the ring nut (1) fastening the fuel pump to the tank.
Page 373 Caponord 1200 - Caponord 1200 Rally Power supply • Undo and remove the four screws (2) fixing the fuel level probe to the tank. • Remove the fuel level probe (3). P SUPP - 373...
Page 374 INDEX OF TOPICS SUSP USPENSIONS...
Page 375 Caponord 1200 - Caponord 1200 Rally Suspensions Front Handlebar 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 U-bolt to lower clamp Screws fastening light switch assem- 2 + 2...
Page 376 Caponord 1200 - Caponord 1200 Rally Suspensions Front fork RONT FORK pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lb ft) Screw (Piston fixing to the stem 30 Nm (22.13 lb ft) base) Upper cap 20 Nm (14.75 lb ft)
Page 377 Caponord 1200 - Caponord 1200 Rally Suspensions RONT FORK pos. Description Type Quantity Torque Notes Sensor upper cover screw M6x20 10 Nm (7.37 lb ft) Sensor lower cover screw M6x12 10 Nm (7.37 lb ft) Screw (Piston fixing to the stem 30 Nm (22.13 lb ft) base) Upper cover...
Page 378 Caponord 1200 - Caponord 1200 Rally Suspensions TEERING Pos. Description Type Quantity Torque Notes Headstock ring nut - pre-tightening M25x1 60 Nm (44.25 lb ft) Unscrew after pre- tightening Headstock ring nut - tightening M25x1 50 +/- 5 Nm (36.88 +/- 3.69 lb ft) Headstock cap M22x1...
Page 379 Caponord 1200 - Caponord 1200 Rally Suspensions • Undo and remove the sensor base fix- ing screw located above the fork. • Disconnect the connector. • Remove the cable guide, making sure that you do not damage the cable itself. At this point the stem can be removed from the plate.
Page 380 Caponord 1200 - Caponord 1200 Rally Suspensions • Using the appropriate tool fasten the stem in the vice. Specific tooling AP8140149 Guard for assembly operations • Operating on the upper screw, unload the spring. • Loosen the cover without unscrewing it completely, using the suitable equip- ment.
Page 381 Caponord 1200 - Caponord 1200 Rally Suspensions • Using the specific tool, fixed to the pre- loading pipe, compress the spring. • Insert a spanner in the lock nut of the cover. Specific tooling 020888Y Clamp for pre-load pipe • Unscrew the cap and remove it.
Page 382 Caponord 1200 - Caponord 1200 Rally 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. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
Page 383 Caponord 1200 - Caponord 1200 Rally 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 384 Caponord 1200 - Caponord 1200 Rally Suspensions • Remove the pumping member pin. THE FOLLOWING PROCEDURE APPLIES TO aDD VERSION OF THE LH STEM. • Using the appropriate tool fasten the stem in the vice. • Undo completely the sleeve cap using the special tool.
Page 385 Caponord 1200 - Caponord 1200 Rally Suspensions • Unscrew and remove the bottom screw and collect the washer. • Remove the pumping member pin. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim.
Page 386 Caponord 1200 - Caponord 1200 Rally Suspensions • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem. • remove the ring and the dust guard. THE FOLLOWING PROCEDURE APPLIES TO THE ADD VERSION.
Page 387 Caponord 1200 - Caponord 1200 Rally Suspensions NOTE DURING THE ASSEMBLY PHASE REMEMBER TO REPLACE THE CABLE GUIDE WITH A NEW ONE. WARNING DURING THE REASSEMBLY PHASE TIGHTEN THE RING NUT (2) AND THE SLEEVE (3) TO THE TORQUE 20 Nm (14.75 lb ft) •...
Page 388 Caponord 1200 - Caponord 1200 Rally Suspensions A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK- ENED MAKING THE VEHICLE DANGEROUS TO USE. Characteristic Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check the spring is in good conditions.
Page 389 Caponord 1200 - Caponord 1200 Rally Suspensions Replace the following components with new ones: • seal ring; • dust gaiter; • O-Ring on the cap. Reassembling the fork NOTE THE OPERATIONS REPORTED BELOW ARE VALID FOR BOTH CAPONORD 1200 STANCHIONS, AND THE RH STANCHION OF CAPONORD 1200 aDD VERSION.
Page 390 Caponord 1200 - Caponord 1200 Rally Suspensions • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool.
Page 391 Caponord 1200 - Caponord 1200 Rally Suspensions • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight • Insert the pumping member pin in the stem.
Page 392 Caponord 1200 - Caponord 1200 Rally Suspensions • Fill the forks with oil, according to the indicated quantities. • Insert the spring. CAUTION PROCEED WITH CAUTION WHEN INSERTING THE SPRING AND ENSURE THAT THE PART WHERE THE SPI- RAL IS MORE COMPRESSED IS FACING DOWNWARDS. See also Filling oil •...
Page 393 Caponord 1200 - Caponord 1200 Rally Suspensions • Tighten the nut as much as possible. • Insert the cover and tighten until it stops. • Remove the specific tools. • Screw the cover in the sleeve to the prescribed torque. THE FOLLOWING PROCEDURE APPLIES TO THE ADD VERSION.
Page 394 Caponord 1200 - Caponord 1200 Rally Suspensions • With the key hold, turn the spring clock- wise until the ring nut is fully uncovered and manually tighten the ring nut against the cap. • Insert the key on the ring nut seat. •...
Page 395 Caponord 1200 - Caponord 1200 Rally Suspensions • Install first the dust scraper (1), then the oil seal (2), the ring (3) and the movable bushing. • When inserting the above listed ele- ments, pay attention not to damage them passing over the hole on the stem.
Page 396 Caponord 1200 - Caponord 1200 Rally Suspensions • Insert the retainer ring in its position. • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight •...
Page 397 Caponord 1200 - Caponord 1200 Rally Suspensions • Pour part of the fork oil into the sleeve. • Wait a few minutes until the oil fills all the ducts. • Pour the remaining oil. • Pump out oil a few times. •...
Page 398 Caponord 1200 - Caponord 1200 Rally Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Headstock ring nut - tightening M35x1 60 ± 12 Nm (44.25 ± 8.85 lb ft) Headstock cap 20 ± 4 Nm (14.75 ± 2.95 lb ft) SHC screw fastening fork stanchions M8x35...
Page 399 Caponord 1200 - Caponord 1200 Rally Suspensions STEERING CLEARANCE ADJUSTMENT • Place the vehicle in such a way so as to keep both wheels on the ground. • Disconnect the ADD system connector • Undo and remove the ADD sensor cov- er fixing screw.
Page 400 Caponord 1200 - Caponord 1200 Rally Suspensions • Remove the cable guide, taking care not to damage the cable itself. WARNING USING AN APPROPRIATE TOOL, APPLY LEVERAGE BE- TWEEN THE CABLE GUIDE AND THE CABLE, TAKING CARE NOT TO DAMAGE THE CABLE. •...
Page 401 Caponord 1200 - Caponord 1200 Rally Suspensions • Remove the upper plate central fixing screw • Remove the upper plate • Using an appropriate tool remove the self-locking ring nut Specific tooling 020966Y Steering adjustment socket • Using the same tool, loosen the ring nut and tighten it again to the prescri- bed torque.
Page 402 Caponord 1200 - Caponord 1200 Rally Suspensions Disassembling • Remove the front brake callipers • Remove the front wheel and the fork stanchions • Remove the upper steering yoke • After removing the self-locking ring nut and the ring nut, remove the dust gaiter ring •...
Page 403 Caponord 1200 - Caponord 1200 Rally Suspensions • Remove the lower plate from the steer- ing column • Slide off the bearing (1), the lower bearing seat (2) and the dust gaiter (3) • If necessary, to remove the bearing seats inside the steering column, use a generic puller. Assembling •...
Page 404 Caponord 1200 - Caponord 1200 Rally Suspensions • Insert the lower plate into the steering column • Insert the bearing • Insert the bearing upper seat • Insert the internal dust gaiter ring SUSP - 404...
Page 405 Caponord 1200 - Caponord 1200 Rally Suspensions • Insert the dust gaiter ring • Tighten the ring nut to the prescribed torque using an appropriate tool Specific tooling 020966Y Steering adjustment socket • Tighten the self-locking ring nut to the prescribed torque using an appropriate tool Specific tooling...
Page 406 Caponord 1200 - Caponord 1200 Rally Suspensions • Insert the dust gaiter ring • Tighten the ring nut to the prescribed torque using an appropriate tool Specific tooling 020966Y Steering adjustment socket • Tighten the self-locking ring nut to the prescribed torque using an appropriate tool Specific tooling...
Page 407 Caponord 1200 - Caponord 1200 Rally Suspensions • Tighten the upper plate central fixing screw • Working from both sides, tighten the screws fixing the stanchions to the up- per plate • Tighten the upper cap on the steering yoke pin •...
Page 408 Caponord 1200 - Caponord 1200 Rally Suspensions • Insert the cable guide and secure the lower cover of the ADD sensor after positioning it. • Insert the sensor correctly. Position and secure the ADD sensor cover Connect the ADD sensor connector Rear SUSP - 408...
Page 409 Caponord 1200 - Caponord 1200 Rally Suspensions Shock absorbers EAR SUSPENSION Pos. Description Type Quantity Torque Notes Upper SHC mounting screw M10x50 50 Nm (36.88 lb ft) Lower TCEI mounting screw M10x80 50 Nm (36.88 lb ft) ADD Version SUSP - 409...
Page 410 Caponord 1200 - Caponord 1200 Rally Suspensions EAR SUSPENSION A pos. Description Type Quantity Torque Notes Upper SHC mounting screw M10x50 50 Nm (36.88 lb ft) Lower SHC mounting screw M10x59 50 Nm (36.88 lb ft) Removing PROCEDURE TO LIFT THE REAR WHEEL The following procedure must be performed to lift the rear wheel, if the vehicle is not equipped with a central stand.
Page 411 Caponord 1200 - Caponord 1200 Rally Suspensions • Insert the first gear, keep the front brake lever blocked with an elastic, then lift the rear wheel of the vehicle. • Once the rear wheel is lifted, solidly fix the vehicle on the lift. •...
Page 412 Caponord 1200 - Caponord 1200 Rally Suspensions • Unscrew and remove the shock ab- sorber upper fixing screw. • Unscrew and remove the shock ab- sorber lower fixing screw. • Disconnect the shock absorber valve. SUSP - 412...
Page 413 Caponord 1200 - Caponord 1200 Rally Suspensions • When removing the shock absorber pay attention to the electric motor, it must be removed from the frame taking care not to damage it. Revision • Disconnect the cabling from the sup- port bracket •...
Page 414 Caponord 1200 - Caponord 1200 Rally Suspensions • Compress the shock absorber spring • Remove the retainer ring. • Discharge the spring and remove the suspension from the specific tool • Remove the lock plate of the spring making sure not to damage the cable harness SUSP - 414...
Page 415 Caponord 1200 - Caponord 1200 Rally Suspensions • Remove the spring making sure not to damage the cable harness BLEEDING • It is possible to carry out a bleeding and replace the oil in the suspension using a special pump. •...
Page 416 Caponord 1200 - Caponord 1200 Rally Suspensions • Connect the tube for the oil bleeding/ filling to the tool • After the bleeding and the oil filling re- move the tube from the joints • Remove the joints • Insert and tighten the screw for bleeding the suspension SUSP - 416...
Page 417 INDEX OF TOPICS CHAS HASSIS...
Page 418 Caponord 1200 - Caponord 1200 Rally Chassis Front wheel RONT WHEEL APONORD pos. Description Type Quantity Torque Notes Wheel axle M25 x 1.25 80 ± 12 Nm (59 ± 8.85 lb ft) Wheel nut M25 x 1.25 80 ± 12 Nm (59 ± 8.85 lb ft) Front brake disc fixing screws M8x20 30 Nm (22.13 lb ft)
Page 419 Caponord 1200 - Caponord 1200 Rally Chassis • Remove the wheel hub fastening 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 420 Caponord 1200 - Caponord 1200 Rally Chassis • Place the vehicle on a stable support so that the front wheel does not touch the ground. • Unscrew and remove the fixing nut (1) of the wheel axle. • Retrieve the sealing washer (2). •...
Page 421 Caponord 1200 - Caponord 1200 Rally Chassis • While holding the front wheel remove the wheel axle (6). • Collect the spacer from the front wheel right side. Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel. CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR.
Page 422 Caponord 1200 - Caponord 1200 Rally Chassis WHEEL AXLE • Use a dial gauge to check the wheel axle eccentricity. Replace the wheel axle if the eccentricity exceeds the limit value. 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 423 Caponord 1200 - Caponord 1200 Rally Chassis Rear wheel EAR WHEEL pos. Description Type Quantity Torque Notes ● Fastening screws flexible coupling Rear wheel axle M25x1.25 120 ± 18 Nm (88.50 ± 13.27 lb ft) Rear brake disc fixing screws M8x18 30 Nm (22.13 lb ft) Rimozione...
Page 424 Caponord 1200 - Caponord 1200 Rally Chassis CAUTION REMOVE THE SPEED SENSOR BEFORE REMOVING THE REAR WHEEL, THUS PREVENTING TO DAMAGE IT • Fully slacken the gearing chain ten- sion. • Make the wheel move forward and re- lease the gearing chain from the sprocket.
Page 425 Caponord 1200 - Caponord 1200 Rally Chassis • Collect the rear wheel spacer. • Working from the left side, unscrew and remove the five nuts and remove the sprocket and the bolts. • Unscrew and remove the five screws and remove the anti-vibration buffer holder.
Page 426 Caponord 1200 - Caponord 1200 Rally Chassis • Fully slacken the gearing chain ten- sion, acting on both nuts as indicated in the figure. • Unscrew and remove the nut (1). • Collect the washer (2). • Retrieve the right chain tensioner slider (3).
Page 427 Caponord 1200 - Caponord 1200 Rally Chassis • While holding the rear wheel slide the wheel axle (4) together with the chain tensioner slider (5). • Make the rear wheel (6) move forward and release the gearing chain from the sprocket.
Page 428 Caponord 1200 - Caponord 1200 Rally Chassis ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE. • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: •...
Page 429 Caponord 1200 - Caponord 1200 Rally Chassis REMOVAL OF RIGHT SIDE REAR WHEEL BEARING • Carry out the removal of the rear wheel. • Remove the spacer (1). • Remove the dust gaiter (2). • Remove the seeger ring (3). •...
Page 430 Caponord 1200 - Caponord 1200 Rally Chassis • Remove the Seeger ring (4). • Remove the bearing (5) from the sprocket guard using a generic bearing extractor. • Then using a generic bearing extractor remove the bearing (6). CHAS - 430...
Page 431 Caponord 1200 - Caponord 1200 Rally Chassis Swinging arm pos. Description Type Quantity Torque Notes Swingarm Pin adjustment bushing 12 Nm (8.85 lb ft) Swingarm pin ring nut 60 Nm (44.25 lb ft) Fork pin nut M20 x 1.5 90 Nm (66.38 lb ft) TPSI screw fastening rear stand M6x40 10 Nm (7.37 lb ft)
Page 432 Caponord 1200 - Caponord 1200 Rally Chassis • Cut the clamp. • 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. OTHERWISE, THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT, RESULTING IN BRAKE FLUID LEAKAGE.
Page 433 Caponord 1200 - Caponord 1200 Rally 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. PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOW- ERING AND TO KEEP IT UPRIGHT.
Page 434 Caponord 1200 - Caponord 1200 Rally Chassis To dismantle and remove the chain, proceed as follows: • Partially remove the pins (3) using a generic chain breaker. • Remove the outer plate (4). • Remove the outer O-ring rings (5). •...
Page 435 Caponord 1200 - Caponord 1200 Rally Chassis • Collect the inner O-ring rings (7) and completely remove the transmission chain. SPROCKET REMOVAL • Carry out the removal of the rear wheel • Remove the sprocket from the sprock- et guard. •...
Page 436 Caponord 1200 - Caponord 1200 Rally Chassis Perform the procedure described as follows to check chain wear: • Tauten the chain. • Place the jaws of the tool on the rollers at the opposite ends of a STRAIGHT length of chain consisting of 8 chain links.
Page 437 Caponord 1200 - Caponord 1200 Rally Chassis • Check that the links in the transmission chain are not seized and that it can move in both directions. • Use a generic clincher to re-tighten the pins of the link (checking riveting at points "A"). •...
Page 438 Caponord 1200 - Caponord 1200 Rally Chassis To check the clearance: • Shut off the engine. • Rest the vehicle on its stand. • Engage neutral gear. • Check that the vertical oscillation at a point between the pinion and the sprocket on the lower branch of the chain is approx.
Page 439 Caponord 1200 - Caponord 1200 Rally Chassis Also regularly check the following parts and make sure that the chain, the pinion and the sprocket do not show: • damaged rollers; • loosened pins; • dry, rusty, flattened or jammed chain links; •...
Page 440 Caponord 1200 - Caponord 1200 Rally Chassis Stand TAND pos. Description Type Quantity Torque Notes Central stand pre-soaked fixing screws M10x33 50 Nm (36.88 lb ft) Loctite 243 Plate fastening screws M8x30 25 ± 5 Nm (18.43 ± 3.68 lb Loctite 243 Stand screw 25 ±...
Page 441 Caponord 1200 - Caponord 1200 Rally Chassis • Working on the left inside, unscrew and remove the central stand fixing screw. • Undo and remove the two central stand fixing screws. NOTE IF THE REMOVED SCREWS MUST NOT BE REPLACED, RESTORE THE LOCTITE DURING THE REFITTING FOR A CORRECT TIGHTENING •...
Page 442 Caponord 1200 - Caponord 1200 Rally Chassis • Unscrew and remove the three fixing screws. • Remove the side stand. Exhaust ISCHARGE pos. Description Type Quantity Torque Notes TBEI silencer protection screws M6x16 5 Nm (3.69 lb ft) SHC silencer flange screws M8x25 18 ±...
Page 443 Caponord 1200 - Caponord 1200 Rally Chassis • Unscrew and remove the two exhaust valve motor fixing screws. • Remove the exhaust valve motor. • Unscrew and remove the three ex- haust end cover fixing screws. • Remove the cover. •...
Page 444 Caponord 1200 - Caponord 1200 Rally Chassis • Unscrew and remove the fixing screws (2). • Remove the heat guard (3). • Undo and remove the two fixing screws (4). • Undo and remove the fixing screw (5). CHAS - 444...
Page 445 Caponord 1200 - Caponord 1200 Rally Chassis • While holding the exhaust undo the nuts (6) and remove the cables from their housing (7). • Remove the exhaust end (8). Removing the catalytic converter • Remove the exhaust end first. •...
Page 446 Caponord 1200 - Caponord 1200 Rally Chassis Removing the exhaust manifold (OPTION 01) CAUTION NOTE THE MOTORCYCLE ACCORDING TO THE COUNTRY OF DESTINATION SHOWS A FRONT EX- HAUST MANIFOLD COMPLETE WITH A RESONATOR FIXED WITH A METAL CLAMP. THE FRONT EXHAUST MANIFOLD, IN THE TWO OPTIONS ARE DIFFERENT, SO IN CASE OF REPLACEMENT PAY ATTENTION NOT TO INTERCHANGE THEM •...
Page 447 Caponord 1200 - Caponord 1200 Rally Chassis • Disengage the spring joining the rear exhaust manifold and the catalytic con- verter. • Disconnect the front and rear lambda probe. • Remove the exhaust manifolds. (OPTION 02) • Carry out the removal of the side fair- ing.
Page 448 Caponord 1200 - Caponord 1200 Rally Chassis • Remove the clamp (2). • Remove the cover (3). • Disconnect the lambda probe connec- tor (4). • Remove the spring (5). CHAS - 448...
Page 449 Caponord 1200 - Caponord 1200 Rally Chassis • Unscrew and remove the three fixing nuts (6). • Remove the exhaust manifold (7). • Then collect the gasket (8). Removing the lambda sensor • Carry out the manifold removal. • Undo and remove the lambda probe (1) from the point indicated in the fig- ure.
Page 450 Caponord 1200 - Caponord 1200 Rally Chassis • Disconnect the horn connectors. See also Side body panels • Working on the left side, unscrew and remove the screw from the front cylin- der. • Remove the seeger ring and slide off the pin.
Page 451 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 452 Caponord 1200 - Caponord 1200 Rally 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 Notes ABS ECU fastener screw M6x25 8-10 Nm (5.90-7.37 lb ABS ECU fastener nut 10 Nm (7.37 lb ft) BRAK SYS - 452...
Page 453 Caponord 1200 - Caponord 1200 Rally Braking system Key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main fuse 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.ABS control unit fuse ABS ECU control unit pin configuration •...
Page 454 Caponord 1200 - Caponord 1200 Rally Braking system • PIN 13 - F_GND - Front ABS sensor ground connection • PIN 14 - F_SIG - Front ABS sensor signal • PIN 15 - PCC2 - Vehicle identification ground connection • PIN 16 - ISO_K - K line (diagnosis) •...
Page 455 Caponord 1200 - Caponord 1200 Rally Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake master cylinder 3. Front brake control lever 4. Rear system circuit BRAK SYS - 455...
Page 456 Caponord 1200 - Caponord 1200 Rally 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) 13.Rear brake exhaust circuit solenoid valve (normally closed) 14.Rear/front brake circuit low pressure accumulator 15.Front brake exhaust circuit solenoid valve (normally closed)
Page 457 Caponord 1200 - Caponord 1200 Rally Braking system The system restores the fluid taken from the calliper (8-9) in the section of the system between the brake pump (2-5) and the ABS inlet valve (10-12). D - Pressure restoration: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached.
Page 458 Caponord 1200 - Caponord 1200 Rally Braking system When sensors (3) detect a significant speed difference between the rear and the front wheels (for example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation. In this case, 2 things may occur: - the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel;...
Page 459 Caponord 1200 - Caponord 1200 Rally Braking system The function will automatically appear after five seconds, if the selection is not made promptly, or when the motorcycle is running. NOTE AT KEY ON, IF THE SYSTEM IS FUNCTIONING CORRECT- LY, THE ABS INDICATOR LIGHT WILL BLINK (ONCE A VEHICLE SPEED OF 5 Km/h - 3.1 mph IS EXCEEDED, THE SYSTEM WILL ONLY BE ACTIVE IF THE WARNING LIGHT GOES OFF)
Page 460 Caponord 1200 - Caponord 1200 Rally Braking system • the ABS warning light ABS keeps flashing ABS FAULTS - GUIDE TO THE DIAGNOSIS 1. ABS WARNING LIGHT ON 2. CONNECT P.A.D.S. DOES P.A.D.S. COMMUNICATES? (NO, go to 3; YES, go to 4) 3.
Page 461 Caponord 1200 - Caponord 1200 Rally Braking system INFO ECU SCREEN PAGE Characteristic Value/example Unit of Notes measure ment Date of vehicle manufacture Chassis number Software version Vehicle code Caponord 1200 The vehicle code stored in the control unit is read. Vehicle identification according to Norge / Stelvio / Identi- A different type of vehicle is associated with each...
Page 462 Caponord 1200 - Caponord 1200 Rally Braking system Characteristic Value/example Unit of Notes measure ment Battery voltage 11.9 ACTIVATION screen page On this screen, you can delete the errors from the memory of the controller and you can enable some systems controlled by the control unit.
Page 463 Caponord 1200 - Caponord 1200 Rally Braking system ERRORS screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS Characteristic Value/example Unit of Notes measure ment...
Page 464 Caponord 1200 - Caponord 1200 Rally Braking system Characteristic Value/example Unit of Notes measure ment (can be read in the ISO page on the Vehicle code line) and the value detected by the cabling identi- fication PINs (can be read in the ISO page Vehicle identification line on the basis of the status of Pins 2 and 15) and, for Caponord 1200, from the CAN signal re- ceived from the injection control unit...
Page 465 Caponord 1200 - Caponord 1200 Rally 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 466 Caponord 1200 - Caponord 1200 Rally Braking system Rear brake calliper EAR BRAKE pos. Description Type Quantity Torque Notes Rear brake lever pin 10 Nm (7.37 lbf ft) Loctite 243 Flanged TE screw fastening pump to M6x16 10 Nm (7.37 lbf ft) footrest mounting TBEI screw fastening oil pipe to M5x12...
Page 467 Caponord 1200 - Caponord 1200 Rally 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 50 Nm (36.88 lbf ft) Loctite 270 stems) Rear brake disc...
Page 468 Caponord 1200 - Caponord 1200 Rally Braking system • Retrieve the tone wheel (2). • Then retrieve the brake disc (3). Front brake disc Removal REMOVAL OF FRONT LEFT DISC BRAKE • Carry out the removal of the front wheel. •...
Page 469 Caponord 1200 - Caponord 1200 Rally Braking system • Retrieve the tone wheel (2). • Undo and remove the six fixing screws (3). • Retrieve the brake disc (4). Front brake pads Removal (OPTION 01) BRAK SYS - 469...
Page 470 Caponord 1200 - Caponord 1200 Rally Braking system • Remove the cotter pin. • Unscrew and remove the pin. • Collect the anti-vibration springs. • 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 LEAKAGE.
Page 471 Caponord 1200 - Caponord 1200 Rally Braking system • Remove the pads (4). • The procedure is valid for both front clamps. 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 LEAKAGE.
Page 472 Caponord 1200 - Caponord 1200 Rally 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 LEAKAGE.
Page 473 Caponord 1200 - Caponord 1200 Rally Braking system • It is important to ensure that there is always a sufficient quantity of brake fluid in the tank. • These operations may be simplified by using a bleeding device when carrying out the "Re- placing the brake fluid"...
Page 474 Caponord 1200 - Caponord 1200 Rally Braking system • Then perform the same procedure for the rear brake calliper, acting only on the valve installed on that calliper. • Fill the reservoir until it reaches the ref- erence "MAX" and refit the cap (check pad wear).
Page 475 Caponord 1200 - Caponord 1200 Rally Braking system Afterwards, remove pipes (2-3) that go from the ABS control unit to the brakes and also seal these unions with protective caps. • Install the new ABS control unit, previ- ously filled up. •...
Page 476 Caponord 1200 - Caponord 1200 Rally Braking system • Close the bleed screws of the front cal- liper and remove the bleed bottle. • Replace the damaged calliper with a new one. • Unlock the brake lever. • Remove the cap of the reservoir and fill it with the new DOT 4 brake fluid up to the reference "MAX".
Page 477 Caponord 1200 - Caponord 1200 Rally Braking system Changing the brake fluid BRAKE FLUID REPLACEMENT VEHICLE PREPARATION • Connect the bleeding unit to the reser- voir of the braking system. Max. filling pressure to be applied to the sys- tem= 3 bar (300 kPa - 43.51 PSI). PURGING PROCESS TO CHANGE THE BRAK- ING SYSTEM FLUID Connect the bleed bottle to the bleed screw of the...
Page 478 Caponord 1200 - Caponord 1200 Rally Braking system Front brake pump RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Brake pump fixing screws 10 ± 1,5 Nm (7.37 ± 1.10 lb BRAK SYS - 478...
Page 479 Caponord 1200 - Caponord 1200 Rally Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake lever pin 25 ± 3.75 Nm (18.44 ± 2.76 Loctite 243 lb ft) Microswitch fixing nuts 0.4 ± 0.08 Nm (0.29 ± 0.05 lb ft) Spring linking pin M5x7...
Page 480 INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
Page 481 Caponord 1200 - Caponord 1200 Rally Clutch system LUTCH CONTROL pos. Description Type Quantity Torque Notes Clutch pump fixing screws 10 ± 1,5 Nm (7.37 ± 1.10 lb Throttle control fixing screws 10 Nm (7.37 lb ft) Bleeding the system •...
Page 482 Caponord 1200 - Caponord 1200 Rally Clutch system • Repeatedly act on the clutch lever for its complete stroke, so to put the sys- tem under pressure and drain out the air in it towards the bleed screw. • Keep the clutch lever pressed and at the same time unscrew the bleed screw.
Page 483 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 484 Caponord 1200 - Caponord 1200 Rally Cooling system Circuit diagram OOLING SYSTEM pos. Description Type Quantity Torque Notes Electric fan fastener screw M4x45 3 Nm (2.21 lb ft) Flanged TE screw fastening left Ra- M6x25 10 Nm (7.37 lb ft) diator to trellis Flanged TE screw fastening expan- M6x20...
Page 485 Caponord 1200 - Caponord 1200 Rally Cooling system • Unscrew and remove the three nuts on the opposite side, collecting the wash- ers. • Remove the electric fan collecting the spacers. • From the front side, collect the screws and dished washers. (OPTION 02) •...
Page 486 Caponord 1200 - Caponord 1200 Rally Cooling system Coolant replacement (OPTION 01) • Remove the right side fairing. • Place a container of suitable capacity. • Loosen the screw, move the clamp and slide off the sleeve. • Remove the cap. •...
Page 487 Caponord 1200 - Caponord 1200 Rally Cooling system • Remove the right side fairing. • Place a container of suitable capacity under the vehicle. • Loosen the clamp (1) and move it in the direction indicated in the figure. • Remove the cover (2).
Page 488 Caponord 1200 - Caponord 1200 Rally 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 / 13 Nm (9.59 lbf ft) Clutch Cover / clutch side crankcase...
Page 489 Caponord 1200 - Caponord 1200 Rally Cooling system • Release the clamp. See also Coolant replacement • Remove the water pump cover. PUMP ROTOR REMOVAL • Remove the water pump cover H20. • Unscrew and remove the (anticlock- wise) screw •...
Page 490 Caponord 1200 - Caponord 1200 Rally Cooling system Removing the radiator • Remove both fairing lugs • Remove the right duct bulkhead • Remove the screw (1) fixing the oil ra- diator to the securing bracket • For an easier removal of the radiator lock lower pin, remove the screw (2) on the engine head that secures the radi- ator clamp.
Page 491 Caponord 1200 - Caponord 1200 Rally Cooling system • Proceed with the emptying of the hy- draulic system gradually disconnecting the water pipes • Remove the upper right side fastener screw (5) of the water radiator • Unhook the water radiator from the pin present on the left side and remove it Thermostatic valve Traditional circuit, three-way thermostatic valve: 1.
Page 492 INDEX OF TOPICS BODYW ODYWORK...
Page 493 Caponord 1200 - Caponord 1200 Rally Bodywork OP FAIRING INDSHIELD pos. Description Type Quantity Torque Notes Windshield on support fastener M6x18 10 Nm (7.37 lb ft) screw Bracket retainer screw M6x25 10 Nm (7.37 lb ft) RONT FAIRING pos. Description Type Quantity Torque...
Page 494 Caponord 1200 - Caponord 1200 Rally Bodywork pos. Description Type Quantity Torque Notes Deflector fixing screw M5x16 6 Nm (4.42 lb ft) UDGUARD pos. Description Type Quantity Torque Notes Lug fixing screw M6x20 10 Nm (7.37 lb ft) Control unit support fixing screw M6x35 10 Nm (7.37 lb ft) Front with rear lug fixing screw...
Page 495 Caponord 1200 - Caponord 1200 Rally Bodywork ANK COVER pos. Description Type Quantity Torque Notes Covers fastening screws M5x9 3 ± 0.60 Nm (2.21 ± 0.44 lb AIRINGS pos. Description Type Quantity Torque Notes Fairing fastener screw M5x9 6 Nm (4.42 lb ft) BODYW - 495...
Page 496 Caponord 1200 - Caponord 1200 Rally Bodywork pos. Description Type Quantity Torque Notes Fairing fastener screw M5x16 6 Nm (4.42 lb ft) ADDLE pos. Description Type Quantity Torque Notes Saddle fixing screw M5x12 6 Nm (4.42 lb ft) BODYW - 496...
Page 497 Caponord 1200 - Caponord 1200 Rally Bodywork ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Covers fastener screw M5x20 6 Nm (4.42 lb ft) Compartment fixing screw M5x12 6 Nm (4.42 lb ft) UGGAGE RACK pos. Description Type Quantity Torque Notes Luggage rack screw 3.9x14...
Page 498 Caponord 1200 - Caponord 1200 Rally Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes Tail fairing fastener screw M5x12 6 Nm (4.42 lb ft) Panniers connection fixing screw License plate holder fastener screw 10 Nm (7.37 lb ft) BODYW - 498...
Page 499 Caponord 1200 - Caponord 1200 Rally Bodywork EAR MUDGUARD pos. Description Type Quantity Torque Notes Mudguard TEFL fixing screws on wheel ad- M6x16 10 ± 2 Nm (7.37 ± 1.47 lb Loctite 270 justment EAR LIGHTS pos. Description Type Quantity Torque Notes Turn indicator fixing screw...
Page 500 Caponord 1200 - Caponord 1200 Rally Bodywork OCKS Pos. Description Type Quantity Torque Notes Switch fastener shear head Manual screw TE screw fastening saddle lock / bat- M6x25 10 Nm (7.37 lb ft) To reuse: Loctite tery compartment to saddle mount- BODYW - 500...
Page 501 Caponord 1200 - Caponord 1200 Rally Bodywork OOTRESTS Pos. Description Type Quantity Torque Notes Upper screw fastening passenger M8x35 25 Nm (18.44 lb ft) Loct. 243 footrests to frame side panels Lower TCEI screw fastening passen- M8x35 25 Nm (18.44 lb ft) Loct.
Page 502 Caponord 1200 - Caponord 1200 Rally Bodywork UEL TANK pos. Description Type Quantity Torque Notes Plastic ring nut 20 ± 3 Nm (14.75 ± 2.21 lb Level indicator fixing screws M6x16 3 ± 0.45 Nm (2.21 ± 0.33 lb Saddle fixing M5 x 9.5 3 ±...
Page 503 Caponord 1200 - Caponord 1200 Rally Bodywork ANK COVER pos. Description Type Quantity Torque Notes Covers fastening screws M5x9 3 ± 0.60 Nm (2.21 ± 0.44 lb BODYW - 503...
Page 504 Caponord 1200 - Caponord 1200 Rally Bodywork NSTRUMENT SUPPORT Pos. Description Type Quantity Torque Notes Instrument panel to trellis fixing screws M8x25 25 ± 5 Nm (18.43 ± 3.68 lb Seat • Insert the key in the lock located on the left fairing.
Page 505 Caponord 1200 - Caponord 1200 Rally Bodywork • Loosen the two fastening screws. • Remove the dashboard upper cover. • Remove the two screws fastening the lower cover of the dashboard. • Remove the cover. BODYW - 505...
Page 506 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the connector. • Remove the instrument panel. (OPTION 02) • Remove the windscreen. • Undo and remove the two fixing screws (1). • Remove the dashboard upper cover (2). • Undo and remove the two fixing screws (3).
Page 507 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the cover (4). • Disconnect the connector (5). • Remove the instrument panel (6). Headlight assy. (OPTION 01) • The following procedure refers to one single part of the dashboard, but is val- id for both.
Page 508 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the two fixing screws of the central dashboard. • Unscrew and remove the screw in the lower part of the light unit. • Remove the headlight assembly. • Unscrew and remove the light unit up- per fixing screw.
Page 509 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the screw in the lower part of the light unit. • Remove the headlight assembly. (OPTION 02) • The following procedure is only visible from one side of the vehicle, but in or- der to perform the removal correct and complete, it must be done from both sides of the vehicle.
Page 510 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the two connectors (8). • Remove the front fairing (9) together with the headlight assembly. • Unscrew and remove the screw (10). • Unscrew and remove the four fixing screws (11). •...
Page 511 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the headlight (14) from the support. Taillight assy. • Remove the tail fairing and license plate holder first. • Unscrew and remove the two fixing screws. • Disconnect the connector, then re- move the rear light unit.
Page 512 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the right footrest • Unscrew and remove both rear brake pump internal fixing screws. LEFT FOOTREST • Unscrew and remove the two external screws. • Loosen the gear shift lever rod screw. •...
Page 513 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the front expansion cap. • Release the fairing from its fasteners. • Remove the fairing. BODYW - 513...
Page 514 Caponord 1200 - Caponord 1200 Rally Bodywork • For the left side fairing, the cable of the saddle lock must be removed. OPTION 02 • The following procedure refers to one single vehicle side, but is valid for both. • Unscrew and remove the screw (1).
Page 515 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the expansion cap (4). • Release the side fairing (5) from its fas- teners. • For the left side fairing, the cable of the saddle lock (6) must be removed. • Once the left side fairing is removed, the lower fairing can be removed, as shown in the following.
Page 516 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the lower side fairing (2). License plate holder • Remove the cover (1). • Undo and remove the fixing screw (2). • Undo and remove the four fixing screws (3) and remove the plastic cov- er (4).
Page 517 Caponord 1200 - Caponord 1200 Rally Bodywork • Keeping the nuts (5) locked, undo and remove the two screws operating from the lower side of the tail fairing. • Collect the two washers (6). • Disconnect the connector (7). • Remove the clamp (8).
Page 518 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the connector (9). • Remove the license plate holder (10). Air box • Remove the air filter box cover. • Remove the four screws. • Remove the two intake ducts. See also Air filter BODYW - 518...
Page 519 Caponord 1200 - Caponord 1200 Rally Bodywork • Cut the ties. • Disconnect the air temperature sensor. • Remove the three clamps, disconnect the breather tubes and the recovery tube. • Remove the entire Blow-by tank air filter box. Splash guard OPTION 01 BODYW - 519...
Page 520 Caponord 1200 - Caponord 1200 Rally Bodywork • Operating from both sides, unscrew and remove the four fixing screws. • Remove the rear splash guard. OPTION 02 • Remove the expansion cap (1). BODYW - 520...
Page 521 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the two fixing screws (2). • Remove the mudflap (3). Fuel tank OPTION 01 Before accessing the tank (1), the side covers (2), the central cover (3) and the tank cap (4) must be removed.
Page 522 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the front fixing screw. • Remove the three expansion caps on the inside of the fairing. • Remove the internal upper expansion cap. BODYW - 522...
Page 523 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the front screw. • Remove the expansion cap placed on the side part of the fairing, near the turn indicator. • Disconnect the turn indicator connec- tor. • Remove the side plastic. •...
Page 524 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the four fixing screws of the tank cap. • Remove the tank cap. • Remove the tank central cover. • Undo and remove the two mounting fixing screws. BODYW - 524...
Page 525 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the level sensor. • Working from both sides, disconnect both breather pipes. • Unscrew and remove the two fixing screws that connect the tank to the un- derfairing. BODYW - 525...
Page 526 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the fuel pump connector. • Disconnect the fuel pipe from the pump. • Remove the tank. OPTION 02 • Remove the passenger and the rider saddle. • Remove the tail fairing. •...
Page 527 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the fixing screw (3). • Undo and remove the fixing screw (4). • Undo and remove the fixing screw (5). • Undo and remove the fixing screw (6). BODYW - 527...
Page 528 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the fixing screw (7). • Undo and remove the fixing screw (8). • Disconnect the turn indicator connec- tor (9). • Remove the side tank cover (10). BODYW - 528...
Page 529 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the four screws (11). • Remove the fuel tank cap (12). • Unscrew and remove the two fixing screws (13). • Remove the central cover (14). BODYW - 529...
Page 530 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the four fixing screws (15). • Remove the supporting clamp (16). • Disconnect the breather tubes placed under the front part of the vehicle. • Undo and remove the two nuts (17) and collect the two thrust washers.
Page 531 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the fuel tank (23). CAUTION DURING REFITTING OF THE FUEL TANK, FOR BOTH OP- TIONS CHECK THAT THE VENTS ARE NOT BLOCKED. TO AVOID CRUSHING, GENTLY PULL THE VENTS AS INDI- CATED AND BRING THE TANK IN ITS POSITION See also Seat...
Page 532 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the fuel pump connector (19). • Disconnect the preload pipe connector (20). • Disconnect the fuel pipe (21). Rear • Remove the lock and turn the key an- ticlockwise. BODYW - 532...
Page 533 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the case. • Repeat the operation for the case on the opposite side. Rear grab rail • Remove the passenger saddle. • Remove the plastic that covers the handgrip central fixing screw. •...
Page 534 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the two front fix- ing screws. • Unscrew and remove the two central fixing screws. • Disconnect the saddle lock by undoing the two screws. • Remove the handgrip. See also Seat Windscreen...
Page 535 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the four fixing screws of the top fairing paying atten- tion to recover the Teflon washers. • Remove the windscreen. • Pay special attention to the correct position of the Teflon washers when refitting. OPTION 02 •...
Page 536 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the windshield (3). • Remove the rubbers from the wind- shield (4). Instrument cluster support • Undo and remove the two instrument panel support fixing screws. • Remove the instrument panel paying attention to the cable harness.
Page 537 Caponord 1200 - Caponord 1200 Rally Bodywork Radiator cover • Undo and remove the three fixing screws of the expansion tank. • Remove the expansion tank. • Unscrew and remove the screw indi- cated in the figure. • Disconnect the connector of the ADD management control unit •...
Page 538 Caponord 1200 - Caponord 1200 Rally Bodywork • Disconnect the indicated connector. • Unscrew and remove the left fairing lug fixing screw. • Unscrew and remove the left fairing lug rear fixing screw. • Unscrew and remove the front fairing lug fixing screw.
Page 539 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the left fairing lug. • Unscrew and remove the two right fair- ing lug fixing screws. • Remove the right fairing lug. • Undo and remove the two upper fixing screws of the right duct bulkhead. BODYW - 539...
Page 540 Caponord 1200 - Caponord 1200 Rally Bodywork • Unscrew and remove the lower fixing screw of the right duct bulkhead. • Remove the right duct bulkhead. • Undo and remove the fairing lug lower screw. • Unscrew and remove the fixing screw of the left part of the fairing lug.
Page 541 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the fixing screw of the oil radiator support. • Undo and remove the fairing lug lower screw. • Undo the two upper fixing screws of the fairing lug. • Undo the radiator fixing screw.
Page 542 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the stud bolt. • Disconnect the radiator pipe. • Remove the expansion caps. • Separate the two radiators and remove the radiator protection. BODYW - 542...
Page 543 Caponord 1200 - Caponord 1200 Rally Bodywork Battery • Remove the saddle. • Unscrew and remove the eight fixing screws of the two covers. • Remove the two covers. • Disconnect the battery and remove it. Tail guard OPTION 01 •...
Page 544 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the two expansion caps. • Remove the rear handgrip and the li- cense plate support. • Remove the tail fairing. OPTION 02 • Remove the side panniers supports. • Remove the rear handle. •...
Page 545 Caponord 1200 - Caponord 1200 Rally Bodywork • Undo and remove the six fixing screws (2). • Remove the tail fairing (3). • Undo and remove the six fixing screws (4). • Remove the right (5) and left (6) tail fairing from the seat post closure (7).
Page 546 Caponord 1200 - Caponord 1200 Rally Bodywork Side air deflectors • Undo and remove the upper screw. • Unscrew and remove the front screw placed near the radiator. • Unscrew and remove the rear screw. • Remove the duct. BODYW - 546...
Page 547 Caponord 1200 - Caponord 1200 Rally Bodywork INSIDE FAIRING The following procedure refers to one single fair- ing, but is valid for both. • Cut and remove the clamp. • Remove the relay indicated in the fig- ure. • Disconnect the voltage regulator. •...
Page 548 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the relay box. • Cut and remove the clamp. BODYW - 548...
Page 549 Caponord 1200 - Caponord 1200 Rally Bodywork • Remove the inside fairing. BODYW - 549...
Page 550 INDEX OF TOPICS...
Page 551 PRE DE DELIVERY...
Page 552 Caponord 1200 - Caponord 1200 Rally 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 - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit...
Page 553 Caponord 1200 - Caponord 1200 Rally 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 554 Caponord 1200 - Caponord 1200 Rally 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)
Page 555 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Remove the TCEI M6 X 50 screw which fastens the antivibration weight. • Fit the rubber ring in the hand guards. • Position and fasten the top screw en- suring to insert the bushing between the hand guard and the handlebar fas- tening point.
Page 556 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Place the hand guards fastening them on the sides using TCEI M6 X 50 screw being careful when inserting the bush- ing. Caponord 1200 Rally - OPTION 02 The vehicle comes equipped with additional head- lamps clamped to the windscreen fixing brackets.
Page 557 Caponord 1200 - Caponord 1200 Rally Pre-delivery CAUTION THE PROTECTIVE SHEATH IN THE SUPPLY CABLES OF THE ADDITIONAL HEADLAMPS COULD, DURING THE AS- SEMBLY, LOOSE THE CORRECT POSITION AND UNCOV- ER THE SUPPLY CABLES AND RISK DAMAGE OR EVEN THE BREAKAGE OF THE SUPPLY CABLES. IF THIS OC- CURS, MALFUNCTION OR EVEN NON-USE OF THE ADDI- TIONAL HEADLAMPS CAN BE VERIFIED.
Page 558 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Insert the supply cable again inside the cable grommet (4) and refit the lower fork plate (2). • The clamp is visible in the point indica- ted in the figure. WARNING DURING THE PREVIOUSLY DESCRIBED OPERATIONS, IT IS POSSIBLE THAT THE ELECTRIC CONNECTOR OF THE ADDITIONAL HEADLAMP IS DISCONNECTED AND CAUSES THE NON- USE OF THE ADDITIONAL HEADLAMP.
Page 559 Caponord 1200 - Caponord 1200 Rally Pre-delivery BUMPERS • Insert the rubber (1) in the central bumper (2). • Insert the left bumper (3) in the central bumper (2). • Insert the two screws (4) adjusting them without tightening them. •...
Page 560 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Apply the protective decals included the kit on the frame and on both sides of the vehicle, as indicated in the figure. • Place the bumper as shown in the fig- ure. •...
Page 561 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Insert the fixing screw (6). • Fit the nut (7). • Tighten the screw (6) and the nut (7). • Position the top part of the left bumper in the middle of the adhesive label lo- cated on the frame.
Page 562 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Apply Loctite 243 to the screws (9). Screw them adjusting them without tightening them. • Insert the right bumper (10) in the cen- tral bumper (2) and follow the same fixing procedure of the left bumper. •...
Page 563 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Tighten the four fixing screws (9), left side and right side, to the torque of 10 Nm (7.38 lb ft). • Tighten the two screws (6) and the two nuts (7), left side and right side, to the torque of 50 Nm (36.88 lb ft).
Page 564 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Insert the four screws (4) in the proper seats present in the two side bumpers. • Insert the additional headlamps in the screws (4). • Insert the four washers (5) in both ad- ditional headlamps.
Page 565 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Insert two clamps (8) as indicated in the figure to fix the additional headlamp cables to the support bracket. • Insert two more clamps (8) as indicated in the figure to fix the additional head- lamp cables to the central bumper, in a way to make the two cables less visible from the front view.
Page 566 Caponord 1200 - Caponord 1200 Rally Pre-delivery Vertical adjustment • Loosen the relative nut (1). • Proceed with the alignment of the ad- ditional headlamp and then tighten it at the torque 10 Nm (7.38 lb ft). Horizontal adjustment • Directly act on the screw (2) turning it clockwise to align the light beam to- wards the road centre and anticlock-...
Page 567 Caponord 1200 - Caponord 1200 Rally Pre-delivery • 4 - Rubber ring • 5 - Washer • 6 - Self-locking nut • 7 - Bushing • 8 - TBEI screw • 9 - Elastic clip • 10 - Rubber ring •...
Page 568 Caponord 1200 - Caponord 1200 Rally Pre-delivery ASSEMBLING THE WINDSCREEN • Insert the two washers in the points in- dicated in the figure. • Insert the four rubber rings (1) in the windscreen (2). • Insert the windscreen (2) on the sup- port brackets.
Page 569 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Unscrew and remove the fixing screws (2). • Remove the cover (3) and the cover (4). • Insert the battery (5) in the battery sup- port. • Insert and tighten the fixing screw (6) of the positive pole (7).
Page 570 Caponord 1200 - Caponord 1200 Rally Pre-delivery • Insert the four bushings (3) in the prop- er seats and place the fixing holes of the oil sump guard (2) in the four spacers (4) on both vehicle sides. • Operating from both sides of the vehi- cle, insert and tighten the four fixing screws (5).
Page 571 ABS: 260, 452, 460 Air filter: 81, 518 Air temperature sensor: 193 Battery: 153, 173, 543 Brake: 238, 466–469, 471, 477–479 Brake calliper: 466, 467 Brake disc: 467, 468 Brake fluid: 477 Brake pads: 469, 471 Brake pump: 478, 479 Bulbs: CAN line: 261 Catalytic converter: 445...
Page 572 Fuel pump: 203, 372 Fuses: 158 Gearbox selector: 294 Handlebar: 375 Head cover: 82, 317, 318, 325 Headlight: 507 Helmet compartment: Identification: 12 Instrument panel: 504 Intake pressure sensor: 186 License plate holder: 516 Luggage rack: Magneto flywheel: 298, 300, 328, 352 Maintenance: 10, 74 Mudguard: Oil filter: 80...
Page 573 Tyres: 17 Use: 460 Warning lights: Water pump: 488 Wiring diagram: 133...

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APRILIA Caponord 1200 2016 Manual

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