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APRILIA DORSODURO 900 2017 Service Station Manual

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SERVICE STATION MANUAL

2Q000336

DORSODURO 900

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Page 1 SERVICE STATION MANUAL 2Q000336 DORSODURO 900...
Page 2: The Value Of Service
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 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE 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 PRE DE...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
DORSODURO 900 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8: Maintenance Rules
DORSODURO 900 Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
Page 9 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 10 DORSODURO 900 Characteristics • Grip the two connectors and disconnect them by pulling them in opposite directions. • If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air. •...
Page 11: Vehicle Identification
DORSODURO 900 Characteristics MAINTENANCE PROGRAMME SECTION CARRIED OUT AT THE SPECIFIED MILEAGE INTER- VALS. Vehicle identification Write down the chassis and engine number in the specific space in this booklet. The chassis number is handy when purchasing spare parts. CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.
Page 12: Weight And Dimensions
DORSODURO 900 Characteristics Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Max. length 2185 mm (86.02 in) Max width (measured at the handguards) 905 mm (35.63 in) Max height (at the windshield) 1185 mm (46.65 in) Wheelbase 1515 mm (59.65 in) Kerb weight 212 kg (467.38 lb) Weight fully loaded...
Page 13 DORSODURO 900 Characteristics Capacities CAPACITY Specification Desc./Quantity Fuel (reserve included) 11.5 l (2.53 UK gal; 3,03 US gal) Fuel reserve 3 l (0.66 UK gal; 0.79 US gal) Engine oil 3.0 l (without oil change filter)(0.66 UK gal; 0.79 US gal) 3.2 l (with oil filter change) (0.70 Uk gal;...
Page 14: Wheel Rims
DORSODURO 900 Characteristics Specification Desc./Quantity Frame and suspensions FRAME Specification Desc./Quantity Type Die-cast aluminium plates and high yield steel tube trellis. Steering tilt angle (with extended suspensions) 26° Trail 108 mm (4.25 in) SUSPENSIONS Specification Desc./Quantity Front Upside-down hydraulically operated telescopic fork. 41 mm (1.61 in) diam.
Page 15: Fuel Supply System
DORSODURO 900 Characteristics TYRES Specification Desc./Quantity Tyre (as standard) DUNLOP SPORTMAX QUALIFIER Front 120/70 ZR17" (58W) Front tyre pressure rider only: 2.3 bar (230 kPa) (33.36 PSI) rider + passenger: 2.4 bar (240 kPa) (34.81 PSI) Rear 180/55 ZR17" (73W) Rear tyre pressure rider only: 2.5 bar (250 kPa) (36.26 PSI) rider + passenger: 2.7 bar (270 kPa) (39.16 PSI)
Page 16 DORSODURO 900 Characteristics Front side OOLING YSTEM Pos. Description Type Quantity Torque Notes Electric fan fastening screws Self-tapping 3 Nm (2.21 lb ft) 4.2x22 Screw for fastening the radiator to M6x25 10 Nm (7.38 lb ft) the frame on the left-hand side Screws for fastening the radiator M6x25 10 Nm (7.38 lb ft)
Page 17 DORSODURO 900 Characteristics RONT FORK Pos. Description Type Quantity Torque Notes Fork feet closure screws M6x40 10 Nm (7.38 lb ft) Screw for fastening the ABS sensor M5x16 6 Nm (4.43 lb ft) to the right fork foot CHAR - 17...
Page 18 DORSODURO 900 Characteristics TEERING Pos. Description Type Quantity Torque Notes Steering headstock ring nut M25x1 Tightening torque 50 Nm (36.88 lb ft) (for steering assembly peri- od of adjustment) | Make two complete turns to the right and two complete turns to the left | Loosen the ring nut by making a 90°...
Page 19 DORSODURO 900 Characteristics GUARD Pos. Description Type Quantity Torque Notes Screws for fastening the anti-vibra- M6x50 10 Nm (7.38 lb ft) tion weights and the hand guards to the handlebar terminals Screws for fastening the upper U-bolt M8x25 25 Nm (18.44 lb ft) to the lower U-bolt Light switch closure screws 1.5 Nm (1.11 lb ft)
Page 20 DORSODURO 900 Characteristics LUTCH PUMP Pos. Description Type Quantity Torque Notes Clutch cylinder fastening screws M6x20 8 Nm (5.90 lb ft) Perform two tight- ening cycles Screw for fastening the pipe to the M10x1 25 Nm (18.44 lb ft) clutch pump Screws for fastening the clutch pump 10 Nm (7.38 lb ft) to the handlebars...
Page 21 DORSODURO 900 Characteristics RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Screw for fastening the pipe to the M10x1 25 Nm (18.44 lb ft) brake pump Screws for fastening the front brake 10 Nm (7.38 lb ft) pump to the handlebars CHAR - 21...
Page 22 DORSODURO 900 Characteristics EADLAMP Pos. Description Type Quantity Torque Notes Headlamp support fastening screw 10 Nm (7.38 lb ft) Front turn indicators fastening M5x16 3 Nm (2.21 lb ft) screws Screw for fastening the lower head- 7 Nm (5.16 lb ft) lamp support to the lower plate Turn indicator fastening nut 3 Nm (2.21 lb ft)
Page 23 DORSODURO 900 Characteristics OP FAIRING Pos. Description Type Quantity Torque Notes Screws for fastening the top fairing to Self-tapping 2 Nm (1.48 lb ft) the front headlamp 3.9x14 RONT BODYWORK Pos. Description Type Quantity Torque Notes Screw for fastening the front convey- M6x16 7 Nm (5.16 lb ft) ors to the radiator...
Page 24 DORSODURO 900 Characteristics Pos. Description Type Quantity Torque Notes Screws for fastening the conveyors M5x9 4 Nm (2.95 lb ft) to the tank Screws for fastening the starter as- M5x9 4 Nm (2.95 lb ft) sembly cover to the tank Front tank fastening screws 10 Nm (7.38 lb ft) RONT WHEEL...
Page 25: Front Brake Calipers
DORSODURO 900 Characteristics RONT BRAKE CALIPERS Pos. Description Type Quantity Torque Notes Screws for fastening the brake pipe M10x1 25 Nm (18.44 lb ft) to the callipers Screws for fastening the callipers to M10x1.25 50 Nm (36.88 lb ft) the fork stanchions Central part CHAR - 25...
Page 26 DORSODURO 900 Characteristics HASSIS Pos. Description Type Quantity Torque Notes Screw for fastening the shock ab- M10x30 50 Nm (36.88 lb ft) Pre-impregnated sorber backplate to the right side screw frame Screws fastening the sides to the en- M12x282 80 Nm (59.00 lb ft) Nuts on the left side gine Screws fastening the framework to...
Page 27 DORSODURO 900 Characteristics TAND Pos. Description Type Quantity Torque Notes Screw for fastening the stand to the M10x1.25 10 Nm (7.38 lb ft) plate Nut for fastening the stand to the M10x1.25 30 Nm (22.13 lb ft) Loctite 243 plate Peg for fastening the springs to the 7.5 Nm (5.53 lb ft) Loctite 243...
Page 28 DORSODURO 900 Characteristics UEL TANK Pos. Description Type Quantity Torque Notes Fuel cap fastening screws M5x12 5 Nm (3.69 lb ft) Rear fuel tank fastening screw M6x90 10 Nm (7.38 lb ft) Fuel pump fastening screw M5x16 6 Nm (4.43 lb ft) CHAR - 28...
Page 29: Gear Lever
DORSODURO 900 Characteristics EAR LEVER Pos. Description Type Quantity Torque Notes Pinion fastening screw M10x1.25x26 50 Nm (36.88 lb ft) Pre-impregnated screw Screw for fastening the peg to the M6x16 10 Nm (7.38 lb ft) gearshift lever Nut for ball joint 10 Nm (7.38 lb ft) Nut for ball joint 10 Nm (7.38 lb ft)
Page 30 DORSODURO 900 Characteristics EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screws for fastening the control unit M5x20 2.5 Nm (1.84 lb ft) to the base of the filter casing Fall sensor fastening screw M5x35 3 Nm (2.21 lb ft) Starter relay fastening screws M5x8 4.5 Nm (3.32 lb ft)
Page 31 DORSODURO 900 Characteristics OCKS Pos. Description Type Quantity Torque Notes Screws for fastening the ignition M8x40 Manual switch to the frame Hex head screws for fastening the M6x30 10 Nm (7.38 lb ft) saddle lock / battery compartment to the saddle mounting APOUR RECOVERY SYSTEM Pos.
Page 32 DORSODURO 900 Characteristics IR FILTER CASING Pos. Description Type Quantity Torque Notes Air temperature sensor fastening Self-tapping 3 Nm (2.21 lb ft) screw 2.9x12 Filter casing cover fastening screw M5x20 3 Nm (2.21 lb ft) Filter casing / divider fastening M5x20 3 Nm (2.21 lb ft) screws...
Page 33: Back Side
DORSODURO 900 Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Intake union fastener screw 12 Nm (8.85 lb ft) Loctite 242 RBW control unit fastener screw 3.50 Nm (2.58 lbf ft) Loctite 242 Injector fastener screw 12 Nm (8.85 lb ft) Loctite 242 Injection Throttle Body fastener 12 Nm (8.85 lb ft)
Page 34: Abs System
DORSODURO 900 Characteristics SYSTEM Pos. Description Type Quantity Torque Notes Screws for fastening the support to M6x25 10 Nm (7.38 lb ft) the engine and the ABS control unit Engine support fastening screws M6x35 10 Nm (7.38 lb ft) Nut for fastening the backplate to the 10 Nm (7.38 lb ft) support Screws for fastening spacers to the...
Page 35 DORSODURO 900 Characteristics EAR SUSPENSION Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw M10x50 50 Nm (36.88 lb ft) Pre-impregnated screw Lower shock absorber clamping M10x80 50 Nm (36.88 lb ft) screw CHAR - 35...
Page 36: Exhaust System
DORSODURO 900 Characteristics XHAUST SYSTEM Pos. Description Type Quantity Torque Notes Exhaust flange self-locking fastening 12.5 Nm (9.22 lb ft) Clamp for fastening the front mani- 7 Nm (5.16 lb ft) fold to the central manifold Clamp for fastening the rear manifold 7 Nm (5.16 lb ft) to the central manifold Screws for fastening the central...
Page 37: Rear Brake
DORSODURO 900 Characteristics EAR BRAKE Pos. Description Type Quantity Torque Notes Pin for fastening the lever to the right 25 Nm (18.44 lb ft) footrest support Screw for fastening the Pump to the M6x20 10 Nm (7.38 lb ft) right footrest support Fastener for securing the spring at- 6 Nm (4.43 lb ft) tachment pin to the right driver foot-...
Page 38 DORSODURO 900 Characteristics AILLIGHT Pos. Description Type Quantity Torque Notes Licence plate light fastening screws 5 Nm (3.69 lb ft) Rear turn indicator fastening screws M5x20 3 Nm (2.21 lb ft) Reflector fastening screw 3 Nm (2.21 lb ft) Licence plate light fastening nut 5 Nm (3.69 lb ft) Tail light upper fastening screw M5x16...
Page 39 DORSODURO 900 Characteristics NDER SADDLE COMPARTMENT Pos. Description Type Quantity Torque Notes Screws for fastening the battery cov- M5x16 3 Nm (2.21 lb ft) er to the under-saddle compartment Screws for fastening the battery M5x9 6 Nm (4.43 lb ft) compartment to the saddle mounting Elastic fastening screw Self-tapping...
Page 40: Head Cover
DORSODURO 900 Characteristics Pos. Description Type Quantity Torque Notes Screw for fastening the cover to the M4x12 3 Nm (2.21 lb ft) plate holder Engine EAD COVER Pos. Description Type Quantity Torque Notes Special head cover fastening screw 9 Nm (6.64 lb ft) CHAR - 40...
Page 41 DORSODURO 900 Characteristics IMING SYSTEM Pos. Description Type Quantity Torque Notes Cam shaft gear fastening nut M15x1 88 Nm (64.91 lb ft) Thoroughly de- grease both of the coupling surfaces (axle cone and gear cone) Timing lay shaft fastening screw M24x1.5 88 Nm (64.91 lb ft) 3M SCOTCH GRIP...
Page 42 DORSODURO 900 Characteristics Pos. Description Type Quantity Torque Notes Cam tower / head fastening screws M6x37 13 Nm (9.59 lb ft) Follow the number- ing sequence stam- ped on the cam tow- Cam tower / plate fastening screws M4x10 3 Nm (2.21 lb ft) 3M SCOTCH GRIP 2353 Decompressor fastening screws...
Page 43 DORSODURO 900 Characteristics YLINDER Pos. Description Type Quantity Torque Notes Chain tensioner fastener screw M6x30 13 Nm (9.59 lb ft) Cylinder plate fastening screw M6x16 9 Nm (6.64 lb ft) Chain tensioner adjustment screw 5 Nm (3.69 lb ft) CHAR - 43...
Page 44: Clutch Cover
DORSODURO 900 Characteristics LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover / Clutch side cover fas- 13 Nm (9.59 lb ft) tening screw Clutch fastening nut M24x1.5 177 Nm (130.55 lb ft) Chamfer Oil filler cap on clutch cover M25x1.25 2 Nm (1.48 lb ft) Clutch Control Plate / Support coun-...
Page 45 DORSODURO 900 Characteristics ATER PUMP Pos. Description Type Quantity Torque Notes Clutch side cover fixing screw M6x40 13 Nm (9.59 lb ft) Pump cover / Clutch side cover fas- M6x25 13 Nm (9.59 lb ft) tening screw Pump cover / Clutch cover / clutch M6x60 13 Nm (9.59 lb ft) side half-crankcase fastening screw...
Page 46 DORSODURO 900 Characteristics GNITION Pos. Description Type Quantity Torque Notes Spark plug 13 Nm (9.59 lb ft) Free wheel ring fastening screw M6x18 14 Nm (10.33 lb ft) 3M SCOTCH GRIP 2353 Rotor fastening screw - Crankshaft M14x1.5 191 Nm (140.87 lb ft) Thoroughly de- grease both of the coupling surfaces...
Page 47 DORSODURO 900 Characteristics RANKCASE Pos. Description Type Quantity Torque Notes Half-crankcase coupling screw M8x80 28 Nm (20.65 lb ft) Half-crankcase coupling screw M6x65 13 Nm (9.59 lb ft) Special oil calibration screw M10x1 14 Nm (10.33 lb ft) CHAR - 47...
Page 48 DORSODURO 900 Characteristics RANKCASE Pos. Description Type Quantity Torque Notes Crankcase-cylinder-head fastening M10x1.25x166 Distance-based tighten- SCOTCH GRIP stud bolts 2510 GREEN Bearing retainer fastening screws M6x12 10 Nm (7.38 lb ft) 3M SCOTCH GRIP 2353 or Loct. DRI- LOC 2045 BLUE Threaded plug M8x1 15 Nm (11.06 lb ft)
Page 49 DORSODURO 900 Characteristics EAR SELECTOR Pos. Description Type Quantity Torque Notes Gear sensor fastening screw 6 Nm (4.43 lb ft) Loct. 270 Selector plate fastening screw M5x12 5 Nm (3.69 lb ft) 3M SCOTCH GRIP 2353 Desmodromic drum/sprocket fasten- M8x1.25x17 15 Nm (11.06 lb ft) 3M SCOTCH GRIP ing screw...
Page 50: Overhaul Data
DORSODURO 900 Characteristics RANKSHAFT Pos. Description Type Quantity Torque Notes Primary crankshaft fastening net M24x1.5 294 Nm (216.84 lb ft) Thoroughly de- grease both of the coupling surfaces (shaft cone and gear cone) Connecting rod fastening screws - M10x1x40 15 Nm (11.06 lb ft) Lubricate the Pre-torque threads before tight-...
Page 51 DORSODURO 900 Characteristics Specification Desc./Quantity Fitting clearance 0.050 - 0.064 mm (0.00197 - 0.00252 in) Crankcase - crankshaft - connecting rod MARKINGS ON THE INSIDE OF THE CRANKCASES Crankcases selectable in two classes (1 or 2), based on the diameter of the main housing. The categories are indicated on both half-crankcases: •...
Page 52: Main Bearings
DORSODURO 900 Characteristics • crankcase • flywheel side block journal • clutch side block journal the bearings to be used for their coupling can be selected based on the following table. MAIN BEARINGS Block journal Crankcase class 1 Crankcase class 2 Block journal class 4 (l.v.) Half bearings A (red) Half bearings B (blue)
Page 53: Connecting Rods
DORSODURO 900 Characteristics ** 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 Removing the flywheel cover...
Page 54: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 55 DORSODURO 900 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 - 55...
Page 56 DORSODURO 900 Special tools Stores code Description 020714Y Dial gauge mount 9100896 Clutch bell stopper 020716Y Connecting stem lock 020470Y Pin snap ring fitting tool AP8140302 tool for installing seal rings 020718Y Camshaft gearwheel alignment pin S-TOOLS - 56...
Page 57 DORSODURO 900 Special tools Stores code Description 020719Y Timing pin 020720Y Timing tool AP8140179 Valve springs compressor 020721Y Valve removal adaptor 020376Y Adaptor handle 020629Y 8 mm guide (0.31 in) 020412Y 15mm oil seal guide S-TOOLS - 57...
Page 58 DORSODURO 900 Special tools Stores code Description 020439Y 17mm oil seal guide 020263Y Driven pulley assembly sheath 020365Y 22 mm guide (0.87 in) 020364Y 25-mm guide 020483Y 30-mm guide 020441Y Oil seals punch S-TOOLS - 58...
Page 59 DORSODURO 900 Special tools Stores code Description 020358Y 37 x 40 mm Adaptor 020357Y 32 x 35-mm Adaptor 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55-mm Adaptor 020724Y Punch cage with rollers gearbox control stem 020726Y Bushing extractor 020727Y Bushing punch S-TOOLS - 59...
Page 60 DORSODURO 900 Special tools Stores code Description 020884Y 46 mm wrench for steering ferrule AP8140180 Bearing extractor AP8140199 Tool storage panel 8140426 Hooks for panel Stores code Description AP8140149 Guard for assembly operations 020888Y Pre-load pipe clamp S-TOOLS - 60...
Page 61 DORSODURO 900 Special tools Stores code Description AP8140148 Plunger-spacer separator plate AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight AP8140150 Bored shaft for bleeding plunger air CAUTION BEFORE USING THE "PRIMARY GEARWHEEL LOCK TOOL - 020850Y", IT IS NECESSARY TO MAKE THREE HOLES SO THAT IT MAY BE POSITIONED CORRECTLY ON THE ENGINE GUARD.
Page 62 DORSODURO 900 Special tools S-TOOLS - 62...
Page 63: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 64: Scheduled Maintenance Table
DORSODURO 900 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 65 DORSODURO 900 Maintenance SCHEDULED MAINTENANCE TABLE RESERVED FOR THE USA-LATAM MARKET I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean, adjust or replace, if necessary, every 1000 Km (621 mi) (2) Replace every 2 years (3) Replace every 4 years (4) At each engine start...
Page 66: Recommended Products
DORSODURO 900 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. These indications also apply when topping up fluid levels.
Page 67: Engine Oil
DORSODURO 900 Maintenance • Remove the ignition coils. • Remove the spark plugs using a spe- cial key. • Check the distance between the elec- trodes using a thread thickness gauge. CAUTION DO NOT ATTEMPT IN ANY WAY TO CHANGE THE DIS- TANCE BETWEEN THE ELECTRODES.
Page 68 DORSODURO 900 Maintenance THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL. PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km (10 miles) IN EXTRA-URBAN CONDITIONS (ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE).
Page 69: Engine Oil Filter
DORSODURO 900 Maintenance Engine oil filter • Move the ABS control unit. • Drain the motor oil. • Remove the oil filter. • Screw a new engine oil filter. • Restore the correct engine oil level. CAUTION NEVER REUSE AN OLD FILTER. See also Replacement Air filter...
Page 70 DORSODURO 900 Maintenance • Remove the eight screws fixing the air filter cover. • Remove the filter case cover. • Operating from both ducts, turn the up- per part of the intake duct anticlock- wise and remove it. • Remove the filter element. COVER THE INTAKE DUCTS WITH A CLEAN CLOTH TO PREVENT FOREIGN BODIES FROM ENTERING THE IN- TAKE DUCTS.
Page 71: Checking The Valve Clearance
DORSODURO 900 Maintenance • Check the correct positioning of the fil- ter, making sure that the arrow printed on it is directed toward the steering clutch. Checking the valve clearance • Remove the fuel tank and the radiator. • Disconnect the coils and remove the spark plugs. •...
Page 72: Specific Tooling
DORSODURO 900 Maintenance • Secure the cam shafts in position using the dedicated timing pins. Specific tooling 020719Y Timing pin • Remove one cam shaft at a time • leave the other camshaft in position and secured by the timing pin. CAUTION IF BOTH CAMSHAFTS ARE REMOVED AT THE SAME TIME, THE ENGINE COULD ROTATE, RENDERING IT NEC-...
Page 73 DORSODURO 900 Maintenance 8. Calibrated pad 2.85 9. Calibrated pad 2.90 10.Calibrated pad 2.95 11.Calibrated pad 3.00 12.Calibrated pad 3.05 13.Calibrated pad 3.10 14.Calibrated pad 3.15 15.Calibrated pad 3.20 16.Calibrated pad 3.25 17.Calibrated pad 3.30 18.Calibrated pad 3.35 19.Calibrated pad 3.40 •...
Page 74: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 75 DORSODURO 900 Electrical system RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Coil fixing screw 13 Nm (9.59 lb ft) Screws for fastening the regulator to M6x20 10 Nm (7.38 lb ft) the frame ELE SYS - 75...
Page 76 DORSODURO 900 Electrical system EAR ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Screws for fastening the control unit M5x20 2.5 Nm (1.84 lb ft) to the base of the filter casing Fall sensor fastening screw M5x35 3 Nm (2.21 lb ft) Starter relay fastening screws M5x8 4.5 Nm (3.32 lb ft)
Page 77: Relay Layout
DORSODURO 900 Electrical system 1. fall sensor 2. Intake air pressure sensor 3. Intake air temperature sensor 4. Instrument panel 5. Engine control unit 6. Headlamp 7. Start-up relay 8. Front ABS sensor 9. Starter motor 10.Engine revolution sensor 11.Lambda probe 12.Rear ABS sensor 13.Coils 14.Main fuses...
Page 78 DORSODURO 900 Electrical system The following section defines the position of the vehicle wiring harness, how it is routed and fixed to the chassis, instrument holder arch brace and saddle post, any problems and special checks to be made on the cable connections and routing in order to achieve the vehicle's reliability objectives. Materials used and corresponding quantities The electrical system consists of the following wiring harnesses and parts: •...
Page 79 DORSODURO 900 Electrical system • 1 Spring washer • 2 Spring washers • 1 Starter motor nut • 3 Connector supports • 1 Edge gasket • 1 Connector clip Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure. 1.
Page 80: Front Side
DORSODURO 900 Electrical system • Check the rear stop switch connection • Check that the R&W connector is connected and routed correctly • Check that the right and left front turn indicators are connected and routed correctly • Check that the ignition switch assembly's antenna is connected and routed correctly •...
Page 81 DORSODURO 900 Electrical system TABLE A2 - CABLE ROUTE ON FRONT FRAME 1. Large clamp TABLE A3 - CABLE ROUTE ON FRONT FRAME 1. Canister support TABLE A4 - CABLE ROUTE ON FRONT FRAME 1. Large clamps TABLE B - CABLE ROUTE ON THE STEERING HEADSTOCK 1.
Page 82 DORSODURO 900 Electrical system TABLE B1 - CABLE ROUTE ON THE STEERING HEADSTOCK 1. Right hand column light switch 2. Antenna cable 3. Left hand column light switch 4. Ride by wire gas hand grip cable TABLE B2 - CABLE ROUTE ON THE STEERING HEADSTOCK 1.
Page 83 DORSODURO 900 Electrical system TABLE B4 - CABLE ROUTE ON THE STEERING HEADSTOCK 1. Ride by wire gas hand grip cable 2. Right hand column light switch TABLE B5 - CABLE ROUTE ON THE STEERING HEADSTOCK • Proceed as indicated in figure TABLE C - REGULATOR AND FLYWHEEL CONNECTORS 1.
Page 84 DORSODURO 900 Electrical system TABLE D - KEY ROUTE 1. Ignition switch 2. Antenna cable TABLE D1 - KEY ROUTE 1. Ignition switch 2. Antenna cable TABLE E - COLUMN LIGHT SWITCH CONNEC- TIONS 1. Large clamp 2. Rubber hood TABLE E1 - COLUMN LIGHT SWITCH CON- NECTIONS 1.
Page 85 DORSODURO 900 Electrical system TABLE E2 - COLUMN LIGHT SWITCH CON- NECTIONS 1. Large clamp 2. Rubber hood TABLE E3 - COLUMN LIGHT SWITCH CON- NECTIONS 1. Rubber hood 2. Column light switch cable TABLE F - FRONT ABS SENSOR ROUTE 1.
Page 86 DORSODURO 900 Electrical system TABLE F2 - FRONT ABS SENSOR ROUTE 1. cable supports 2. Front ABS sensor TABLE F3 - FRONT ABS SENSOR ROUTE 1. Small sized clamps TABLE F4 - FRONT ABS SENSOR ROUTE 1. Small clamp TABLE F5 - FRONT ABS SENSOR ROUTE 1.
Page 87 DORSODURO 900 Electrical system TABLE F6 - FRONT ABS SENSOR ROUTE 1. Front ABS sensor connector 2. Support for edges TABLE G - FAN AND REGULATOR CABLES ROUTE 1. Fan connector TABLE G1 - FAN AND REGULATOR CABLES ROUTE 1. Regulator TABLE G2 - FAN AND REGULATOR CABLES ROUTE 1.
Page 88 DORSODURO 900 Electrical system TABLE G3 - FAN AND REGULATOR CABLES ROUTE 1. Fan connector 2. Large clamp CAUTION THE FAN CONNECTOR MUST BE COUPLED CORRECTLY TO ITS COUNTERPART AND CLEARLY IDENTIFIED ON THE RADIATOR BY MEANS OF A CLAMP. TABLE G4 - FAN AND REGULATOR CABLES ROUTE 1.
Page 89 DORSODURO 900 Electrical system TABLE I - HORN FASTENINGS 1. Horn 2. Horn connectors TABLE I1 - HORN FASTENINGS 1. Horn connectors CAUTION THERE MUST BE NO CONTACT WHATSOEVER BETWEEN THE HORN AND ANY OTHER COMPONENT. TABLE L - INSTRUMENT PANEL CABLES ROUTE 1.
Page 90 DORSODURO 900 Electrical system TABLE L2 - INSTRUMENT PANEL CABLES ROUTE 1. Front right hand direction indicator connec- 2. Instrument panel connector 3. Front left hand direction indicator connector 4. Antenna connector TABLE L3 - INSTRUMENT PANEL CABLES ROUTE 1. Instrument panel connector 2.
Page 91 DORSODURO 900 Electrical system TABLE M - RIGHT AND LEFT COLUMN LIGHT SWITCH CABLES ROUTE 1. Front brake switch cable 2. Right light switch 3. Clamps 4. Ride by wire gas control 5. Rubber clamp TABLE M1 - RIGHT AND LEFT COLUMN LIGHT SWITCH CABLES ROUTE 1.
Page 92 DORSODURO 900 Electrical system Central part TABLE A - ASSEMBLY 1. Large clamp 2. Clamp TABLE A1 - ASSEMBLY 1. Regulator cable 2. Clamp 3. Pipe conduit TABLE A2 - ASSEMBLY 1. Clamps 2. Canister filter TABLE B - CHECK CONNECTION BETWEEN ENGINE WIRING HARNESS AND MAIN WIRING HARNESS 1.
Page 93 DORSODURO 900 Electrical system TABLE C - ENGINE EARTH 1. Main wiring harness earth cable 2. Engine wiring harness earth cable 3. Battery earth cable 4. Screw CAUTION IF THE SCREW (4) IS NOT FASTENED CORRECTLY IT MAY CAUSE THE VEHICLE TO CATCH FIRE CHECK THE TIGHTENING TOQUE WITH A DYNAMOMETER.
Page 94 DORSODURO 900 Electrical system TABLE E - STARTER MOTOR CABLE ROUTE 1. Elastic washers 2. Nut TABLE E1 - STARTER MOTOR CABLE ROUTE 1. Starter motor-relay cable CAUTION IF THE STARTER MOTOR - RELAY CABLE IS NOT FAS- TENED CORRECTLY IT MAY CAUSE THE VEHICLE TO CATCH FIRE.
Page 95 DORSODURO 900 Electrical system TABLE F - OIL PRESSURE BULB CABLE ROUTE 1. Oil pressure sensor 2. Small clamp CAUTION CHECK THAT THE TERMINAL IS CONNECTED CORRECT- LY AND THAT THE HOOD IS INSERTED IN THE BULB CORRECTLY. THE CAP LEG MUST BE BENT BY 180° AND FASTENED USING A CLAMP, AS INDICATED IN FIGURE.
Page 96 DORSODURO 900 Electrical system TABLE G2 - PROCEDURE FITTING THE ABS CONTROL UNIT CONNECTOR CORRECTLY • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 • If the initial position of the connector and the lever is not as indicated in the preceding operation, the connector will not couple correctly and the distance...
Page 97 DORSODURO 900 Electrical system TABLE I - CABLE ROUTE ON ABS SUPPORT BRACKET 1. Rear ABS sensor connector TABLE I1 - CABLE ROUTE ON ABS SUPPORT BRACKET 1. Large clamp 2. Rear ABS sensor connector TABLE L - ABS CABLES ROUTE 1.
Page 98 DORSODURO 900 Electrical system TABLE L2 - ABS CABLES ROUTE 1. ABS control unit connector 2. Large clamp CAUTION CHECK THAT THE ABS CONNECTOR IS CONNECTED CORRECTLY AND RESPECT THE PROCEDURE DESCRI- BED IN PARAGRAPH "G". TABLE M - REAR BRAKE AND REAR ABS SEN- SOR CABLES ROUTE 1.
Page 99 DORSODURO 900 Electrical system TABLE O - FRONT LAMBDA ROUTE 1. Front lambda probe connector 2. Large clamp TABLE O1 - FRONT LAMBDA ROUTE 1. Small clamp 2. Front lambda probe cable CAUTION CHECK THAT THE CLAMP (1) IS PRESENT AT THE POINT INDICATED IN FIGURE.
Page 100 DORSODURO 900 Electrical system TABLE P1 - REAR LAMBDA ROUTE 1. Rear lambda probe connector TABLE P2 - REAR LAMBDA ROUTE 1. Cable clamp TABLE P3 - REAR LAMBDA ROUTE 1. Small clamp 2. Cable clamp 3. Rear lambda probe cable TABLE Q - SIDE STAND ROUTE 1.
Page 101 DORSODURO 900 Electrical system TABLE Q1 - SIDE STAND ROUTE 1. Side stand connector TABLE Q2 - SIDE STAND ROUTE 1. Side stand connector • Route the stand switch cable as indi- cated in figure TABLE Q3 - SIDE STAND ROUTE 1.
Page 102 DORSODURO 900 Electrical system TABLE Q5 - SIDE STAND ROUTE 1. Side stand switch connector 2. Medium sized clamp • The clamp (2) ensures that the clutch pipe remains attached to the flywheel cable clamp CAUTION CHECK THAT THE SIDE STAND SWITCH CONNECTOR HAS BEEN CONNECTED CORRECTLY.
Page 103 DORSODURO 900 Electrical system Back side TABLE A - REAR WHEEL ABS SENSOR ROUT- 1. Rear ABS sensor 2. Small sized clamps TABLE A1 - REAR WHEEL ABS SENSOR ROUTE 1. Rear ABS sensor TABLE A2 - REAR WHEEL ABS SENSOR ROUTE 1.
Page 104 DORSODURO 900 Electrical system TABLE B1 - REAR NUMBER PLATE HOLDER AND DIRECTION INDICATOR CABLES ROUTE 1. Large clamps 2. Rear right turn indicator 3. Rear left turn indicator 4. Licence plate light TABLE B2 - REAR NUMBER PLATE HOLDER AND DIRECTION INDICATOR CABLES ROUTE 1.
Page 105 DORSODURO 900 Electrical system TABLE C2 - SADDLE SUPPORT PRE-ASSEM- 1. Clip for edges TABLE D - CLAMP FOR WIRING ON SADDLE SUPPORT 1. Clamps TABLE E - NUMBER PLATE SUPPORT CA- BLES ROUTE ON SADDLE SUPPORT 1. Pipe conduit 2.
Page 106 DORSODURO 900 Electrical system TABLE E2 - NUMBER PLATE SUPPORT CA- BLES ROUTE ON SADDLE SUPPORT 1. Pipe conduit 2. Clamp 3. Large clamp 4. Taillight connector TABLE F - FASTENING CABLES ON STARTER RELAY 1. Start-up relay 2. Relay booster cables 3.
Page 107 DORSODURO 900 Electrical system TABLE G - BATTERY ZONE CABLES ROUTE 1. Fuse box 2. Starter relay connector 3. Fall sensor 4. AMP option connector 5. Battery positive cable 6. Positive battery lead. TABLE G1 - BATTERY ZONE CABLES ROUTE 1.
Page 108 DORSODURO 900 Electrical system 5. Clamp 6. Clip for edges TABLE G4 - BATTERY ZONE CABLES ROUTE 1. Fuse box 2. Start-up relay 3. Clamp 4. Edge clamp TABLE H - REAR STOP AND REAR ABS SEN- SOR CONNECTIONS 1. Fuse box 2.
Page 109: General Wiring Diagram
DORSODURO 900 Electrical system General wiring diagram ELE SYS - 109...
Page 110 DORSODURO 900 Electrical system Key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. COMPLETE HEADLAMP 4. FRONT LEFT TURN INDICATOR 5. HIGH BEAM/LOW BEAM LIGHT 6. DAYLIGHT RUNNING LIGHT 7. LOW BEAM LIGHT RELAY 8. LIGHTS RELAY 9. HORN 10.LEFT LIGHT SWITCH 11.- 12.INSTRUMENT PANEL...
Page 111 DORSODURO 900 Electrical system 37.FAN 38.FAN CONTROL RELAY 39.RIGHT LIGHT SWITCH 40.AMP CONTROL UNIT 41.FUEL LEVEL SENSOR 42.FUEL PUMP 43.USB PORT (IF APPLICABLE) 44.ECU DIAGNOSTICS 45.FALL SENSOR 46.STAND SWITCH 47.GEAR SENSOR 48.REAR MAP SENSOR 49.FRONT MAP SENSOR 50.REAR MOTORIZED THROTTLE 51.FRONT MOTORIZED THROTTLE 52.INTAKE AIR TEMPERATURE SENSOR 53.WATER TEMPERATURE SENSOR...
Page 112: Checks And Inspections
DORSODURO 900 Electrical system 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; NOTE THAT THE DRAWING ALWAYS DEPICT THE CONNECTOR/COMPONENT VIEWED FROM THE WIRING HARNESS SIDE, I.E.
Page 113 DORSODURO 900 Electrical system Purpose of check: the purpose of this check is ensure that there are no interruptions or excess re- sistance (due to corroded terminals, for example) in the circuit under inspection. Tester: set the tester selector to the "continuity" symbol and place the probes of the tested at the two ends of the circuit.
Page 114: System Components
DORSODURO 900 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 Position: • on the vehicle: in the ignition switch as- sembly • connector: two way, grey colour, be- hind the instrument panel Electrical specifications •...
Page 115 DORSODURO 900 Electrical system • Immobilizer fault: aerial not working (open or short-circuited) Error cause • An electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting • Check the sensor connector on the cable harness and the instrument panel connector. If not OK, restore;...
Page 116 DORSODURO 900 Electrical system • At this point, a screen with a warning message will be visible. Press "OK" and start programming the keys. NOTE IF THE IMMOBILIZER ANTENNA IS DISCONNECTED, YOU WILL NOT BE ABLE TO START KEY PROGRAMMING. •...
Page 117: Recharging System
DORSODURO 900 Electrical system Diagnosis • In case of malfunction of certain or- gans, the digital display of the instru- ment panel may display errors. To check and diagnose the specific com- ponent, check the dedicated section. Azzeramento icona manutenzione The system displays the function as follows: •...
Page 118 DORSODURO 900 Electrical system Measurement of resistance (with engine off) • For a correct detection of the alternator resistance, an ambient temperature measurement must be carried out and afterwards a heat stabilisation (after turning fan on) by using a tester, using alternatively the 3 connector pins: stage "1"...
Page 119 DORSODURO 900 Electrical system • Effective resistance stage 1 = 0.65-0.47 = 0.18 Ohm • If there is a significant difference between one stage and another (other than 0.15 Ohm), this means that the alternator is defective and must be replaced. ESISTANCE MEASUREMENT Winding stage Ambient temperature (ohm)
Page 120 DORSODURO 900 Electrical system • Start the engine and with an ammeter clamp measure each single cable. • If there is a significant difference be- tween the measure of the single cables (other than 10 A), this means that the alternator is defective and must be re- placed.
Page 121 DORSODURO 900 Electrical system • on the vehicle: Right hand light switch. • connector: behind the steering head- stock, inside the protection case (black colour, 4 way). Electrical specifications: • key released: open circuit • key pressed: closed circuit Pin out: 1.
Page 122 DORSODURO 900 Electrical system • Check the locking cause and restore. Lights list Front headlamp Characteristic Front daylight running light 12V - 6W H6 Low beam light 12 V - 50 W H4 High beam light 12 V - 60 W H4 Taillight Characteristic Rear daylight running light /stop light...
Page 123 DORSODURO 900 Electrical system SECONDARY FUSES Before replacing the fuse, find, if possible, the cause of the problem. To check the secondary fuses: • Remove the elastic (1) and lift the rub- ber protective cover (2). • Open the cover of the secondary fuse box (3).
Page 124: Main Fuses
DORSODURO 900 Electrical system MAIN FUSES To check the main fuse (H) • Remove the protective cover (3), un- screwing the three screws (4). • Remove the protective cover, take out the fuse (H) and check whether the fil- ament (2) is broken. In this case change it with one of the same amper- age.
Page 125 DORSODURO 900 Electrical system CONTROL UNIT - Diagnosis Function It manages the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves the control unit Position: •...
Page 126 DORSODURO 900 Electrical system • Lambda probe voltage / - (indicates the value of the lambda probe voltage) • Atmospheric pressure / - (indicates the atmospheric pressure) • Objective minimum speed / - (minimum rpm required by the control unit) •...
Page 127 DORSODURO 900 Electrical system • Headlights relay / (activates the headlight relay) DIAGNOSTIC TOOL: ADJUSTMENTS • Self-adaptive param. reset / (self-adaptive parameter reset) • Saved data download / (save data files download) • TPS reset DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0601 EEPROM error Electrical diagnosis: •...
Page 128 DORSODURO 900 Electrical system The instrument panel indicates this error by lighting up in a fixed manner the MI warning light and by flashing the general warning light. NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. DIAGNOSTIC TOOL: LOGIC ERRORS P160C Level 2 safety reset Error cause: •...
Page 129 DORSODURO 900 Electrical system Troubleshooting • Perform the troubleshooting for the other detected errors. P1650 Engine events configuration Checksum calculation error Error cause: • Corrupt Flash-eeprom (hardware problem). • Upload (e.g. in service) of an incompatible software version, therefore missing the reference check-sum.
Page 130 DORSODURO 900 Electrical system Battery Function Provides electrical power to vehicle: the YTZ 12 BS battery is already activated, charged and sealed; Level in electrical circuit diagram: Battery charge Position: • on the vehicle: under the saddle • connector: on the battery Electrical specifications:12 V / 10 Ah Pin out: 1.
Page 131: Speed Sensor
DORSODURO 900 Electrical system The instrument cluster indicates the presence of this error with the MI warning light on fixed. Troubleshooting • If too high: check that the voltage regulator is working correctly. • If too low: check voltage regulator connectors, engine-vehicle wiring harness connector and ECU connector (check in particular for oxidation): if not OK, repair.
Page 132: Diagnostic Tool
DORSODURO 900 Electrical system Electrical circuit diagram - Level in electrical circuit diagram: ABS system Position on vehicle: On right-hand stanchion of fork, near the brake calliper mounting bracket. Position of connector (if applicable): On the filter housing, right side. Pin-out: •...
Page 133 DORSODURO 900 Electrical system • Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise, replace the speed sensor.
Page 134 DORSODURO 900 Electrical system Error cause: • ABS system malfunction Troubleshooting: • Connect to the ABS control unit diagnosis. REAR ABS VEHICLE SENSOR Function: Generates a signal used by the ABS control unit to determine the speed value of the wheel. Operation / Operating principle: Magneto-resistive sensor: generates a square wave signal with an amplitude of approximately 1V...
Page 135 DORSODURO 900 Electrical system side, with the sensor disconnected and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity with the vehicle ground connection: if it is grounded, restore the wiring harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check continuity of the yellow cable between PIN 1 of the sensor on the wiring harness side and PIN 12 of the ABS control unit connector.
Page 136: Engine Rpm Sensor
DORSODURO 900 Electrical system • Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed.
Page 137 DORSODURO 900 Electrical system Pin out: 1. positive signal 2. negative signal DIAGNOSTIC TOOL:PARAMETERS Engine rpm:rpm 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 138 DORSODURO 900 Electrical system The handle command is used to convert the driver's power demand to an electrical signal to be sent to the electronic control unit. Operation / Operating principle in the handle command there is an integrated double track potentiometer through which the torque demand is read (and verified).
Page 139 DORSODURO 900 Electrical system • open circuit, short circuit to negative: check the handle sensor connector and engine control unit connector, if not ok restore, if ok check cable continuity between the two terminals, if not ok restore, if ok check the ground insulation of the cable (from the handle sensor con- nector or control unit connector): if not ground insulated, restore the wiring harness, if ground insulated check, with key ON, that power supply is present at PIN 1 of the potentiometer and that the ground is present at PIN 2, if present correctly replace the handle sensor, if not...
Page 140: Intake Air Pressure Sensor
DORSODURO 900 Electrical system • Detected two voltages signals at PIN 39 and 13 of the ENGINE connector (tracks A-B) This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light.
Page 141 DORSODURO 900 Electrical system Front cylinder intake sensor Example value: 1003 mbar Pressure read through the front sensor. Rear cylinder intake sensor Example value: 1004 mbar Pressure read through the rear sensor. Front cylinder intake estimated pressure Example value: 1003 mbar Pressure estimated by the control unit, based on the throttle valve position Rear cylinder intake estimated pressure Example value: 1004 mbar...
Page 142 DORSODURO 900 Electrical system key in ON position) for continuity between PIN 3 on the sensor connector and ground: if NOT OK, restore the wiring harness; if OK, replace the sensor. P1105 Rear cylinder air pressure sensor Electrical diagnosis: • short circuit to positive / open circuit, short circuit to negative, signal not plausible.
Page 143 DORSODURO 900 Electrical system Troubleshooting: • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. P1601 Error due to unexpected air intake in the rear cylinder manifold Functional diagnosis: •...
Page 144 DORSODURO 900 Electrical system • A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the pipe between sensor and throttle body is fully detached/ clogged or squashed). This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light.
Page 145: Engine Temperature Sensor
DORSODURO 900 Electrical system Engine temperature sensor Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram: Temperature sensors Position: •...
Page 146 DORSODURO 900 Electrical system • If open circuit, short circuit to positive: check the sensor connector and the Marelli control unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if OK, check continuity between the ENGINE connector PIN 12 and the sensor PIN 3: If continuity is absent, restore the wiring harness;...
Page 147: Air Temperature Sensor
DORSODURO 900 Electrical system Air temperature sensor Function indicates to the control unit the temperature of the intake air, used to calculate the oxygen, to opti- mise the required fuel quantity for the correct com- bustion Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature) Level in the electrical circuit diagram:...
Page 148: Lambda Sensor
DORSODURO 900 Electrical system • open circuit, short circuit to positive / short circuit to negative Error cause • If open circuit, short circuit to positive: an excessive voltage was detected at PIN 37 of the ENGINE connector. If short circuit to negative: zero voltage detected. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Page 149 DORSODURO 900 Electrical system • Heater circuit: 7-9Ω at ambient temp. Pin out: 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white cable) 4. Heater power supply (white cable) DIAGNOSTIC TOOL:PARAMETERS Lambda probe •...
Page 150 DORSODURO 900 Electrical system Electrical continuity is required in the wiring for the relay to activate correctly: no errors are generated in case of no activation. DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0130 Front lambda probe Electrical diagnosis: • Short circuit to positive. Error cause: •...
Page 151 DORSODURO 900 Electrical system (PIN 3): if NOT OK, restore the wiring harness; if OK, check the continuity of the Green/ Black cable (between PIN 3 of the sensor connector and ENGINE PIN 32) and restore the wiring harness. • If open circuit, short circuit to negative: check the continuity from the probe connector (PIN 3 and 4) to the probe: if NOT OK, replace the probe;...
Page 152 DORSODURO 900 Electrical system the switching from "HIGH RATIO" to "LOW RATIO" is missing for a certain"adjusted" number of upper dead points (PMS or TDC). The instrument panel indicates this error by lighting up in a fixed manner the MI warning light. Troubleshooting: •...
Page 153 DORSODURO 900 Electrical system • Example value with key ON: about 3300 mV • Example value with engine on: 100-1000 mV If there is a short circuit at + 5 V or higher, the lambda probe parameter is not equal to the value read by the control unit, but a recovery value is displayed Lambda correction •...
Page 154 DORSODURO 900 Electrical system • Excessive voltage detected (battery voltage) at PIN 9 and 38 of the ENGINE connector. Caution: the "lambda probe" parameter is not the actual read value but a recovery value is displayed. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light. Troubleshooting: •...
Page 155 DORSODURO 900 Electrical system Troubleshooting • Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: if NOT OK, restore; if OK, check the continuity between the ENGINE connector PIN 9 and PIN 38 and restore the wiring harness.
Page 156 DORSODURO 900 Electrical system Injector Function Provide the correct amount of fuel at the correct time. Operation / Operating principle Injector coil is energised for the petrol passage to open Level in electrical circuit diagram: Coils and injectors Position: • on the vehicle: on the throttle body •...
Page 157 DORSODURO 900 Electrical system • The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel tank, on the right side of the filter housing; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to the control unit is closed to ground for 4 ms per each second.
Page 158: Fuel Pump
DORSODURO 900 Electrical system on the injector connector: if there is, restore the wiring harness of the filter housing; if not, replace the sensor. • If short circuit to negative: disconnect the injector connector, turn the key to ON and check if there is ground connection in the cable white/black: if the connection is present, restore the wiring harness, if not present replace the injector •...
Page 159 DORSODURO 900 Electrical system 1. + 12 V - Orange/Green colour, from the fuel pump to the power supply 2. ground - Blue colour - Section 1.5 3. + 12 V (signal) reserve sensor - Green/Grey colour - Section 0.5 4.
Page 160 DORSODURO 900 Electrical system Coil Function Spark generation Operation / Operating principle With inductive discharge Level in electrical circuit diagram: Coils and injectors Position: • on the vehicle: on the big end covers. • connector: For each coil 3 way black connector.
Page 161 DORSODURO 900 Electrical system Rear coils: The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel tank, on the right side of the filter housing. However, CHECK the relay identification with the cables colour - blue taping) for 5 seconds and the violet/grey coil cable is closed to ground for 2 ms per each second.
Page 162: Throttle Body
DORSODURO 900 Electrical system • Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil with the diagnostic tool and check the voltage at PIN 27 of the connector: if there is voltage, restore the wiring harness, if the voltage is 0, replace the coil. •...
Page 163 DORSODURO 900 Electrical system • Example value with key ON: 0,0° • Example value with engine on: -0.2° Reading the intake pressures, the system tries to balance the intake pressure through the front and rear cylinder, operating on the throttle valves positions: an acceptable value should be between -0.5 and +0.5 Potentiometer front throttle valve (degrees) •...
Page 164 DORSODURO 900 Electrical system is not engaged, at approximately ???? rpm the throttle valves opening s very small and the requested torque is very low (approximately 5-7°) Potentiometer 2 rear throttle valve (degrees) • Example value with key ON: 8.2° •...
Page 165 DORSODURO 900 Electrical system • Performed/Not performed Indicates if the self-learning with the diagnostic tool was performed/not performed: if it was performed one time, it will always remain performed unless a control unit EEPROM reset is carried out DIAGNOSTIC TOOL: ELECTRICAL ERRORS CAUTION IF ERRORS ARE DETECTED ON BOTH THROTTLE BODIES, CHECK ALSO THE CORRECT SUP- PLY OF THE CONTROL UNIT TO PIN 42.
Page 166 DORSODURO 900 Electrical system tinuity of the circuit between the two ends; if not ok, restore the wiring harness, if ok, check the ground insulation of the circuit (from the throttle body connector or control unit connec- tor); if ground insulated, check that at PIN 2of the throttle boy connector there is power supply (+5 V) and that at PIN 6 there is ground;...
Page 167 DORSODURO 900 Electrical system tor); if ground insulated, check that at PIN 2of the throttle boy connector there is power supply (+5 V) and that at PIN 6 there is ground; if they are correct, replace the throttle body. P2119 Front throttle valve command circuit Electrical diagnosis: •...
Page 168 DORSODURO 900 Electrical system tenths of an Ohm. Otherwise, restore the wiring harness; if ok, replace the complete throttle body. P2126 Rear throttle body potentiometer 2 Functional diagnosis: • Signal not plausible. Error cause: • Signal outside the specified value determined based on the values of the intake pressure. Troubleshooting: •...
Page 169 DORSODURO 900 Electrical system • Test failed. Error cause: • Position of the throttle valve stopper outside of the specified range (at each key ON). Troubleshooting: • Check the cleanliness of the throttle body and the intake duct. If ok, replace the throttle body. P1403 Front throttle valve recovery conditions detection (Tair,Twater) Functional diagnosis: •...
Page 170 DORSODURO 900 Electrical system • Position of the throttle valve, maintained by the springs, outside the specified range (at each key ON). The instrument panel indicates this error by lighting up in a fixed manner the MI warning light. Troubleshooting: •...
Page 171 DORSODURO 900 Electrical system • The throttle valve power supply voltage is too low to correctly perform the self-learning test (at each key ON). The instrument panel indicates this error by lighting up in a fixed manner the MI warning light. Troubleshooting: •...
Page 172: Engine Oil Pressure Sensor
DORSODURO 900 Electrical system • Using the diagnostic tool, erase the error, then perform the throttle self-learning procedure. If the error is displayed again, it may mean a mechanical problem at the throttle boy. • Check the cleanliness of the throttle body and the intake duct. Check if there are any me- chanical ruptures.
Page 173 DORSODURO 900 Electrical system Electrical specifications: - Pin out: 1. Voltage: 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 174 DORSODURO 900 Electrical system electric voltage, identifies the engaged gear and transmits the information via CAN to the instru- ment panel, the other for the idle indication whose voltage is reduced to zero if in the neutral position. Level in electrical circuit diagram: Start enable switches Position: •...
Page 175 DORSODURO 900 Electrical system DIAGNOSTIC TOOL: STATUSES Gearbox in neutral • Yes/No gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6 DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0914 Gear sensor • short circuit to positive or open circuit/ short circuit to negative. Error cause •...
Page 176 DORSODURO 900 Electrical system • on the vehicle: on the handlebar. • connector: on the sensor. Electrical specifications: • Clutch engaged: closed circuit (con- tinuity) • Clutch released: open circuit (infinite resistance). Pin out: 1. voltage 5V 2. ground lead CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING...
Page 177 DORSODURO 900 Electrical system • If the error is active only with the lever engaged: the problem is generated by the engaged clutch contact of the which is interrupted or by the released clutch contact which is in short circuit to ground. •...
Page 178: Bank Angle Sensor
DORSODURO 900 Electrical system Side stand functional diagnosis: up/down Troubleshooting: • Indication on the diagnostic tool always down: perform the connector check procedure: if not ok, restore; if ok, disconnect the two ends from the sensor and check the PIN 1 continuity to ground: if there is no continuity, restore cable harness;...
Page 179 DORSODURO 900 Electrical system 2. Signal - Pink/White colour, from VEHICLE PIN 65 to the fall sensor, passing through multiple connector - Section 0.5 3. Ground - Green/Pink colour, from ENGINE PIN6/PIN17 to the fall sensor, passing through multiple connector - Section 0.5 Electric fan circuit Function Activates coolant radiator fan...
Page 180 DORSODURO 900 Electrical system are generated if the relay fails to acti- vate 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 181: Run/Stop Switch
DORSODURO 900 Electrical system RUN/STOP switch Function Indicates the control unit if the rider wishes to en- able engine start-up or to keep the engine running. Operation / Operating principle If you want to stop the engine or to prevent it from starting, the switch must be open, meaning that PIN 78 of the VEHICLE connector of the Marelli control unit must not be grounded.
Page 182 DORSODURO 900 Electrical system cable: if it is missing, restore the wiring harness; if there is, check the ground insulation of the Yellow/Red cable: if there is continuity with the ground, restore the wiring harness; if ok, turn the key to OFF and perform the VEHICLE connector and engine-vehicle wiring harness connector check: if not ok, restore;...
Page 183 DORSODURO 900 Electrical system Engine pinout key: • PIN 1 - • PIN 2 - • PIN 3 - Motorised throttle valve (+) (rear cylinder) • PIN 4 - Analogic ground 2 • PIN 5 - Power ground • PIN 6 - Analogic ground 1 •...
Page 184 DORSODURO 900 Electrical system • PIN 20 - Engine rpm sensor (-) • PIN 21 - Throttle valve potentiometer 2 signal (rear cylinder) • PIN 22 - Front cylinder lambda probe (-) • PIN 23 - • PIN 24 - Intake pressure sensor signal (front cylinder) •...
Page 185 DORSODURO 900 Electrical system Vehicle pinout key: • PIN 53 - Front cylinder injector • PIN 54 - • PIN 55 - • PIN 56 - Clutch sensor • PIN 57 - Analogic ground 2 • PIN 58 - Engine start-up •...
Page 186 DORSODURO 900 Electrical system • PIN 74 - • PIN 75 - • PIN 76 - • PIN 77 - • PIN 78 - Engine stop input • PIN 79 - • PIN 80 - H CAN line Engine-vehicle connector pinout key: •...
Page 187 DORSODURO 900 Electrical system Dashboard Instrument panel pinout key: • PIN 1 - • PIN 2 - Antenna 1 • PIN 3 - Antenna 2 ELE SYS - 187...
Page 188 DORSODURO 900 Electrical system • PIN 4 - Oil temperature sensor • PIN 5 - • PIN 6 - Arrow reset • PIN 7 - Light relay • PIN 8 - • PIN 9 - Battery positive • PIN 10 - •...
Page 189: Abs Modulator
DORSODURO 900 Electrical system ABS Modulator ABS control unit pinout key: • PIN 1 - Power ground 1 • PIN 2 - Power ground 2 • PIN 3 - • PIN 4 - Ignition switched live • PIN 5 - H CAN line •...
Page 190 DORSODURO 900 Electrical system of the electric system and consequently its total mass. With this communication line, it was possible to avoid useless duplications of various sensors on the motorcycle, since the signals coming from them are divided among the three electronic processing units (instrument panel, control unit and ABS). •...
Page 191 DORSODURO 900 Electrical system 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. DIAGNOSTIC TOOL: ELECTRICAL ERRORS U1125 Frame counter "Sensor Box" CAN line diagnosis Electrical diagnosis: •...
Page 192 DORSODURO 900 Electrical system • In case of CAN error during acquisition, system warns that the procedure can not be com- pleted due to a communication problem on the CAN line. • If the signal is not plausible, there was a transcription error of the value of the rear wheel radius from the non volatile memory (EEPROM) to the volatile memory (RAM) at key ON.
Page 193: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 194 DORSODURO 900 Engine from vehicle HASSIS Pos. Description Type Quantity Torque Notes Screw for fastening the shock ab- M10x30 50 Nm (36.88 lb ft) Pre-impregnated sorber backplate to the right side screw frame Screws fastening the sides to the en- M12x282 80 Nm (59.00 lb ft) Nuts on the left side...
Page 195: Vehicle Preparation
DORSODURO 900 Engine from vehicle EAR LEVER Pos. Description Type Quantity Torque Notes Pinion fastening screw M10x1.25x26 50 Nm (36.88 lb ft) Pre-impregnated screw Screw for fastening the peg to the M6x16 10 Nm (7.38 lb ft) gearshift lever Nut for ball joint 10 Nm (7.38 lb ft) Nut for ball joint 10 Nm (7.38 lb ft)
Page 196 DORSODURO 900 Engine from vehicle • Disconnect the timing sensor (3) and the voltage regulator connectors (4). • Remove the three clutch pump fasten- ing screws (4). • Remove the clutch pump (5) and use the clamps to secure the pump so that the piston cannot fall out.
Page 197 DORSODURO 900 Engine from vehicle • Remove the two screws (6) used to fasten the pinion cover (7), taking care to retrieve the respective bushings. • Remove the cover (7). • Remove the two clutch pump support fastening screws (8). •...
Page 198 DORSODURO 900 Engine from vehicle • Remove the gear lever (11) • Disconnect the vehicle stand switch connector (12). • Remove the three screws (13) used to fasten the stand support. • Remove the stand support (14). ENG VE - 198...
Page 199 DORSODURO 900 Engine from vehicle • Remove the screw (15) used to fasten the pinion, retrieving the washer (16) and the spring washer (17) and taking care to reposition them correctly during reassembly. • Remove the pinion (18) and detach the drive chain (19).
Page 200 DORSODURO 900 Engine from vehicle • Remove the two screws (23) used to secure the cable clamp (24) positioned under the swingarm, and remove it. • Remove the two screws (25) used to fasten the right hand rider's footrest. • Disconnect the engine oil pressure sensor connector (26).
Page 201: Removing The Engine From The Vehicle
DORSODURO 900 Engine from vehicle • Remove the two screws (29) used to fasten the plate positioned under the steering headstock. • Move the complete ABS system (30) towards the outside so that it is easier to remove the engine. Removing the engine from the vehicle •...
Page 202 DORSODURO 900 Engine from vehicle • Access the left hand side of the motor- cycle, unscrew the front nut (3) and remove it. • Access the right hand side of the mo- torcycle, partially extract the central pin (4) and remove the spacer (5) position on the internal, left hand side of the frame.
Page 203 DORSODURO 900 Engine from vehicle • Position a central stand in order to sup- port the engine and a trestle under the rear of the motorcycle in order to raise • Lower the engine partially, unscrew the screws (13) used to fasten the earth cables to the engine, and remove them.
Page 204 INDEX OF TOPICS NGINE...
Page 205 DORSODURO 900 Engine Gearbox Diagram 1. Complete desmodromic 2. Fork 3. Primary fork 4. Fork shaft 5. complete index lever 6. Gear stopper lever spring 7. Threaded rod 8. Selector stopper plate 9. Screw 10.Selector shaft 11.Flat washer 14x30x1 12.Selector spring 13.Threaded rod M8x1.25 14.Selector sprocket 15.Gear selector drum...
Page 206: Gearbox Shafts
DORSODURO 900 Engine 17.Spring 18.Tip for spring 19.Domed head torx screw 20.O-Ring 21.Gear sensor 22.Spacer 23.O-Ring 24.Selector stopper 25.Self-locking nut Gearbox shafts Gearbox shafts diagram Key: 1. Primary transmission shaft Z=14 2. 2nd gear on primary Z=17 3. 3rd - 4th gear on primary Z=20/22 4.
Page 207 DORSODURO 900 Engine 8. Shoulder washer 9. Shoulder washer 10.Snap ring 11.Floating bushing 12.Secondary transmission shaft 13.1st gear on secondary Z=36 14.2nd gear on secondary Z=32 15.3rd gear on secondary Z=30 16.4th gear on secondary Z=28 17.5th gear on secondary Z=26 18.6th gear on secondary Z=25 19.Floating bushing 20.Shoulder washer...
Page 208 DORSODURO 900 Engine • 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. • Remove the shim. • Carefully turn the engine support. •...
Page 209: Gear Selector
DORSODURO 900 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 210 DORSODURO 900 Engine EAR SELECTOR Pos. Description Type Quantity Torque Notes Gear sensor fastening screw 6 Nm (4.43 lb ft) Loct. 270 Selector plate fastening screw M5x12 5 Nm (3.69 lb ft) 3M SCOTCH GRIP 2353 Desmodromic drum/sprocket fasten- M8x1.25x17 15 Nm (11.06 lb ft) 3M SCOTCH GRIP ing screw...
Page 211: Specific Tooling
DORSODURO 900 Engine Selector plate spring With a thickness gauge, check that the spring is not deformed by over-stretching. Gearbox Selector Shaft Removal • Place the left hand crankcase in a press and extract the roller cage with the specific tool. NOTE REPEAT THE SAME OPERATION FOR THE RIGHT HAND CRANKCASE HALF.
Page 212: Starter Motor
DORSODURO 900 Engine Starter motor GNITION Pos. Description Type Quantity Torque Notes Spark plug 13 Nm (9.59 lb ft) Free wheel ring fastening screw M6x18 14 Nm (10.33 lb ft) 3M SCOTCH GRIP 2353 Rotor fastening screw - Crankshaft M14x1.5 191 Nm (140.87 lb ft) Thoroughly de- grease both of the...
Page 213: Removing The Starter Motor
DORSODURO 900 Engine Removing the starter motor • In order to remove the starter motor complete with the support bracket, it is necessary to remove the two screws (1). • If the bracket needs to be removed from the starter motor, first remove the two screws (2) and then the other screws (1).
Page 214 DORSODURO 900 Engine Pos. Description Type Quantity Torque Notes Bracket to starter motor fastening M6x14 7 Nm (5.16 lb ft) Loct. 242 screw Starter motor bracket to crankcase M6x16 13 Nm (9.59 lb ft) fastening screw Removing the flywheel cover •...
Page 215: Magneto Flywheel Removal
DORSODURO 900 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 216 DORSODURO 900 Engine • Remove the tool from the rotor and re- move the screw complete with the washer. • Screw the special tool's left-handed pin onto the outer body. • Keeping the outer body blocked, screw in the pin in such a way as to extract the flywheel from the crankshaft.
Page 217: Installing The Flywheel
DORSODURO 900 Engine • Remove the starter's transmission gear bearing. • In the event of a malfunction, the start- er's transmission gear bearing cannot be overhauled and must be completely replaced. Freewheel removal • Heat the magneto flywheel with the specific heater.
Page 218 DORSODURO 900 Engine • Apply the flywheel to the crankshaft. • Apply the screw and the washer with- out tightening. • Position the appropriate tool to lock the flywheel in place. • Holding the flywheel still using the ap- propriate tool, tighten the screw on the crankshaft.
Page 219 DORSODURO 900 Engine Clutch side LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover / Clutch side cover fas- 13 Nm (9.59 lb ft) tening screw Clutch fastening nut M24x1.5 177 Nm (130.55 lb ft) Chamfer Oil filler cap on clutch cover M25x1.25 2 Nm (1.48 lb ft) Clutch Control Plate / Support coun-...
Page 220 DORSODURO 900 Engine LUTCH Pos. Description Type Quantity Torque Notes Clutch spring fastening screw 12 Nm (8.85 lb ft) ATER PUMP Pos. Description Type Quantity Torque Notes Clutch side cover fixing screw M6x40 13 Nm (9.59 lb ft) Pump cover / Clutch side cover fas- M6x25 13 Nm (9.59 lb ft) tening screw...
Page 221: Removing The Clutch Cover
DORSODURO 900 Engine Pos. Description Type Quantity Torque Notes Pump cover / Clutch cover / clutch M6x60 13 Nm (9.59 lb ft) side half-crankcase fastening screw Water pump control crown fastening 12 Nm (8.85 lb ft) Loct. 244 Water pump impeller (brass insert) 4 Nm (2.95 lb ft) Flanged hex head screw for fasten- M6x12...
Page 222 DORSODURO 900 Engine Pos. Description Type Quantity Torque Notes Flywheel side clutch control support / 13 Nm (9.59 lb ft) half-crankcase fastening screw Based on the engine design development, there are two types of clutch crankcases, associated to the specific water pumps. The second generation cover is distinguished through punch marks, as indicated in the image.
Page 223: Disassembling The Clutch
DORSODURO 900 Engine • upon refitting, before tightening the clutch nut, check that the measure has not changed. If it is different, turn the crank shaft in such a way as to properly align the engine's oil pump control gear on the clutch bell with the oil pump's driven gear.
Page 224 DORSODURO 900 Engine • Remove the thrust plate. • Remove the mushroom-head clutch control rod • Remove the discs. • Block the clutch bell using the appro- priate tool and unscrew the nut on the hub. Specific tooling 9100896 Clutch bell stopper ENG - 224...
Page 225 DORSODURO 900 Engine • Remove the disc spring. • Remove the clutch hub. • Remove the special washer between the clutch hub and the clutch bell. • Remove the clutch bell. ENG - 225...
Page 226: Checking The Clutch Plates
DORSODURO 900 Engine • Retrieve the spacer and the roller bear- ings. • Retrieve the shim. 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 227: Checking The Clutch Housing
DORSODURO 900 Engine MUSHROOM VALVE CHECK • Check if the valve slides freely, without jamming. • Blow compressed air into the valve and check that the lubricating oil passage holes open. Checking the clutch housing • Remove the clutch bell. •...
Page 228 DORSODURO 900 Engine Check for the presence of any damage or signs of wear on the primary driven gear, and replace the primary transmission's driven gear and the clutch bell, if necessary. Verify that the noise level is not too high during operation; replace the primary transmission's driven gear and the clutch bell, if necessary.
Page 229: Assembling The Clutch
DORSODURO 900 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 230: Specific Tooling
DORSODURO 900 Engine • Position the clutch hub. • Install the clutch cover. • Before tightening the clutch nut, check to make sure that the measurement has not changed with respect to that which was measured during the disas- sembly phase. If it is different, turn the crank shaft in such a way as to properly align the engine's oil pump control gear on the clutch bell with the oil pump's...
Page 231 DORSODURO 900 Engine • After having tightened the nut, proceed with the chamfering. • Insert the flat ring (1). • Insert the disc ring (2). CAUTION MAKE SURE THE DISC RING IS INSERTED FACING THE RIGHT DIRECTION; THE RING'S CONE MUST BE FACING THE ENGINE.
Page 232 DORSODURO 900 Engine • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally. • Replace the gasket upon refitting. Head and timing EAD COVER Pos. Description Type Quantity Torque Notes Special head cover fastening screw 9 Nm (6.64 lb ft) ENG - 232...
Page 233 DORSODURO 900 Engine Pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 20 Nm (14.75 lb ft) Threaded plug M12x1.5 10 Nm (7.38 lb ft) Loct. drise AL 506 Nut for fastening the stud bolts to the M10x1.25 13 Nm (9.59 lb ft) Lubricate the head - Pre-tightening threads before tight-...
Page 234: Removing The Head Cover
DORSODURO 900 Engine Removing the head cover The following operations are valid for both of the heads. • Unscrew and remove the four screws, and retrieve the rubber blocks. • Remove the head cover. Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO THE REMOVAL OF ONE HEAD ONLY, BUT ARE VALID FOR BOTH.
Page 235: Cylinder Head
DORSODURO 900 Engine Cylinder head Pos. Description Type Quantity Torque Notes Water Temperature Sensor M12x1.5 20 Nm (14.75 lb ft) Threaded plug M12x1.5 10 Nm (7.38 lb ft) Loct. drise AL 506 Nut for fastening the stud bolts to the M10x1.25 13 Nm (9.59 lb ft) Lubricate the...
Page 236: Removing The Valves
DORSODURO 900 Engine Removing the overhead camshaft • Remove the clutch side crankcase. • Turn the crankshaft of the head for which the camshafts need to be re- moved to TDC. In order to remove the head camshafts, it is nec- essary to remove the head covers.
Page 237 DORSODURO 900 Engine • Remove the bucket tappets and the adjustment shims using a magnet. • Compress the valve springs with the specific wrench and with the spring compressing tool. Specific tooling AP8140179 Valve springs compressor 020721Y Valve removal adaptor •...
Page 238 DORSODURO 900 Engine • Release the valve springs. • Remove the valve spring fittings and the springs. • Remove the valves. Checking the overhead camshaft Check that the camshaft toothed wheel works properly: if it is damaged or does not move smoothly, replace both the timing chain and the camshaft toothed wheel.
Page 239: Valve Check
DORSODURO 900 Engine • a: 35.13 / 35.17 mm (1.3831 / 1.3846 in); Limit: 35.00 mm (1.3779 in); • b: 28 mm (1.1023 in); • Fasten the camshaft in horizontal po- sition, as shown in the figure, and make it spin to check the eccentricity with a dial gauge;...
Page 240: Valve Springs
DORSODURO 900 Engine Check the valve eccentricity: valve stem (3) maximum eccentricity allowed: 0.05 mm (0.00197 in) valve head (4) maximum eccentricity allowed: 0.05 mm (0.00197 in) Check that the fixing grooves (5) of the valve cot- ters are in proper conditions. VALVE SPRINGS Carry out a measurement and a visual inspection of the valve springs for damage, distortion or loss...
Page 241: Timing System
DORSODURO 900 Engine Timing IMING SYSTEM Pos. Description Type Quantity Torque Notes Cam shaft gear fastening nut M15x1 88 Nm (64.91 lb ft) Thoroughly de- grease both of the coupling surfaces (axle cone and gear cone) Timing lay shaft fastening screw M24x1.5 88 Nm (64.91 lb ft) 3M SCOTCH GRIP...
Page 242 DORSODURO 900 Engine Pos. Description Type Quantity Torque Notes Special mobile / fixed slider fastening 18 Nm (13.28 lb ft) 3M SCOTCH GRIP screw 2353 Cam tower / head fastening screws M6x37 13 Nm (9.59 lb ft) Follow the number- ing sequence stam- ped on the cam tow- Cam tower / plate fastening screws...
Page 243: Chain Removal
DORSODURO 900 Engine Removing the chain tensioner • Unscrew and remove the screw, and retrieve the washer and the internal spring. • Unscrew and remove the two screws. • Remove the chain tensioner and re- trieve the gasket. Chain removal •...
Page 244: Front Head
DORSODURO 900 Engine • Extract the timing chain from the crank- shaft. NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED. • Remove the timing chain complete with the gear. See also Removing the chain sliders...
Page 245: Rear Cylinder Head
DORSODURO 900 Engine • Unscrew and remove the fixed chain tensioner slider's screw. • The head must be removed in order to remove it. REAR CYLINDER HEAD • In order to remove the rear head's chain sliders, it is necessary to remove the flywheel.
Page 246: Cam Timing
DORSODURO 900 Engine Installing the chain tensioner • Fit the chain tensioner body on the cyl- inder and insert a new paper gasket. • Tighten the two screws to the prescri- bed torque. • Insert the spring and tighten the screw together with the washer.
Page 247 DORSODURO 900 Engine • Rotate the crankshaft anticlockwise until the front cylinder piston is posi- tioned at top dead centre, while check- ing that there is sufficient play on the camshafts. • The front cylinder top dead centre po- sition must correspond to position (A). If necessary, remove the distribution gearwheels from the cam shafts: •...
Page 248: Specific Tooling
DORSODURO 900 Engine • Align the play compensation gear- wheel with the main distribution gear- wheel using the dedicated tool. Specific tooling 020718Y Camshaft gearwheel alignment pin • Position the cam tower. • Tighten the screws provisionally. • Time the camshafts, using the appro- priate pins.
Page 249: Removing The Cylinder
DORSODURO 900 Engine • Remove the gearwheel alignment tool. Specific tooling 020718Y Camshaft gearwheel alignment pin • Reposition the cam tower and the cam- shafts, applying the pre-defined tight- ening torque. • Rotate the camshaft anticlockwise until the rear cylinder piston is at TDC (B). •...
Page 250: Disassembling The Piston
DORSODURO 900 Engine • Remove the gasket on the cylinder base. See also Chain removal Removing the cylinder head Disassembling the piston • Remove the big end and the cylinder. • Extract the pin locking ring. • Lock the connecting rod using the spe- cific tool.
Page 251 DORSODURO 900 Engine • Lock the connecting stem with elastic straps FOR SAFETY REASONS, COVER THE CRANKCASE WITH A CLEAN MATERIAL TO AVOID THE FALL OF THE SAFE- TY RINGS IN THE CRANKCASE. • Remove the upper ring, the second ring and the oil ring.
Page 252: Checking The Cylinder
DORSODURO 900 Engine Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions. • Check cylinder sliding surface for signs of friction and scratches. Also check the seal sur- faces for damages.
Page 253: Piston Rings
DORSODURO 900 Engine PISTON RINGS • Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves. • Measure the piston ring side clearance and replace the piston and the piston rings all together if not complying with specifications.
Page 254: Fitting The Piston
DORSODURO 900 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) • Measure the pin housing diameter (b) and replace the piston if not complying with specifications.
Page 255 DORSODURO 900 Engine • The elastic bands are different from one another, and must be mounted with the "N" marking facing upwards. • Apply the lower oil scraper ring to the piston with the opening facing the out- put side. •...
Page 256: Installing The Cylinder
DORSODURO 900 Engine • Position the piston on the connecting rod and insert the pin using the appro- priate tool. Specific tooling 020470Y Pin snap ring fitting tool • Insert the piston's missing stopper ring using the appropriate tool, as descri- bed above, to lock the pin in place.
Page 257 DORSODURO 900 Engine • Using the band tightener, compress the piston's bands and insert the cylin- der onto the stud bolts. NOTE BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL. See also Selecting the base gasket Selecting the base gasket •...
Page 258: Installing The Cylinder Head
DORSODURO 900 Engine 020714Y Dial gauge mount • Turn the crankshaft to TDC (the rever- sal point of the dial gauge's rotation). • Lock the crankshaft at TDC using the appropriate tool. • Calculate the difference between the two measurements: use the chart be- low to identify the thickness of the cyl- inder base gasket to be used for refitting.
Page 259 DORSODURO 900 Engine • Position the gasket on the cylinder base. • Insert the head onto the stud bolts. • Apply the nuts (1) to the stud bolts and tighten them to the required torque val- ue, proceeding in a crossover fashion. •...
Page 260 DORSODURO 900 Engine BEFORE REMOVING THE BIG END COVERS, CAREFULLY CLEAN THE SURFACES OF THE BIG END AND THE COVER. CAUTION REPLACE THE FOUR RUBBER INSERTS AND THE GASKET EACH TIME THE BIG END COVER IS REMOVED. • Apply THREEBOND around the perim- eter of the big end cover along the gasket housings.
Page 261: Crankcase - Crankshaft
DORSODURO 900 Engine Crankcase - crankshaft RANKCASE Pos. Description Type Quantity Torque Notes Crankcase-cylinder-head fastening M10x1.25x166 Distance-based tighten- SCOTCH GRIP stud bolts 2510 GREEN Bearing retainer fastening screws M6x12 10 Nm (7.38 lb ft) 3M SCOTCH GRIP 2353 or Loct. DRI- LOC 2045 BLUE Threaded plug M8x1...
Page 262 DORSODURO 900 Engine RANKCASE Pos. Description Type Quantity Torque Notes Half-crankcase coupling screw M8x80 28 Nm (20.65 lb ft) Half-crankcase coupling screw M6x65 13 Nm (9.59 lb ft) Special oil calibration screw M10x1 14 Nm (10.33 lb ft) ENG - 262...
Page 263 DORSODURO 900 Engine RANKSHAFT Pos. Description Type Quantity Torque Notes Primary crankshaft fastening net M24x1.5 294 Nm (216.84 lb ft) Thoroughly de- grease both of the coupling surfaces (shaft cone and gear cone) Connecting rod fastening screws - M10x1x40 15 Nm (11.06 lb ft) Lubricate the Pre-torque threads before tight-...
Page 264 DORSODURO 900 Engine 020850Y Primary gear lock • Heat up the crankshaft gearwheel re- taining nut using a suitable heater • Remove the nut and the flat washer. • Remove the motor pinion locking tool. • Using a generic extractor tool, remove the water pump gearwheel (4) and the primary drive gearwheel (5) simultane- ously.
Page 265 DORSODURO 900 Engine • Remove the gearbox control rod, tak- ing care to retrieve the washer. • Heat up the gearbox selector support plate screws. • Unscrew the three gearbox selector plate fastening screws and remove them.. • Remove the plate. ENG - 265...
Page 266 DORSODURO 900 Engine • Press the springs on the selector sprocket simultaneously in order to re- move it. • Unscrew the threaded pin used to fas- ten the selector drum and remove it. • Move the index lever to one side so that it is possible to remove the selector drum.
Page 267 DORSODURO 900 Engine • Remove the clutch control rod. • Working on the left hand side, unscrew and remove the nine M8 crankcase fastener screws. • Working on the left hand side, unscrew and remove the nine M6 crankcase fastener screws. •...
Page 268: Removing The Crankshaft
DORSODURO 900 Engine • Rotate the engine and the engine sup- port to the horizontal position. • Using a rubber mallet, strike the guards gently in order to separate them. • Open the guards. • If necessary, unscrew the two pick-up tube fastening screws and remove them.
Page 269 DORSODURO 900 Engine Inspecting the crankcase halves BEARINGS AND OIL SEAL CHECK Thoroughly clean the two sections of the crankcase, the ball bearings, the threads of the crankcase fixing screws and the bearing seats with a non-aggressive solvent. Clean the seal surfaces and check that they are not damaged.
Page 270 DORSODURO 900 Engine • Replace the O-ring on the oil passage duct. Before refitting UPON REFITTING THE CRANKSHAFT, GREASE THE SHAFT BUSHING-CONNECTING ROD COUPLING. Inspecting the crankshaft components Checking crankshaft endfloat • The shaft axial clearance on the crank- case should be checked with a dial gauge mounted on the specific dial gauge support.
Page 271 DORSODURO 900 Engine • Remove the bushings with the crank- case cold, using a press and the spe- cific tool and pushing inward from the outside of the crankcase. Specific tooling 020726Y Bushing extractor Installing • The orientation of the semi-bushings must match the specifications indica- ted in the drawing as closely as possi- ble.
Page 272: Installing The Crankshaft
DORSODURO 900 Engine Installing the crankshaft • Place the left side crankcase half on the engine support adequately. • Place the crankshaft on the seat of the crankcase half with caution. Refitting the crankcase halves • In order to reposition the guards, repeat the procedure described in the section "OPENING THE GUARDS"...
Page 273 DORSODURO 900 Engine Conceptual diagrams Key: 1. Filter head support. 2. Oil pump. 3. Oil pressure regulator valve. 4. Oil pressure sensor. ENG - 273...
Page 274 DORSODURO 900 Engine 5. Oil filter. 6. Oil pressure regulator screw. 7. Secondary transmission shaft lubrication. 8. Primary transmission shaft lubrication. 9. Clutch discs lubrication. 10.Oil pressure sensor. 11.Main bushing lubrication. 12.Piston oil jets. 13.Water pump shaft lubrication. 14.Distribution command gearwheels. 15.Front big end cam axis.
Page 275: Oil Pump
DORSODURO 900 Engine Oil pump UBRICATION Pos. Description Type Quantity Torque Notes Oil drainage plug M16x1.5 17 Nm (12.54 lb ft) +/- Oil pressure sensor M10x1 13 Nm (9.59 lb ft) Fitting fixing of the oil filter 20 Nm (14.75 lb ft) ENG - 275...
Page 276 DORSODURO 900 Engine Pos. Description Type Quantity Torque Notes Oil filter 14 Nm (10.33 lb ft) Oil pressure regulation valve M16x1.5 41 Nm (30.24 lb ft) Oil pump / bulkhead fastening M6x45 5 Nm (3.69 lb ft) 3M SCOTCH GRIP screws 2353 Strainer fastening screws...
Page 277 DORSODURO 900 Engine • Retrieve the shim. • Undo and remove the two screws fixing the oil pump. • Remove the entire pump. Inspection • Undo and remove the two fixing screws. ENG - 277...
Page 278 DORSODURO 900 Engine • Using a thickness gauge check clear- ance between rotor and stator and re- place the rotor / stator unit if necessary. clearance between rotor and stator: 0.04 ± 0.10 mm (0.0016 in - 0.0039 in). • Slide off the shaft with the cover.
Page 279 DORSODURO 900 Engine • Remove the oil pump stator. CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAM- AGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTH- ER MARKS). Installing NOTE PAY ATTENTION TO ALIGN THE REFERENCES ON STA- TOR AND ROTOR DURING INSTALLATION AND CHECK CLEARANCE WITH A FEELER GAUGE.
Page 280 DORSODURO 900 Engine • Tighten both oil pump fixing screws. • Fit the shim washer. • Insert the oil pump gearwheel, making sure that the machined groove coin- cides with the pin on the pump. • Insert the safety washer. •...
Page 281 DORSODURO 900 Engine • Using a screwdriver, raise and bend the safety washer on the side opposite the slot until it is touching the nut. ENG - 281...
Page 282: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 283 DORSODURO 900 Power supply Fuel pump UEL TANK Pos. Description Type Quantity Torque Notes Fuel cap fastening screws M5x12 5 Nm (3.69 lb ft) Rear fuel tank fastening screw M6x90 10 Nm (7.38 lb ft) Fuel pump fastening screw M5x16 6 Nm (4.43 lb ft) Removing •...
Page 284: Removing The Throttle Body
DORSODURO 900 Power supply • Remove the fuel pump. Injection Removing the throttle body HROTTLE BODY Pos. Description Type Quantity Torque Notes Flanged, hex. head screws used for M6x60 12 Nm (8.85 lb ft) Loct. 242 fastening the inlet coupling Button head, hex.
Page 285 DORSODURO 900 Power supply • Remove the filter casing. • Working on both bodies, undo and re- move the four screws and slide off the filter support. • Remove the upper plate. • Remove both bodies. UPON REFITTING, REPLACE THE THROTTLE BODY GASKET WITH A NEW ONE OF THE SAME TYPE.
Page 286 DORSODURO 900 Power supply • Remove the plate. • Working on both bodies, undo and re- move the screw and detach the body. • Working on the body in question, re- move the injector, slide off the clip and the injector itself. CAUTION NEVER UNDO THE SCREWS IN THE FIGURE Use of diagnostics instrument for injection system...
Page 287 INDEX OF TOPICS SUSP USPENSIONS...
Page 288 DORSODURO 900 Suspensions Handlebar GUARD Pos. Description Type Quantity Torque Notes Screws for fastening the anti-vibra- M6x50 10 Nm (7.38 lb ft) tion weights and the hand guards to the handlebar terminals Screws for fastening the upper U-bolt M8x25 25 Nm (18.44 lb ft) to the lower U-bolt Light switch closure screws 1.5 Nm (1.11 lb ft)
Page 289: Front Fork
DORSODURO 900 Suspensions • Remove the upper U-bolt (2) • Remove the handlebar (3) Front fork RONT FORK Pos. Description Type Quantity Torque Notes Fork feet closure screws M6x40 10 Nm (7.38 lb ft) Screw for fastening the ABS sensor M5x16 6 Nm (4.43 lb ft) to the right fork foot...
Page 290 DORSODURO 900 Suspensions Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates. The right stem of the fork has an upper nut (2) for adjusting the spring pre-load and an upper adjust- ment screw (1) for adjusting the hydraulic braking in rebound.
Page 291: Removing The Fork Legs
DORSODURO 900 Suspensions Removing the fork legs • Remove the handlebar • Remove the upper steering yoke • Remove the front wheel • Remove the clamp (1) • Undo and remove the screw (2) • Undo and remove the screw (3) •...
Page 292: Disassembling The Fork
DORSODURO 900 Suspensions • Loosen the two screws (5) • Remove the lh front fork (6) • Loosen the two screws (7) • Remove the rh front fork (8) Disassembling the fork NOTE THE STEMS ARE NOT THE SAME, THEREFORE THEY REQUIRE SEPARATE REMOVAL PRO- CEDURES.
Page 293 DORSODURO 900 Suspensions THE FOLLOWING OPERATIONS APPLY WHEN REMOVING THE RIGHT HAND STEM • Taking care not to damage it, secure the fork vertically in a vice, using the appropriate protection devices. • Unscrew the upper cap (1). Specific tooling AP8140149 Guard for assembly operations •...
Page 294 DORSODURO 900 Suspensions • Extract the shaft (6) and remove it. • After removing the locking plate and the device used to compress the spring, remove the upper plate (7) and the pre-loading pipe (3). • Remove the spring (8) allowing the oil inside the stem to drip out.
Page 295: Specific Tooling
DORSODURO 900 Suspensions • Taking care not to damage it, secure the sleeve horizontally in a vice, using the appropriate protection devices. • Extract the dust guard (9). Specific tooling AP8140149 Guard for assembly operations • Remove the seeger ring (10) from in- side the sleeve.
Page 296 DORSODURO 900 Suspensions • Remove the complete plunger (13). • Observing the indicated sequence, ex- tract and remove the slider bushing (14), the guide bushing (15), the ring (16), the oil seal (17), the seeger ring (10) and the dust guard (9). THE FOLLOWING OPERATIONS APPLY WHEN REMOVING THE RIGHT HAND STEM •...
Page 297 DORSODURO 900 Suspensions • Unscrew and remove the cap (1). • Unscrew the special nut (2) and re- move it. • Remove the buffer (3). • Drain the oil into a container having sufficient capacity, extending the stem several times in order to ensure the oil is drained completely.
Page 298: Checking The Components
DORSODURO 900 Suspensions • Taking care not to damage it, secure the sleeve horizontally in a vice, using the appropriate protection devices. • Extract the dust guard (4). Specific tooling AP8140149 Guard for assembly operations • Remove the seeger ring (5) from inside the sleeve.
Page 299 DORSODURO 900 Suspensions If the scratches are deep, replace the stem. Using a dial gauge, check than any bending of the stem is below the limit value. If it is over the limit, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK- ENED MAKING THE VEHICLE DANGEROUS TO USE.
Page 300 DORSODURO 900 Suspensions THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE RIGHT HAND STEM • Observing the indicated sequence, ex- tract and remove the dust guard (1), the seeger ring (2), the oil seal (3), the ring (4), the guide bushing (5) and the slider bushing (6).
Page 301 DORSODURO 900 Suspensions • Using a suitable tool, complete with striking hammer, insert oil seal into its housing (3). Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight • Position the seeger ring (2) inside the sleeve.
Page 302 DORSODURO 900 Suspensions • Insert the spring (10), making sure that it is aligned correctly The end where the spirals are more compressed should be facing upwards • Insert the pre-load tube (11), making sure that it is aligned correctly. The narrower part must be inserted into the spring.
Page 303 DORSODURO 900 Suspensions • Insert the shaft (16) into the plunger. • Before positioning the cap, adjust the hydraulic regulator screw so that the internal distance is as close as possi- ble to 13 mm (0.51 in). • Screw the cap (17) onto the plunger as far as it will go.
Page 304 DORSODURO 900 Suspensions • Tighten the cap on the sleeve, applying the pre-defined torque. THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE LEFT HAND STEM • Observing the indicated sequence, ex- tract and remove the dust guard (1), the seeger ring (2), the oil seal (3), the ring (4), the guide bushing (5) and the slider bushing (6).
Page 305 DORSODURO 900 Suspensions • Position the seeger ring (2) inside the sleeve. • Insert the dust guard (1) into its hous- ing correctly. • Place the fork stem vertically on a work surface. • Fill the stem with the quantity of oil in- dicated in the "Refilling oil"...
Page 306 DORSODURO 900 Suspensions • Insert the special nut (8) and tighten it as far as it will go. • Insert the cap (9) and tighten it as far as it will go. • Ensure that the cap cannot rotate, and then tighten the nut.
Page 307: Filling Oil
DORSODURO 900 Suspensions Filling oil THE FOLLOWING OPERATIONS APPLY WHEN MOUNTING THE RIGHT HAND STEM • Place the fork stem vertically on a work surface. • Fill the STEM with the indicated quan- tity of oil. WARNING OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.
Page 308 DORSODURO 900 Suspensions Upper steering yoke TEERING Pos. Description Type Quantity Torque Notes Steering headstock ring nut M25x1 Tightening torque 50 Nm (36.88 lb ft) (for steering assembly peri- od of adjustment) | Make two complete turns to the right and two complete turns to the left | Loosen the ring nut by making a 90°...
Page 309 DORSODURO 900 Suspensions Removal • Remove the headlight • Remove the handlebar • Loosen the two screws (1) • Loosen the screw (2) • Unscrew the nut (3) and remove it • Retrieve the washer (4) SUSP - 309...
Page 310 DORSODURO 900 Suspensions • Remove the upper steering yoke (5) Steering bottom yoke TEERING Pos. Description Type Quantity Torque Notes Steering headstock ring nut M25x1 Tightening torque 50 Nm (36.88 lb ft) (for steering assembly peri- od of adjustment) | Make two complete turns to the right and two complete turns to...
Page 311 DORSODURO 900 Suspensions Pos. Description Type Quantity Torque Notes Screws for fastening the lower stand M10x60 50 Nm (36.88 lb ft) Loctite 243 to the upper plate Screws for fastening the fork stan- M8x30 25 Nm (18.44 lb ft) chions to the upper plate Screw for fastening the steering M8x30 25 Nm (18.44 lb ft)
Page 312: Steering Bearing
DORSODURO 900 Suspensions Steering bearing TEERING Pos. Description Type Quantity Torque Notes Steering headstock ring nut M25x1 Tightening torque 50 Nm (36.88 lb ft) (for steering assembly peri- od of adjustment) | Make two complete turns to the right and two complete turns to the left | Loosen the ring nut by making a 90°...
Page 313 DORSODURO 900 Suspensions Adjusting play • Secure the rear of the motorcycle using suitable belts and position a central stand under the engine in order to maintain the front wheel in a raised po- sition. • After removing the instrument panel support and the front light assembly, maintain the fuel tank in raised position and remove the four handlebar U-bolt...
Page 314 DORSODURO 900 Suspensions Headlight assy. • Unscrew the three screws used for fas- tening the upper steering plate. • Remove the upper steering plate. • Apply the pre-tightening torque to the ferrule using the dedicated tool. • Execute two complete rotations to the left, and two to the right.
Page 315 DORSODURO 900 Suspensions • Tighten the sleeving blocking screws, applying the pre-defined torque. • Loosen the nut used for fastening the upper steering plate again. • Tighten the upper steering plate cen- tral closure screw, applying the pre- defined torque. •...
Page 316: Shock Absorbers
DORSODURO 900 Suspensions Shock absorbers EAR SUSPENSION Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw M10x50 50 Nm (36.88 lb ft) Pre-impregnated screw Lower shock absorber clamping M10x80 50 Nm (36.88 lb ft) screw Adjusting The rear suspension consists of a spring-shock absorber unit connected to the frame by uniball joints.
Page 317: Rear Shock Absorber Adjustment
DORSODURO 900 Suspensions TO COUNT THE NUMBER OF CLICKS OF THE ADJUSTER (1) ALWAYS START FROM THE MOST RIGID SETTING (COMPLETE CLOCKWISE ROTATION). TO PREVENT DAMAGE TO THE ADJUSTER SCREWS (1), NEVER FORCE THEM BEYOND THE END OF TRAVEL IN EITHER DIRECTION.
Page 318 DORSODURO 900 Suspensions (*) = clockwise (**) = anticlockwise Removing • Undo and remove the screw (1) • Retrieve the washer (2) • Using a suitable wrench, block the nut (3) so that it cannot rotate and remove the screw (4). •...
Page 319 DORSODURO 900 Suspensions • Remove the rear shock absorber (6) SUSP - 319...
Page 320: Index Of Topics
INDEX OF TOPICS CHAS HASSIS...
Page 321: Front Wheel
DORSODURO 900 Chassis Wheels Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle nut 80 Nm (59.00 lb ft) Front brake disc fastening screws M8x20 30 Nm (22.13 lb ft) Pre-impregnated screw Removal • Remove the front mudguard •...
Page 322 DORSODURO 900 Chassis • Retrieve the washer (2) • Loosen the two screws (3) • Loosen the two screws (4) • Remove the wheel axle (5) • Remove the front wheel (6) CHAS - 322...
Page 323: Removing The Front Brake Discs
DORSODURO 900 Chassis • Retrieve the washer (7) REMOVING THE FRONT BRAKE DISCS • Remove the front wheel • Remove the sealing ring (1 • Unscrew and remove the six screws • Remove the tone wheel (3) • Remove the rh front brake disc (4) •...
Page 324 DORSODURO 900 Chassis • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings are not conformant: • Replace both wheel bearings. ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE. SEALS •...
Page 325: Rear Wheel
DORSODURO 900 Chassis Rear wheel EAR WHEEL Pos. Description Type Quantity Torque Notes Nuts for fastening crown to sprocket M10x1.25 50 Nm (36.88 lb ft) Wheel cush support fastening M10x30 50 Nm (36.88 lb ft) Loctite 270 screws Brake disc fastening screws M8x18 30 Nm (22.13 lb ft) Pre-impregnated...
Page 326 DORSODURO 900 Chassis • Retrieve the washer (2) • Retrieve the lh chain guide shoe (3) • Remove the wheel axle (4) • Retrieve the rh chain guide shoe (5) • Disconnect the drive chain from the crown gear (6) CHAS - 326...
Page 327: Flexible Coupling
DORSODURO 900 Chassis • Remove the rear wheel (7) • Retrieve the washer (8) REMOVING THE REAR DISC BRAKE • Remove the rear wheel • Remove the sealing ring (1) • Unscrew and remove the five screws • Remove the tone wheel (3) •...
Page 328: Checking Rotation
DORSODURO 900 Chassis • Remove the five flexible coupling rub- ber inserts (2) • Unscrew and remove the five screws • Remove the flexible coupling (4) Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. REAR WHEEL BEARINGS Check the bearings installed on the wheel.
Page 329: Rear Wheel Axle
DORSODURO 900 Chassis REAR WHEEL AXLE • Use a dial gauge to check the wheel axle eccentricity (1). Replace the wheel axle if the eccentricity exceeds the limit value (1). Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM •...
Page 330: Swinging Arm
DORSODURO 900 Chassis Swinging arm WINGARM Pos. Description Type Quantity Torque Notes Swingarm pivot bolt assembly ad- 12 Nm (8.85 lb ft) justment bushing Swingarm pivot bolt fastening ring 60 Nm (44.25 lb ft) Swingarm pivot bolt fastening nut 90 Nm (66.38 lb ft) Nuts on chain tensioner adjustment Manual screws...
Page 331 DORSODURO 900 Chassis • Slide off the rear calliper holding plate, keeping it linked to the brake pipe. CAUTION DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER REMOVING THE WHEEL. OTHERWISE, THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT, RESULTING IN BRAKE FLUID LEAKAGE.
Page 332: Drive Chain
DORSODURO 900 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 333 DORSODURO 900 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). • Remove the inner plate (6). CHAS - 333...
Page 334 DORSODURO 900 Chassis • Collect the inner O-ring rings (7) and completely remove the transmission chain. Installing • After fitting the chain on the pinion and on the crown, put the inner O-rings (1) back onto the hammerlock pins (2) and connect the two ends of the transmis- sion chain.
Page 335 DORSODURO 900 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 336 DORSODURO 900 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 337 DORSODURO 900 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; • excessive wear; •...
Page 338 DORSODURO 900 Chassis Pedaline OOTRESTS Pos. Description Type Quantity Torque Notes Passenger footrest support fastening M8x35 25 Nm (18.44 lb ft) Loctite 243 screws Passenger footrest rubber fastening M6x12 10 Nm (7.38 lb ft) Loctite 243 screws Screws for fastening the rider foot- M8x35 30 Nm (22.13 lb ft) Pre-impregnated...
Page 339: Removing The Side Stand
DORSODURO 900 Chassis Stand TAND Pos. Description Type Quantity Torque Notes Screw for fastening the stand to the M10x1.25 10 Nm (7.38 lb ft) plate Nut for fastening the stand to the M10x1.25 30 Nm (22.13 lb ft) Loctite 243 plate Peg for fastening the springs to the 7.5 Nm (5.53 lb ft)
Page 340 DORSODURO 900 Chassis • Unscrew the nut (2) and remove it. • Retrieve the washer (3) • Remove the stand pin (4) • Remove the side stand (5). CHAS - 340...
Page 341 DORSODURO 900 Chassis • Retrieve the side stand return plate (6) • Remove the two screws (7) that fasten the footrest support. • Remove the complete lh passenger footrest support (8). • Remove the protection plate (9). CHAS - 341...
Page 342 DORSODURO 900 Chassis • After disconnecting the joint from the gear control lever, remove the two screws (10) used to fasten the rider's footrest (11). • Retrieve the washers (12) and sepa- rate the side stand support plated (13) from the rider's footrest (11). •...
Page 343 DORSODURO 900 Chassis Exhaust XHAUST SYSTEM Pos. Description Type Quantity Torque Notes Exhaust flange self-locking fastening 12.5 Nm (9.22 lb ft) Clamp for fastening the front mani- 7 Nm (5.16 lb ft) fold to the central manifold Clamp for fastening the rear manifold 7 Nm (5.16 lb ft) to the central manifold Screws for fastening the central...
Page 344 DORSODURO 900 Chassis • Retrieve the two washers (2) • Remove the rh silencer cover (3) • Retrieve the washer (4) • Retrieve the two rubber inserts (5) • Retrieve the bushing (6) • Repeat the procedure in order to re- move the lh terminal cover CHAS - 344...
Page 345: Removing The Silencer
DORSODURO 900 Chassis REMOVING THE SILENCER • Remove the exhaust terminal covers • Loosen the clamp between the ex- haust terminal and the manifold • Remove the saddle. • Unscrew and remove the two upper screws, and retrieve the washers. •...
Page 346: Removing The Exhaust Manifold
DORSODURO 900 Chassis Removing the exhaust manifold FRONT MANIFOLD • Remove the lower fairing and cut the upper clamp (1) that fastens the front lambda probe wiring harness to the ABS pump support frame. • Remove the lower clamp (2). •...
Page 347 DORSODURO 900 Chassis • Remove the two nuts (5) used to fasten the front manifold to the head. • Remove the front manifold (6). • Loosen the lower clamp (7) that con- nects the rear manifold to the central manifold. •...
Page 348 DORSODURO 900 Chassis • Remove the central manifold (9). REAR MANIFOLD • Remove the clamp (10) that fastens the rear lambda probe wiring harness to the rear frame. • Remove the clamp (11) that fastens the rear lambda probe wiring harness to the metallic cable clamp and discon- nect the connector.
Page 349 DORSODURO 900 Chassis • Remove the rear manifold (13), sliding out from underneath the motorcycle. CHAS - 349...
Page 350: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 351 DORSODURO 900 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 Screws for fastening the support to M6x25 10 Nm (7.38 lb ft) the engine and the ABS control unit Engine support fastening screws M6x35...
Page 352 DORSODURO 900 Braking system Foreword Key: 1. Rear brake calliper 2. Modulator 3. Front bleed valve 4. Front brake reservoir 5. Front brake callipers 6. Rear brake pump 7. Rear brake reservoir BRAK SYS - 352...
Page 353: Operating Diagram
DORSODURO 900 Braking system Operating diagram Key: 1. Instrument panel 2. Ignition switch 3. Main injection relay 4. ABS control unit BRAK SYS - 353...
Page 354 DORSODURO 900 Braking system 5. Front ABS sensor 6. Rear ABS sensor 7. Start-up relay 8. ABS control unit fuse 9. Main fuse 10.Battery 11.BLUEDASCH set-up (optional) 12.Diagnostics socket 13.7SM engine control unit ABS Electronic Control Unit pin-out • PIN1 - Power ground 1 •...
Page 355: Abs Operation
DORSODURO 900 Braking system ABS OPERATION General specifications: The front circuit is the same as the rear one. • The ABS inlet valve (10 - 12) is normally open and it is closed only when the system inter- venes to avoid wheel locking. •...
Page 356 DORSODURO 900 Braking system • With the system in stand-by mode, the ABS processor controls the wheel speed instant by instant to assess any slippage of the wheels. • When in standby, the system does not intervene at all when the rider brakes; the braking system is the same as the one without ABS.
Page 357 DORSODURO 900 Braking system A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly. CAUTION WHEN THE ABS STARTS WORKING, A PULSING IS FELT ON THE BRAKE LEVER. THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND. AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLE BAR TURNED, ON UN- EVEN OR SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE.
Page 358 DORSODURO 900 Braking system Attivazione/Disattivazione dispositivo ABS Soltanto a moto ferma è possibile modificare lo stato di attivazione/disattivazione del sistema ABS ed è possibile farlo in due modi distinti: 1) Dalla schermata principale, mediante uno spos- tamento breve verso sinistra o verso destra è pos- sibile disattivare o riattivare il sistema ABS Per tornare al menù...
Page 359 DORSODURO 900 Braking system • the ABS warning light flashes. Once the vehicle speed exceeds 5 km/h (3.1 mph): - if errors are not detected: the ABS warning light turns off - if at least one malfunction is detected: the ABS warning light turns on permanently. The ABS system is deactivated! However, the system is perfectly operative as any other braking system without ABS.
Page 360 DORSODURO 900 Braking system PARAMETERS screen page This screen shows the parameters measured by the several sensors (engine revs, engine temper- ature, etc.) or values set by the control unit (injec- tion time, ignition advance, etc.) PARAMETERS AND STATUSES P.A.D.S. characteristic. Value/example Units of Notes...
Page 361 DORSODURO 900 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 Description Code Symptom Front wheel speed sensor 5D90 Electrical fault Front speed sensor - Functional fault...
Page 362 DORSODURO 900 Braking system • Select the vehicle and the component. • Select Self-diagnosis. • Go to the page Error codes. • Select an error and show the Ambient parameter error(where provided). • Repeat the operation by selecting each error and showing the corresponding Ambient parameter error (where provi- ded).
Page 363 DORSODURO 900 Braking system • Go to the page Report and then on Print and select the virtual PDF printer. • If there is no PDF printer, there are several free programs, ask the infor- mation systems to install it. •...
Page 364 DORSODURO 900 Braking system ADJUSTMENTS P.A.D.S. characteristic. Value/example Units of Notes measure ment Front bleed Rear bleed Encoding Resets the vehicle code and obtains it automati- cally from the CAN line at the next key ON Modulator MODULATOR REMOVAL • Remove the fairing lug.
Page 365: Rear Brake Calliper
DORSODURO 900 Braking system Rear brake calliper EAR BRAKE Pos. Description Type Quantity Torque Notes Pin for fastening the lever to the right 25 Nm (18.44 lb ft) footrest support Screw for fastening the Pump to the M6x20 10 Nm (7.38 lb ft) right footrest support Fastener for securing the spring at- 6 Nm (4.43 lb ft)
Page 366: Front Brake Calliper
DORSODURO 900 Braking system Front brake calliper RONT BRAKE CALIPERS Pos. Description Type Quantity Torque Notes Screws for fastening the brake pipe M10x1 25 Nm (18.44 lb ft) to the callipers Screws for fastening the callipers to M10x1.25 50 Nm (36.88 lb ft) the fork stanchions Disc Inspection CAUTION...
Page 367: Front Brake Pads
DORSODURO 900 Braking system Disc Inspection CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. • The following operations must be car- ried out with the brake discs fitted on the wheel; they refer to a single disc, but are valid for both.
Page 368 DORSODURO 900 Braking system AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE. Rear brake pads Removal • Remove the safety circlip. • Unscrew and remove the pin. •...
Page 369 DORSODURO 900 Braking system IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO ITS NORMAL OPERATING CONDITIONS. NOTE THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY, BUT ARE VALID FOR BOTH.
Page 370 DORSODURO 900 Braking system Rear Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess" of the brake and by poor braking. CAUTION IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO...
Page 371 DORSODURO 900 Braking system BRAK SYS - 371...
Page 372: Index Of Topics
INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
Page 373 DORSODURO 900 Clutch system LUTCH PUMP Pos. Description Type Quantity Torque Notes Clutch cylinder fastening screws M6x20 8 Nm (5.90 lb ft) Perform two tight- ening cycles Screw for fastening the pipe to the M10x1 25 Nm (18.44 lb ft) clutch pump Screws for fastening the clutch pump 10 Nm (7.38 lb ft)
Page 374 DORSODURO 900 Clutch system Removing the clutch slave cylinder • Drain the oil from the clutch system and remove the retaining screw (1) from the control cylinder pipe. • Undo and remove the three control cyl- inder fastening screws (2) •...
Page 375: Cooling System
INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 376: Circuit Diagram
DORSODURO 900 Cooling system OOLING YSTEM Pos. Description Type Quantity Torque Notes Electric fan fastening screws Self-tapping 3 Nm (2.21 lb ft) 4.2x22 Screw for fastening the radiator to M6x25 10 Nm (7.38 lb ft) the frame on the left-hand side Screws for fastening the radiator M6x25 10 Nm (7.38 lb ft)
Page 377 DORSODURO 900 Cooling system Key: Yellow = Air purge Orange = Refilling Red = From engine Blue = To the pump Key: 1. Front cylinder. 2. Rear cylinder. 3. Thermostat. 4. Direction of travel of vehicle. COOL SYS - 377...
Page 378: Electric Fan
DORSODURO 900 Cooling system Electric fan • Remove the radiator • Undo and remove the three screws and collect the washers; remove the electric fan. See also Removing the radiator Coolant replacement • Remove the right side fairing. • Place a container of suitable capacity. •...
Page 379: Water Pump
DORSODURO 900 Cooling system • Slide off the sleeve and empty the sys- tem completely. CAUTION SHOULD GREASE BE NOTED IN THE WATER THIS IS TO BE CONSIDERED NORMAL BECAUSE DURING THE AS- SEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LU- BRICATION OF THE SAME IS REQUIRED IN ORDER TO PREVENT DAMAGE.
Page 380 DORSODURO 900 Cooling system Pos. Description Type Quantity Torque Notes Flanged hex head screw for fasten- M6x12 9 Nm (6.64 lb ft) Loct. 242 ing the chain tensioner slider Pump support fastening screw M6x30 12 Nm (8.85 lb ft) Removal Based on the engine design development, there are two types of water pumps, associated to the specific clutch crankcases.
Page 381 DORSODURO 900 Cooling system • - Loosen the clip and remove the cover. REMOVING THE PUMP ROTOR • Remove the H2O pump cover. • Unscrew the rotor and remove it, not- ing the left hand thread on the pin. REMOVING THE COMPLETE H2O PUMP •...
Page 382: Removing The Radiator
DORSODURO 900 Cooling system Installing MOUNTING THE COMPLETE H2O PUMP • - Insert the control chain and position the H2O pump in its housing. • Insert the three H2O pump retaining screws, applying the pre-defined tight- ening torque. • Apply a large quantity of grease to the sides of the H2O pump so that it is eas- ier to insert the cover.
Page 383 DORSODURO 900 Cooling system • Access the left hand side of the motor- cycle, loosen the clamp and move it to one side so that it is possible to dis- connect the tube and drain the coolant. • Loosen the clamp and remove it, then disconnect the tube from the radiator, collecting the coolant in the recipient.
Page 384: Removing The Expansion Tank
DORSODURO 900 Cooling system • Release the clamps of the pipes that connect the radiator to the expansion tank and disconnect them from the ra- diator. • Remove the radiator fixing screw. • Operating from the right side of the mo- torcycle, release and remove the radi- ator from the chassis.
Page 385: Thermostatic Valve
DORSODURO 900 Cooling system • Release the clamp. • Slide off the pipe. • Undo and remove the screw and col- lect the washer. • Slide off the expansion tank. Thermostatic valve Traditional circuit, three-way thermostatic valve: 1. Hot water inlet from big ends. 2.
Page 386 DORSODURO 900 Cooling system 125° COOL SYS - 386...
Page 387 INDEX OF TOPICS BODYW ODYWORK...
Page 388 DORSODURO 900 Bodywork EAR BODYWORK Pos. Description Type Quantity Torque Notes Screws for fastening the rear right M6x20 10 Nm (7.38 lb ft) and left cover to the silencer Screws fastening tail fairing to the M5x9 6 Nm (4.43 lb ft) saddle mounting Screws for fastening the tail fairing to M5x14...
Page 389 DORSODURO 900 Bodywork NDER SADDLE COMPARTMENT Pos. Description Type Quantity Torque Notes Screws for fastening the battery cov- M5x16 3 Nm (2.21 lb ft) er to the under-saddle compartment Screws for fastening the battery M5x9 6 Nm (4.43 lb ft) compartment to the saddle mounting Elastic fastening screw Self-tapping...
Page 390 DORSODURO 900 Bodywork AILLIGHT Pos. Description Type Quantity Torque Notes Licence plate light fastening screws 5 Nm (3.69 lb ft) Rear turn indicator fastening screws M5x20 3 Nm (2.21 lb ft) Reflector fastening screw 3 Nm (2.21 lb ft) Licence plate light fastening nut 5 Nm (3.69 lb ft) Tail light upper fastening screw M5x16...
Page 391 DORSODURO 900 Bodywork OCKS Pos. Description Type Quantity Torque Notes Screws for fastening the ignition M8x40 Manual switch to the frame Hex head screws for fastening the M6x30 10 Nm (7.38 lb ft) saddle lock / battery compartment to the saddle mounting BODYW - 391...
Page 392 DORSODURO 900 Bodywork OOTRESTS Pos. Description Type Quantity Torque Notes Passenger footrest support fastening M8x35 25 Nm (18.44 lb ft) Loctite 243 screws Passenger footrest rubber fastening M6x12 10 Nm (7.38 lb ft) Loctite 243 screws Screws for fastening the rider foot- M8x35 30 Nm (22.13 lb ft) Pre-impregnated...
Page 393 DORSODURO 900 Bodywork EADLAMP Pos. Description Type Quantity Torque Notes Headlamp support fastening screw 10 Nm (7.38 lb ft) Front turn indicators fastening M5x16 3 Nm (2.21 lb ft) screws Screw for fastening the lower head- 7 Nm (5.16 lb ft) lamp support to the lower plate Turn indicator fastening nut 3 Nm (2.21 lb ft)
Page 394 DORSODURO 900 Bodywork RONT BODYWORK Pos. Description Type Quantity Torque Notes Screw for fastening the front convey- M6x16 7 Nm (5.16 lb ft) ors to the radiator Screws for fastening the conveyors M5x9 4 Nm (2.95 lb ft) to the tank Screws for fastening the starter as- M5x9 4 Nm (2.95 lb ft)
Page 395 DORSODURO 900 Bodywork RONT MUDGUARD Pos. Description Type Quantity Torque Notes Screws for fastening the low mud- M5x9 4 Nm (2.95 lb ft) Loctite 243 guard to the fork foot Screws for fastening the high mud- M5x9 5 Nm (3.69 lb ft) guard to the tail light support Screws for fastening the front head- M6x25...
Page 396: Removing The Instrument Panel
DORSODURO 900 Bodywork NSTRUMENT PANEL Pos. Description Type Quantity Torque Notes Screws for fastening the steering M6x20 10 Nm (7.38 lb ft) plate to the instrument panel plate Screws fastening instrument cluster Self-tapping 3 Nm (2.21 lb ft) to support bracket 5x14 Instrument panel adapter fastening M5x12...
Page 397 DORSODURO 900 Bodywork • Retrieve the three washers (5) • Remove the instrument panel support Headlight assy. EADLAMP Pos. Description Type Quantity Torque Notes Headlamp support fastening screw 10 Nm (7.38 lb ft) BODYW - 397...
Page 398 DORSODURO 900 Bodywork Pos. Description Type Quantity Torque Notes Front turn indicators fastening M5x16 3 Nm (2.21 lb ft) screws Screw for fastening the lower head- 7 Nm (5.16 lb ft) lamp support to the lower plate Turn indicator fastening nut 3 Nm (2.21 lb ft) Headlamp fastening nut 10 Nm (7.38 lb ft)
Page 399 DORSODURO 900 Bodywork • Undo and remove the screw (1) • Retrieve the bushing (4) • Retrieve the bushing(6) and the nut (5) • Undo and remove the screw (7) • Retrieve the nut (8) BODYW - 399...
Page 400 DORSODURO 900 Bodywork • Retrieve the bushing (9) • Retrieve the bushing (10) • Disconnect the high beam/low beam light connector (11) • Disconnect the parking light connector (12) BODYW - 400...
Page 401 DORSODURO 900 Bodywork • Removing the clamp (13) • Disconnect the front right hand direc- tion indicator connector (14) • Disconnect the front left hand direction indicator connector (15) • Remove the front light assembly (16), complete with upper fairing BODYW - 401...
Page 402: Headlight Fairing
DORSODURO 900 Bodywork Headlight fairing REMOVAL OF THE TOP FAIRING • Remove the front light cluster • Unscrew and remove the four screws • Remove the top fairing (2) Taillight assy. BODYW - 402...
Page 403 DORSODURO 900 Bodywork AILLIGHT Pos. Description Type Quantity Torque Notes Licence plate light fastening screws 5 Nm (3.69 lb ft) Rear turn indicator fastening screws M5x20 3 Nm (2.21 lb ft) Reflector fastening screw 3 Nm (2.21 lb ft) Licence plate light fastening nut 5 Nm (3.69 lb ft) Tail light upper fastening screw M5x16...
Page 404: Side Body Panels
DORSODURO 900 Bodywork • Working from both sides, unscrew and remove the screw. • Disconnect the taillight connectors. • Remove the taillight. See also Tail guard Side body panels REMOVING SIDE FAIRING PANELS • Undo and remove the screw (1) •...
Page 405 DORSODURO 900 Bodywork • Undo and remove the screw (4) • Retrieve the bushing (5) • Remove the right side fairing panel (6) • Undo and remove the screw (7) • Unscrew and remove the screw (8) • Retrieve the washer (9) BODYW - 405...
Page 406 DORSODURO 900 Bodywork • Undo and remove the screw (10) • Retrieve the bushing (11) • Remove the lh side fairing panel (12) License plate holder PLATE HOLDER REMOVAL • Remove the saddle. • Remove the tail fairing. • Unscrew and remove the three screws. •...
Page 407 DORSODURO 900 Bodywork • Disconnect the saddle unlocking ca- ble. • Slide off the license plate holder to- wards the back. See also Seat Tail guard LICENCE PLATE HOLDER REMOVAL • Remove the saddle unlocking cable (1) from the taillight and release the cable harness (2) •...
Page 408 DORSODURO 900 Bodywork • Remove the three rear screws (4) • Remove the screw (5) and the same from the opposite side • Remove the screw (6) that secures the turn indicator to the license plate holder and to the rear section. •...
Page 409 DORSODURO 900 Bodywork • Turn the turn indicators by 180 degrees and remove them. • Remove the license plate light fixing screw in order to remove the lamp holder and be sure to collect the nut • Remove the lamp holder to replace the license plate light bulb.
Page 410 DORSODURO 900 Bodywork • Remove the fork spring • Remove the hose control plate • Remove the lock block Air box BODYW - 410...
Page 411 DORSODURO 900 Bodywork IR FILTER CASING Pos. Description Type Quantity Torque Notes Self-tapping, SWP air pressure sen- 5x20 2 Nm (1.48 lb ft) sor fastening screws Self-tapping air temperature sensor 2.9x12 2 Nm (1.48 lb ft) fastening screws SWP filter box lid fastening screws 5x20 2 Nm (1.48 lb ft) SWP screws used to fasten the up-...
Page 412 DORSODURO 900 Bodywork • Unscrew the intake ducts (4) anticlock- wise and remove them. • Remove the air filter (5). • Remove the starter relay (6) from the support present on the base of the filter box. • Detach the Ride by Wire control con- nector (7) from the support present on the vase of the filter box BODYW - 412...
Page 413 DORSODURO 900 Bodywork • Remove the fan control relay (8) from the support present on the base of the filter box. • Remove the main injection relay (9) from the support present on the base of the filter box. • Detach the front ABS speed sensor connector (10) from the support present on the base of the filter box.
Page 414 DORSODURO 900 Bodywork • Remove the lights relay (12) from the support present on the base of the filter box. • Remove the highbeam lights relay (13) from the support present on the base of the filter box. • Remove the two instrument cannister support fastening screws (14).
Page 415 DORSODURO 900 Bodywork • Remove the nine screws used to fas- ten the cover (17). • Remove the tenth screw used to fasten the cover (18) positioned in corre- spondence with steering headstock. • Remove the metallic cable clamp (19), taking care to retrieve the washer (20).
Page 416 DORSODURO 900 Bodywork • Remove the upper part (21) of the filter box. • Remove the two screws (22) used to fasten the air pressure sensors. • Disconnect the connectors and re- move the sensors. • Remove the two clamps (23) used to fasten the wiring harness to the throttle body.
Page 417 DORSODURO 900 Bodywork • Access the right hand side of the mo- torcycle and remove the three screws (25) used to fasten the side panel mounted on the filter box in order per- mit the passage of the wiring harness. NOTE DURING REASSEMBLY, REPLACE THE CLAMPS IN THE POSITIONS IDENTIFIED BY THE GREY TAPE.
Page 418 DORSODURO 900 Bodywork • Disconnect the cable clamp (30) from the base of the filter box. • Remove the clamps (31) in order to de- tach the wiring harness from the base of the filter box. • Remove the two screws (32) that fas- ten the plate used to connect the filter box to the frame.
Page 419 DORSODURO 900 Bodywork • Remove the two screws (35) used to fasten the control unit cover. • Slide the control unit cover (36) off ver- tically. • Disconnect the two connectors (37) from the control unit. BODYW - 419...
Page 420 DORSODURO 900 Bodywork • Slide the control unit (38) out vertically. • Remove the screw (39) used to fasten the control unit support to the base of the filter box. • Remove the clamp (40) from the con- trol unit support and release the wiring harnesses.
Page 421 DORSODURO 900 Bodywork • Detach the cable clamp (42) from the base of the filter box. • Remove the four clamps positioned on the front part of the filter box (43) and release the wiring harness. NOTE DURING REASSEMBLY, REPLACE THE CLAMPS IN THE POSITIONS IDENTIFIED BY THE GREY TAPE.
Page 422 DORSODURO 900 Bodywork • Remove the three screws (48) that fas- ten the cable guide (49) and free the wiring harness. • Remove the base from the filter box (50). Fuel tank UEL TANK Pos. Description Type Quantity Torque Notes Fuel cap fastening screws M5x12 5 Nm (3.69 lb ft)
Page 423: Removing The Tank
DORSODURO 900 Bodywork CAUTION WHILE RAISING AND POSITIONING THE FUEL TANK, TAKE CARE TO AVOID CRUSHING/ BENDING THE VENT CAPS AND MAKE SURE THAT THEY DO NOT SLIDE OUT OF THEIR FARE PIPE GUIDES REMOVING THE TANK • Remove the saddle •...
Page 424 DORSODURO 900 Bodywork • Lift the fuel tank. WHEN ROTATING IN ORDER TO OPEN THE FUEL TANK, RAISE IT BY A MAXIMUM OF ABOUT 40°, TAKING CARE NOT TO COME INTO CONTACT WITH THE MAXIMUM RO- TATION INDICATOR PLATE (A). •...
Page 425: Removing The Fuel Pump
DORSODURO 900 Bodywork • Undo and remove the screw (10) • Retrieve the nut (11) • Remove the bracket (12) • Remove the fuel tank (13) REMOVING THE FUEL PUMP • Remove the fuel tank • Unscrew and remove the four screws BODYW - 425...
Page 426: Removing The Front Mudguard
DORSODURO 900 Bodywork • Remove the fuel pump (2) Front mudguard REMOVING THE FRONT MUDGUARD • Unscrew and remove the three screws • Unscrew and remove the three screws • Remove the lower front mudguard (3) BODYW - 426...
Page 427 DORSODURO 900 Bodywork • Unscrew and remove the two screws • Remove the front brake calliper (5) from the brake disc • Remove the front brake pipe from the supports (6) • Unscrew and remove the two screws BODYW - 427...
Page 428 DORSODURO 900 Bodywork • Remove the front brake calliper (8) from the brake disc • Undo and remove the screw (9) • Retrieve the washer (10) • Unscrew and remove the three screws (11) BODYW - 428...
Page 429 DORSODURO 900 Bodywork • Remove the upper front mudguard (12) • Unscrew and remove the two screws (13) • Retrieve the two bushings (14) • Remove the front mudguard support (15) • Retrieve the bushing (16) BODYW - 429...
Page 430: Battery Removal
DORSODURO 900 Bodywork Battery NDER SADDLE COMPARTMENT Pos. Description Type Quantity Torque Notes Screws for fastening the battery cov- M5x16 3 Nm (2.21 lb ft) er to the under-saddle compartment Screws for fastening the battery M5x9 6 Nm (4.43 lb ft) compartment to the saddle mounting Elastic fastening screw Self-tapping...
Page 431 DORSODURO 900 Bodywork • Remove the battery cover (2) When removing the battery, disconnect the nega- tive cable first, then the positive cable • Undo and remove the screw (3) • Remove the negative cable (4) • Undo and remove the screw (5) •...
Page 432 DORSODURO 900 Bodywork Tail guard EAR BODYWORK Pos. Description Type Quantity Torque Notes Screws for fastening the rear right M6x20 10 Nm (7.38 lb ft) and left cover to the silencer Screws fastening tail fairing to the M5x9 6 Nm (4.43 lb ft) saddle mounting Screws for fastening the tail fairing to M5x14...
Page 433 DORSODURO 900 Bodywork REMOVING THE TAIL FAIRING • Remove the saddle • Unscrew and remove the three screws • Undo and remove the screw (2) • Undo and remove the screw (3) • Remove the tail fairing (4) BODYW - 433...
Page 434 INDEX OF TOPICS PRE DE DELIVERY...
Page 435 DORSODURO 900 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 engine - chassis retainers...
Page 436 DORSODURO 900 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 437: Static Test
DORSODURO 900 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
Page 438 DORSODURO 900 Pre-delivery Specific operations for the vehicle HAND-GUARDS The following procedure is only shown from one side of the vehicle, but is valid for both hand- guards • Check the packaging and the compo- nents it contains fro signs of damage •...
Page 439 DORSODURO 900 Pre-delivery • Insert the two spacers (6) • Insert the lock-nut (7) and nut (8) and tighten them • Tighten the screw (3) • Insert the rear-view mirror (9) and the rubber insert (10) PRE DE - 439...
Page 440 DORSODURO 900 Pre-delivery • Tighten the rear-view mirror (9) as in- dicated in figure • Cover the nut and lock-nut with the rub- ber inserts (9) as indicated in figure PRE DE - 440...
Page 441 ABS: 189, 351, 359 Air filter: 69 Air temperature sensor: 147 Battery: 117, 130, 430 Brake: 365–368 Brake calliper: 365, 366 Brake pads: 367, 368 Bulbs: CAN line: 189 Chain: 13, 243–246, 250, 332 Chain tensioner: 243–246 Clutch: 175, 219, 221, 223, 226–229, 373, 374, 381 Coil: 160 Connecting rods: Connectors: 182...
Page 442 Handlebar: 288 Head cover: 234, 245, 259 Headlight: 314, 397, 402 Identification: 11 Instrument panel: 396 Intake pressure sensor: 140 Keys: 115 License plate holder: 406 Magneto flywheel: 215, 245, 264 Maintenance: 8, 64 Mudguard: 426 Oil filter: 69 Oil pressure sensor: 172 Radiator: 196, 378, 382 Rear wheel: 325, 332 Recommended products: 66...
Page 443 Warning lights: Water pump: 379 Wiring diagram: 109...

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2q000336