Page 1 Home SUPERBIKE 848 MY Home Main 2008 file:///C|/848/wsm/en/home.html [11-6-2008 0:34:08] WWW.PlanDeGraissage.ORG...
Page 2 A - General 0A - General 0B - Information about the model 0C - Technical data 0D - Use and maintenance 0E - Fairings 0F - Controls - Devices 0G - Wheels - Suspension - Brakes 0H - Frame 0L - Fuel/Exhaust System 0M - Fuel injection - ignition system 0N - Engine 0P - Electrical system...
Page 3 A - General Identification data for the Superbike 848 3 Section C 0C - Technical data 1.1 - Technical specifications General 3 Colours 4 Transmission 4 Timing system/valves 4 Crankshaft 5 Cylinder/Piston 5 Gearbox 6 Cooling system 6 Front wheel 6 Front suspension 6 Rear wheel 6 Rear suspension 7...
Page 4 A - General Section D 0D - Use and maintenance 1 - Preliminary checks Running-in precautions 3 Pre-ride checks 4 2 - Starting - Engine warmup Starting the engine 5 3 - Routine maintenance table Programmed maintenance plan: operations to be carried out by the dealer 6 Programmed maintenance plan: operations to be carried out by the client 8 4 - Maintenance operations Checking the engine oil level 9...
Page 5 A - General Description of the Ducati Diagnostic System instrument 47 Tester power supply 49 DDS tester 52 Checking and adjusting timing belt tension 53 Resetting the throttle position sensor (TPS) 57 Adjusting the idle speed 61 Checking the engine oil pressure 66...
Page 6 A - General Refitting the pillion seat 35 4 - Front mudguard Removal of the front mudguard 37 Refitting the front mudguard 38 Section F 0F - Controls - Devices 1 - Throttle twistgrip Adjusting the throttle cable 4 Removal of the throttle twistgrip 4 Refitting the throttle twistgrip 5 2 - Hydraulic clutch control Removal of the clutch master cylinder assembly 8...
Page 7 A - General 0G - Wheels - Suspension - Brakes 1 - Front wheel Removal of the front wheel 4 Overhauling the front wheel 6 Refitting the front wheel 9 2 - Front fork Removal of the front forks 12 Overhauling the front forks 13 Refitting the front forks 20 3 - Hydraulic front brake...
Page 8 A - General Removal of the rear shock absorber 56 Overhauling the rear shock absorber 57 Removal of the rear suspension rocker arm 58 Overhauling the rear suspension rocker arm 59 Disassembly of the shock absorber tie-rod 60 Refitting the rear suspension 60 8 - Final drive Inspecting the final drive 64 Removal of the front sprocket 65...
Page 9 A - General Refitting the sidestand 24 6 - Frame inspection Disassembly of structural components and the frame 26 Checking the frame 30 Reassembly of structural components and the frame 32 7 - Number plate holder Removal of the number plate holder 35 Refitting the number plate holder 36 Section L 0L - Fuel/Exhaust System...
Page 10 A - General 0M - Fuel injection - ignition system 2 - Fuel injection-ignition system 3 - System components Electronic Control Unit (ECU) 4 Removal of the battery support 6 Refitting the battery support 9 Fuel injectors 13 Stepper motor 14 Air pressure sensor 15 Coolant temperature sensor 16 Air temperature sensor 17...
Page 11 A - General 3.1 - Cooling system: coolant expansion tank Removal of the expansion tank 22 Refitting the expansion tank 24 3.2 - Cooling system: radiator Removal of the radiator 28 Renewal of the cooling fan 30 Refitting the radiator 31 Removal of the cooling system hoses and unions 33 Refitting the cooling system hoses and unions 36 3.3 - Cooling system: water pump...
Page 12 A - General Refitting the intake manifold and coolant union 84 4.5 - Cylinder head assemblies: valves - rocker arms Removal of the cylinder heads 86 Removal of the valves 87 Removing the valve rocker arms 88 Overhaul of cylinder head components 91 Reassembly of the cylinder head 98 Refitting the cylinder head assemblies 105 5 - Cylinder/piston assemblies...
Page 13 A - General Overhaul of the gearbox 160 Inspection of the gear selector forks 161 Inspection of the gear selector drum 162 Reassembly of the gearbox shafts 163 Reassembly of the gearbox 167 8 - Flywheel-alternator Removal of the alternator-side crankcase cover 169 Disassembly of the alternator-side crankcase cover 171 Removal of the flywheel/alternator assembly 172 Overhaul of the flywheel/alternator assembly 174...
Page 14 A - General Section P 0P - Electrical system 1 - Wiring diagram Key to wiring diagram 5 Wiring colour codes 6 Key to fusebox 6 Routing of wiring on frame 7 Plate 1 9 Plate 2 9 Plate 3 10 Plate 4 10 Plate 5 11 Plate 6 11...
Page 15 A - General Plate 31 34 Plate 32 35 Plate 33 36 Plate 34 37 Plate 35 37 Plate 36 38 Plate 37 39 Plate 38 40 Plate 39 41 Plate 40 42 Plate 41 43 Plate 42 44 Plate 43 45 2 - Battery charging system Checking the battery charging system 46 Recharging the battery 47...
Page 16 A - General 6 - Protection and safety devices Checking protection and safety device components 85 Checking the fuses 87 7 - Instruments Instrument panel 88 Instrument panel system 89 Display settings and functions 91 8 - Immobilizer and transponder 9 - Diagnostic instruments Using a multimeter to check the electrical systems 122 file:///C|/848/wsm/en/848_08_IND.1.1.html (15 of 15) [11-6-2008 0:34:09]...
Page 17 A - General 0A - General 1 - How to use this manual Layout of the manual 4 2 - Symbols - Abbreviations - References Product specifications 6 3 - Hazardous Products - Warnings General safety rules 8 General maintenance indications 10 file:///C|/848/wsm/en/848_08_A_IND_00.2.1.html [11-6-2008 0:34:10] WWW.PlanDeGraissage.ORG...
Page 18 This manual also describes the essential checks to be carried out prior to delivery of the motorcycle. Ducati Motor Holding S.p.A. declines all liability for any technical errors or omissions in this manual and reserves the right to make changes made necessary by the technical evolution of its products without prior notice.
Page 19 The layout of the manual is designed in such a way as to be applicable to all the different models manufactured by DUCATI MOTOR HOLDING. To facilitate consultation of the manual, the table of contents is identical for all motorcycle models.
Page 20 Symbols - Abbreviations - References 2 - Symbols - Abbreviations - References To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which maximum care is required, as well as practical advice or information. Pay attention to the meaning of the symbols since they serve to avoid repeating technical concepts or safety warnings throughout the text.
Page 21 Symbols - Abbreviations - References Anti-freeze (nitride, amine and phosphate free) 30 to SHELL 40% solution in water. Advance coolant or Glycoshell GREASE A Multipurpose, medium fibre, lithium grease. SHELL Alvania R3 GREASE B Molybdenum disulphide grease, high mechanical SHELL stress and high temperature resistant.
Page 22 LOCK 11 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel DUCATI liquid gasket. 942470014 Exhaust pipe paste. Self-sealing paste, hardens Holts Firegum when heated; resists temperatures exceeding 1000 °...
Page 23 Hazardous Products - Warnings 3 - Hazardous Products - Warnings General safety rules Carbon monoxide When a maintenance operation must be performed with the engine running, maker sure that the working area is well-ventilated. Never run the engine in an enclosed space. Warning Exhaust fumes contain carbon monoxide, which is a poisonous gas that can cause unconsciousness or even death if inhaled.
Page 24 When charging the battery, ensure that the working area is properly ventilated. General maintenance indications Useful tips Ducati recommends that you follow the instructions below in order to prevent problems and obtain the best end result: when diagnosing faults, primary consideration should always be given to what the customer reports about motorcycle operation since this information can highlight anomalies;...
Page 25 - Use exclusively Ducati original replacement parts and the recommended brands of lubricants. - Use special service tools where specified. Ducati Technical Bulletins often contain updated versions of the service procedures described in this manual. Check the latest Bulletins for details.
Page 26 B - Information about the model 0B - Information about the model 1 - Identification data Identification data for the Superbike 848 3 file:///C|/848/wsm/en/848_08_B_IND_00.6.1.html [11-6-2008 0:34:12] WWW.PlanDeGraissage.ORG...
Page 27 Identification data 1 - Identification data Identification data for the Superbike 848 Each Ducati motorcycle has two identification numbers - the frame number and the engine number - and an EC nameplate (A) (not present on the US version). Notes Please quote these numbers, which identify the motorcycle model, when ordering spare parts.
Page 28 Identification data Data stamped on the frame Europe version 1 Manufacturer: Ducati Motor Holding 2 Type, same on all 848 models 3 Variant 4 Version 5 Year of manufacture (8=2008) 6 Manufacturing facility 7 Progressive serial No. file:///C|/848/wsm/en/848_08_B_1_1_00.7.1.html (2 of 4) [11-6-2008 0:34:12]...
Page 29 Identification data Data stamped on the frame US version 1 Manufacturer: Ducati Motor Holding 2 Motorcycle type 3 Variant Numeric or X (Check digit) 4 Model year (8=2008) 5 Manufacturing facility 6 Progressive serial No. file:///C|/848/wsm/en/848_08_B_1_1_00.7.1.html (3 of 4) [11-6-2008 0:34:12]...
Page 30 Identification data Data stamped on engine Europe version 1 Manufacturer: Ducati Motor Holding 2 Engine type 3 Progressive production No. Data stamped on engine US version 1 Engine type 2 Model year 3 Progressive production No. file:///C|/848/wsm/en/848_08_B_1_1_00.7.1.html (4 of 4) [11-6-2008 0:34:12]...
Page 31: Table Of Contents
C - Technical data 0C - Technical data 1.1 - Technical specifications General 3 Colours 4 Transmission 4 Timing system/valves 4 Crankshaft 5 Cylinder/Piston 5 Gearbox 6 Cooling system 6 Front wheel 6 Front suspension 6 Rear wheel 6 Rear suspension 7 Hydraulic brakes 7 Charging system/alternator 7 Injection - ignition system 8...
Page 32 Technical specifications 1.1 - Technical specifications General Reference Technical specifications Motorcycle dimensions Total length 2100 mm Total width 758 mm Total height 1100 mm Wheelbase 1430 mm Handlebar height 865 mm Seat height 830 mm Height of pillion passenger foot rest 390 mm Minimum ground clearance 130 mm...
Page 33 Cooling system Liquid cooling Air filter Two filter units Crankshaft type One-piece Colours Description Code no. Ducati Anniversary Red F_473.101 (PPG); Transparent; 228.880 (PPG) Red frame with black wheels Pearl white 490019 (PPG); Transparent; 228.880 (PPG) Grey frame with black wheels.
Page 34 Technical specifications Opening rocker arm - intake 0.13 to 0.18 mm 0.10 to 0.25 mm Opening rocker arm - exhaust 0.13 to 0.18 mm 0.10 to 0.25 mm Closing rocker arm - intake 0.05 to 0.10 mm 0.05 to 0.25 mm Closing rocker arm - exhaust 0.05 to 0.10 mm 0.05 to 0.25 mm...
Page 35 Technical specifications Engine cylinder compression measured with 14.5 bar 12.5 bar (MIN.), difference DDS instrument between the two cylinders: 2 bar (MAX.) Gearbox Reference Standard value Service limit Gearbox shafts Endfloat 0.05 to 0.25 mm Selector drum Endfloat 0.10 to 0.40 mm Gear selector fork Selector fork end thickness 3.90 to 4.00 mm...
Page 36 Technical specifications Swingarm pivot shaft runout On 100 mm 0.2 mm Wheel rim runout Radial 0.8 mm 2 mm Axial 0.5 mm 2 mm Chain Make Type 525 GXW IMPROVED Dimensions 5/8" x 5/16" No. of links 97+1 joining link Rear suspension Reference Technical specifications...
Page 37: Injection - Ignition System
Technical specifications Capacity 10 Ah Type Sealed, maintenance free Alternator Capacity 12 V-480 W Injection - ignition system Reference Technical specifications Ignition Type Inductive electronic ignition Starting Type Electric starter motor 12 V-700 W Spark plugs Make and type NGK MAR10A - J Electrode gap 2-0.8±0.1 mm Fuel system...
Page 38: Dimensions
Dimensions 1.2 - Dimensions file:///C|/848/wsm/en/848_08_C_1B4_00.10.1.html (1 of 2) [11-6-2008 0:34:14] WWW.PlanDeGraissage.ORG...
Page 39 Dimensions file:///C|/848/wsm/en/848_08_C_1B4_00.10.1.html (2 of 2) [11-6-2008 0:34:14] WWW.PlanDeGraissage.ORG...
Page 40: Fuel, Lubricants And Other Fluids
Fuel, lubricants and other fluids 2 - Fuel, lubricants and other fluids Fuel, lubricants and other fluids Type Quantity Unleaded fuel with 95 fuel octane rating (at least) 15.5 dm 3 Fuel tank, including a reserve of 4 dm (litres) (litres) Lubrication circuit SHELL Advance Ultra 4...
Page 41 Torque settings 3 - Torque settings Frame torque settings Part Thread (mm) Nm ±10% Tolerance Notes Accessories and equipment Reflector to bracket fastener 4x0.7 Sidestand Nut securing sidestand pivot bolt 8x1.25 24.0 LOCK 10 (GREASE B on pivot bolt) Bolt securing sidestand to crankcase 10x1.5 43.0 Solid threadlocker on bolt...
Page 42 Torque settings Nut securing contactor cable + starter motor GREASE only on starter motor Bolt securing horn to frame 8x1.25 22.0 Solid threadlocker on bolt Voltage regulator retaining bolt 10.0 Lambda sensor 18x1.5 45.0 Battery support bolt 10.0 Battery cover retaining bolt Speed sensor retaining bolt 10.0 Rear brake switch on master cylinder mounting...
Page 43 Torque settings Bolt securing clutch fluid reservoir bracket to 10.0 master cylinder Nut securing clutch fluid reservoir to bracket 5x0.8 Clutch bleed valve fitting on actuator Clutch bleed valve fitting on master cylinder 10x1 14.0 Clutch lever retaining nut Clutch hose fitting on actuator 10x1 25.0 Handlebar switch housing bolts...
Page 44 Torque settings Fuel tank centring plates retaining bolt LOCK 2 Bolt securing flange to fuel tank 5x0.8 LOCK 2 Bolt securing deformation bracket to subframe 10.0 Unions for fuel tank breather and drain hoses Bolt securing fuel tank to deformation bracket 8x1.25 22.0 Bolt securing side panel brackets to fuel tank...
Page 45: Engine Torque Settings
Torque settings Bolt securing fuel hose guide to airbox 4x0.7 Solid threadlocker on bolt Bolt securing fuel hose guide to base of airbox 5x0.8 Bolt securing EVAP filter bracket to timing belt 10.0 LOCK 2 cover Nut securing EVAP plate to bracket 10.0 Fairings Bolt securing windshield to headlight shell...
Page 46 Torque settings Cylinder head nut: M10x1.5 Apply GREASE C to the Stage 1 underside of the nut and the Stage 1 thread of the stud Stage 2 Cam cap bolt: M8x1.25 Engine oil Stage 1 Stage 2 22.5 Coil retaining bolt M6x1 Pulley flange retaining bolts M6x1...
Page 47 Torque settings Idler gear shaft retaining bolt M6x1 LOCK 2 or TB1324 Flywheel retaining nut M24x1 LOCK 5 or TB1375B Nut securing front sprocket oil clutch M22x1 GREASE B Connecting rod cap bolts: M10x1 Apply GREASE B to thread Tighten at 50 rpm Pause for 2 sec.
Page 48 Torque settings Oil pump retaining bolt M8x1.25 Coolant outlet union M22x1.5 LOCK 5 or TB1375B Coolant circuit hose clamps * dynamic safety-critical point; tightening torque must be within Nm ±5%. Notes For product specifications and symbols, see paragraph Product specifications (Sect.
Page 49: Service Tools
Service tools 4 - Service tools Parts catalogue WORKSHOP SERVICE TOOLS WORKSHOP SERVICE TOOLS Specific tools for the engine Code No. Designation 88713.2011 Tool to lock crankshaft at Top Dead Centre 88713.2676 Wrench for tightening cylinder head nuts 88713.2103 Stand for cylinder head assembly 88765.1523 Timing check tool file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (1 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 50 Service tools Wrench for tightening timing belt tensioner pulley 88713.1821 shafts 88713.2861 Camshaft oil seal installer 88713.2060 Gearbox output shaft oil seal installer 88713.1806 Tool for tightening Z=20 camshaft pulley 88713.2069 Rocker spring tensioning kit file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (2 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 51 Service tools DDS (Ducati Diagnostic System) + 97900.0215 cylinder vacuum gauge kit 88765.1524 Timing belt pulley timing tools 88765.1518 Valve lift gauge 88713.2878 Fork-type feeler gauge 0.1 mm, 0.2 mm, 0.3 mm 88713.2874 Alternator holding tool for tightening nut file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (3 of 13) [11-6-2008 0:34:18]...
Page 52 Service tools 88713.1920 Tool for installing O-rings on crankcase studs 88713.2827 Plate for gear selector fork positioning 88713.2442 Tool for installing valve guide seals 88713.1749 Puller for drive pulley and cover 88713.1832 Engine repair bench file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (4 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 53 Service tools 88713.1904 Punch for fitting half-rings 88713.1980 Punch for installing caps on shafts 88713.1886 Engine cover sheet 88713.1010 Exhaust gases pick-up connector 88713.1805 Tool for tightening timing belt driveshaft pulley file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (5 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 54 Service tools 88765.1188 Top Dead Centre test gauge 88713.0869 Water pump front seal installer Installation tool for counter plate for water pump 88713.0870 front seal 88700.5749 Crankcase assembly cap 88713.2877 Sparkplug wrench file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (6 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 55 Service tools 88713.2842 Inlet/exhaust valve guide installer 88713.2846 Exhaust valve seat installer 88713.2847 Inlet valve seat installer 88713.2870 Connecting rod guide tool 88713.2834 Punch and sleeve for installing camshaft circlip file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (7 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 56 Service tools 88713.2832 Timing belt tensioner pulley wrench Tool for installing needle roller bearings on primary 88713.2669 shaft 88713.2906 Oil filter cartridge wrench 88713.2651 Wet FCC clutch drum holding tool 88713.2423 Reaction wrench file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (8 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 57: Specific Tools For The Frame
Service tools 88713.2422 Wrench for tightening primary sprocket nut Parts catalogue WORKSHOP SERVICE TOOLS Specific tools for the frame Code No. Designation 88713.1072 Drift to install half bearing in bottom yoke 88713.2562 Chain assembly tool 8000.70139 Front wheel axle wrench file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (9 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 58 Service tools 88713.1515 Engine/frame support 88713.1058 Wrench for steering stem nut 88713.1062 Tool for installing steering head bearings 88713.1071 Drift to drive rocker arm needle rollers 88713.2951 Rear wheel balancing tool file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (10 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 59 Service tools 88713.1038 Wrench for adjustment of the eccentric hub 88713.1096 Tool for overhauling SHOWA forks/fitting oil seals 677.4.003.1A Chain joining link 88713.1074 Swingarm pivot bolt removal tool 88713.0957 SHOWA fork spacer holder file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (11 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 60 Service tools 88713.1057 Steering damper bearing installer 88713.1077 Seat lock nut wrench 88713.1068 Tool for installation of swingarm roller bearings 88713.2409 Swingarm bearing installer 88713.2856 Rod guide tool file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (12 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 61 Service tools 88713.2857 Tool for disassembly of sliding bushes 88713.2858 Tool for disassembly of sliding bushes 88713.2855 Bush support bar 88713.2854 Fork plug installation/removal bush file:///C|/848/wsm/en/848_08_C_4_4_00.13.1.html (13 of 13) [11-6-2008 0:34:18] WWW.PlanDeGraissage.ORG...
Page 62 Adjusting the position of the gearchange and rear brake pedals 42 Adjusting the front fork 43 Adjusting the rear shock absorber 44 5 - Diagnostic instruments Description of the Ducati Diagnostic System instrument 47 file:///C|/848/wsm/en/848_08_D_IND_00.14.1.html (1 of 2) [11-6-2008 0:34:19] WWW.PlanDeGraissage.ORG...
Page 63 D - Use and maintenance Tester power supply 49 DDS tester 52 Checking and adjusting timing belt tension 53 Resetting the throttle position sensor (TPS) 57 Adjusting the idle speed 61 Checking the engine oil pressure 66 Cylinder compression test 71 Fuel pressure test 74 Immobilizer override procedure 77 Guided diagnosis 81...
Page 64: Preliminary Checks
Throughout the running-in period, be careful to stick to the recommended maintenance schedule and periodic service intervals indicated in the warranty booklet. Failure to follow these instructions releases Ducati Motor Holding S.p.A. from any liability whatsoever for any engine damage or shorter engine life. Pre-ride checks file:///C|/848/wsm/en/848_08_D_1_5_00.15.1.html (1 of 2) [11-6-2008 0:34:19]...
Page 65 Preliminary checks Warning Failure to carry out these checks before riding may result in damage to the motorcycle and serious injury to the rider. Before starting, check the following points: Fuel level in the tank Check the fuel level in the tank. Fill the tank if needed (Sect. C 2, Fuel, lubricants and other fluids).
Page 66: Starting - Engine Warmup
Starting - Engine warmup 2 - Starting - Engine warmup Starting the engine This motorcycle is equipped with an automatic starter (stepper motor). This allows automation of the engine warmup procedure. For information on the operation of the stepper motor, see Sect. M 3, Stepper motor.
Page 67: Routine Maintenance Table
Routine maintenance table 3 - Routine maintenance table Programmed maintenance plan: operations to be carried out by the dealer List of operations with frequency km x1000 (distance or time interval*) miles x1000 22.5 37.5 Months Change the engine oil Change the engine oil filter Clean the engine oil pick-up filter Check the engine oil pressure Check/adjust the valve clearances (1)
Page 68: Programmed Maintenance Plan: Operations To Be Carried Out By The Client
Routine maintenance table * Service operation to be carried out in accordance with the specified distance or time intervals (km, miles or months), whichever occurs first. (1) Operation to be carried out only at the specified distance intervals. Programmed maintenance plan: operations to be carried out by the client List of operations with frequency km x1000 (distance or time interval*)
Page 69: Maintenance Operations
Maintenance operations 4 - Maintenance operations Checking the engine oil level Check the engine oil level in the sight glass (1) on the right-hand side of the oil sump. Stop the engine and allow a few minutes for the oil to settle to a steady level. Check the level with the motorcycle perfectly vertical and with the engine warm (but not running).
Page 70 Maintenance operations Tighten to the specified torque (Sect. C 3, Engine torque settings). Remove the filter cartridge (4) from the sump using a standard filter wrench. Important Dispose of the used cartridge, do not attempt to reutilise it. Lubricate the rubber seal of the new filter (4) with engine oil before installing it. Screw the cartridge into place and tighten to the specified torque (Sect.
Page 71 Maintenance operations Take out the filter element (8), check the O-rings (9) and replace if necessary. Clean the filter with petrol and compressed air. Take care not to damage the gauze. Refit the gauze filter (8) with the O-rings (9). Apply a bead of liquid gasket to the seating of the cap (6) on the crankcase cover as shown in the figure.
Page 72: Checking Valve Clearances
Maintenance operations other fluids) up to the MAX line in the sight glass (1). Refit the filler cap (2). Run the engine at idle speed for a few minutes. Check for oil leaks. Check that the oil pressure light on the instrument panel switches off a few seconds after the engine starts.
Page 73 Maintenance operations With the valve in the rest position, slide a feeler gauge between closing rocker arm (C) and the highest side of the cam (D) to measure the clearance. Closing rocker arm Intake: Operation 0.05 to 0.10 mm Checking clearance 0.05 to 0.25 mm Exhaust: Operation...
Page 74: Adjusting The Valve Clearances
Maintenance operations Adjusting the valve clearances Proceed as described in Sect. N 4.1, Checking and adjusting the valve clearances. Checking the coolant level At the intervals specified in the Routine maintenance table chart (Sect. D 3), check the coolant level in the expansion tank, located on the right-hand side of the motorcycle.
Page 75: Changing The Coolant
Maintenance operations Important Solutions with less than 30% of coolant will not provide sufficient protection against corrosion. Changing the coolant Warning This operation must only be carried out when the engine is cold. Attempting to change the coolant with the engine hot could lead to burns from hot coolant or scalding steam. Remove the right-hand fairing (Sect.
Page 76: Changing And Cleaning The Air Filters
Maintenance operations Stop the engine and allow it to cool down so that all the air is expelled from the cooling circuit. Warning Keep your hands, clothing and tools well clear of the radiator fan at all times; this fan starts automatically without warning and could cause serious injury or damage.
Page 77 Maintenance operations Extract the filter cartridges (4) from the housings in the airbox. The filter cartridge can be cleaned with a jet of compressed air or renewed as necessary. Important A clogged air filter will reduce air intake and engine power, increase fuel consumption and cause a build up of deposits on the spark plugs.
Page 78: Changing The Brake Fluid
Maintenance operations Changing the brake fluid Warning Brake fluid will damage painted surfaces if spilled on them. In addition, it is very harmful in contact with the skin or with the eyes; in the event of accidental contact wash the affected area with abundant running water.
Page 79 Maintenance operations Attach a length of transparent plastic tubing to the bleed valve (3) and insert the other end of the tubing in a container placed on the floor. Loosen the bleed valve (3) to allow fluid to escape. Warning While filling the system, always keep the fluid level above the MIN mark to prevent the formation of air bubbles in the circuit.
Page 80 Maintenance operations Changing the rear brake circuit fluid Unscrew the cap (4) of the rear brake fluid reservoir (B). Siphon the brake fluid from the reservoir (B). Fill the reservoir (B) with new brake fluid up to the MAX mark. Operate the brake pedal two or three times to pressurize the circuit.
Page 81: Draining The Brake Circuit
Maintenance operations Warning While filling the system, always keep the fluid level above the MIN mark to prevent the formation of air bubbles in the circuit. Allow the fluid to flow from the bleed valve (5) until it changes colour. Tighten the bleed valve (5) and restore the correct fluid level in the reservoir.
Page 82 Maintenance operations Unscrew the cap (4) of the rear brake fluid reservoir (B). Connect a commercially available brake bleeder to the bleed valve (3) or (5). Open the bleed valve (3) or (5) and pump with the bleeder until no more fluid emerges. Notes Follow the manufacturer's instructions when using a commercial brake bleeding tool.
Page 83: Filling The Brake System With Fluid
Maintenance operations Unscrew the bleed valve by a 1/4 turn. Operate the brake lever (or pedal) until all the fluid has drained out. Repeat this operation for each brake caliper. Filling the brake system with fluid Warning Brake fluid will damage painted surfaces if spilled on them. In addition, it is very harmful in contact with the skin or with the eyes;...
Page 84 Maintenance operations Important During the following operation, the fluid level must remain topped up at all times. The end of the transparent plastic tubing must remain immersed in the discharged fluid at all times. Operate the brake lever (or pedal) several times to allow the fluid to reach all points of the circuit and expel any air.
Page 85 Maintenance operations Connect the bleed tool to bleed valve (3) or (5). Notes Follow the manufacturer's instructions when using a commercial brake bleeding tool. Open the bleed valve (3) or (5) and pump with the bleeder. Make sure that the reservoir level does not fall below the MIN mark.
Page 86: Changing The Clutch Fluid
Maintenance operations Open the bleed valve (3) or (5) by a 1/4 turn and operate the brake lever (or pedal) several times until the fluid starts coming out of the bleed valve. Pull the lever fully in and open the bleed valve by at least a 1/4 of a turn.
Page 87 Maintenance operations Clutch fluid will damage painted surfaces if spilled on them. In addition, it is very harmful in contact with the skin or with the eyes; in the event of accidental contact wash the affected area with abundant running water. Remove the cap (1) and membrane from the clutch fluid reservoir (A).
Page 88: Draining The Clutch Hydraulic Circuit
Maintenance operations Warning During the filling operation, always keep the fluid level above the MIN mark to prevent the formation of air bubbles in the circuit. Allow the fluid to flow from the bleed valve (2) until it changes colour. Tighten the bleed valve (2) to the specified torque (Sect.
Page 89 Maintenance operations Unscrew the bleed valve by a 1/4 turn. Remove the cap (1) and membrane from the clutch fluid reservoir (A). Operate the clutch lever until all the fluid has been expelled. To help drain the circuit fully, unscrew the three retaining bolts (3) and remove the slave cylinder cap from the engine.
Page 90: Filling The Clutch Circuit
Maintenance operations Remove the clutch slave cylinder (4) taking care not to damage the internal O-ring (5). Push in the internal piston to force out all the fluid from inside the cap. Refit the slave cylinder cap and tighten retaining screws (3) to the specified torque (Sect. C 3, Frame torque settings).
Page 91 Maintenance operations Warning Clutch fluid will damage painted surfaces if spilled on them. It is also very harmful if it comes into contact with the skin or with the eyes; in the event of accidental contact, wash the affected area with abundant running water.
Page 92: Adjusting The Steering Head Bearings
Maintenance operations Repeat the bleeding operation until the fluid flowing from the tube is completely free of air bubbles. If you do not have a bleeding tool available, connect a length of transparent plastic tubing to the bleed valve (2) as outlined in the draining procedure. Open the bleed valve by a 1/4 turn and operate the clutch lever several times until the fluid starts to emerge from the bleed valve (2).
Page 93: Adjusting The Chain Tension
Maintenance operations Loosen the clamp bolt (1) that holds the steering tube to the top yoke. Loosen the clamp bolts (2) securing the top yoke to the fork legs and loosen the handlebar bolts (3). Using the special wrench 88713.1058, tighten the adjuster nut (4) to the specified torque (Sect. C 3, Frame torque settings).
Page 94 Maintenance operations Move the motorcycle slowly until you find the point at which the upper section of the chain is most taut. Place the motorcycle on its sidestand. Push the chain upwards with a finger in correspondence with the centre of the swingarm (see adhesive label).
Page 95: Checking Brake Pad Wear And Changing Brake Pads
Maintenance operations Checking brake pad wear and changing brake pads Warning Brake fluid will damage painted surfaces if spilled on them. It can also be very harmful if it comes into contact with the skin or with the eyes; in the event of accidental contact, wash the affected area with abundant running water.
Page 96 Maintenance operations Important If either of the pads is worn, both pads must be renewed as a set. Change the brake pads as follows. Remove the cotter pin (2) from the pad retaining pins. Withdraw the pad retaining pins (3) from the outside. Remove the clip (1) from between the two caliper halves.
Page 97 Maintenance operations Notes Change pads that have a shiny or vitrified appearance. Insert the new pads and clip (1). Insert the retaining pins (3) from the exterior of the caliper and secure them with the cotter pins (2). Operate the brake lever repeatedly so that the pads are firmly bedded in against the disc by the force of the brake fluid.
Page 98 Maintenance operations Change the brake pads as follows: Remove the cotter pin (1) (on the inner side of the caliper) from the pad retaining pin. Force the caliper pistons back into their bores by forcing the brake pads apart. Withdraw the pad retaining pin (2) towards the outside. Remove the clip (3) from between the two caliper halves.
Page 99: Adjusting The Throttle Cable
Maintenance operations Notes If it proves difficult to change the brake pads, first remove the caliper from the motorcycle (Sect. G 6, Removal of the rear brake caliper). Warning As the brake calipers are components of vital importance to the safety of the motorcycle, refer to the instructions in Sect.
Page 100 Maintenance operations Peel back the sleeves to access the adjusters and slacken the locknuts. Adjust both adjusters by the same amount: turn clockwise to increase free play and anti-clockwise to reduce free play. When finished, tighten the locknuts and replace the sleeves. Periodically check the condition of the outer cables of the throttle opening (1) and closing cables (2).
Page 101 Maintenance operations Lubricate the ends of the cable and the race (B) with the recommended grease. When refitting the cover, make sure that the cables are correctly positioned in the race (B). Locate the housings (4) and (5) in the handlebar hole (C). Secure the housings (4) and (5) with screws (3) tightened to the specified torque (Sect.
Page 102: Adjusting The Clutch Lever And Front Brake Lever
Maintenance operations Adjusting the clutch lever and front brake lever The lever (1) disengages the clutch. The span adjuster (2) serves to alter the distance of the lever from the handlebar. The lever distance can be adjusted through 10 clicks of the knob (2). Turn the knob clockwise to move the lever away from twistgrip, or anti-clockwise to move it closer.
Page 103: Adjusting The Position Of The Gearchange And Rear Brake Pedals
Maintenance operations Warning Any adjustment of clutch and brake levers must only be carried out when motorcycle is stationary. Adjusting the position of the gearchange and rear brake pedals The position of the gearchange and rear brake pedals in relation to the footrests can be adjusted to suit the preferred riding position.
Page 104: Adjusting The Front Fork
Maintenance operations Operate the pedal by hand to make sure it has 1.5 to 2 mm of free play before the brake begins to bite. If not, adjust the length of the master cylinder pushrod as follows. Slacken off the locknut (7) on the pushrod. Screw the rod into the clevis (6) to increase play, or unscrew it to reduce play.
Page 105: Adjusting The Rear Shock Absorber
Maintenance operations The STANDARD factory settings are as follows: compression: 3/4 turn; rebound: 12 clicks; spring preload (A): 18 mm. Adjusting the rear shock absorber The shock absorber has external adjusters that enable you to adapt the rear suspension to suit the load conditions.
Page 106 Maintenance operations The adjuster (2) located on the rear shock absorber reservoir is used to adjust compression damping. Turn the adjusters (1) and (2) clockwise to increase damping, or anti-clockwise to reduce damping. STANDARD setting: from the fully closed position (turned fully clockwise), unscrew: rebound adjuster (1): 2 turns;...
Page 107 Maintenance operations Warning To turn the preload adjuster ring nuts, use only a specific tool and take care, otherwise the wrench pins may suddenly slip out of the ring nut. This could injure your hands. Never use a wrench with a too small pin or with a too short handle. Warning The shock absorber is filled with high-pressure gas and can cause injuries if inexpertly dismantled.
Page 108: Diagnostic Instruments
Diagnostic instruments 5 - Diagnostic instruments 1 97900.0211 Basic DDS (Ducati Diagnosis System) 2 97900.0227 Power and diagnostic cable D607 3 97900.0222 Power and diagnostic cable 1060838 (Measurement Module) 4 97900.0218 Vacuum sensor 5 552.1.039.1A Pressure sensor 6 97900.0220 Pressure/vacuum pipe 7 97900.0221 Pipe fitting...
Page 109: Description Of The Ducati Diagnostic System Instrument
Description of the Ducati Diagnostic System instrument The Ducati Diagnostic System (DDS) is used for diagnosis of the injection-ignition system via a serial connection. The system is also equipped with functions to test various devices on the motorcycle. The DDS tester can be used to measure current and voltage on any electrical device, to perform tests on individual components and to measure pressure and temperature values.
Page 110 The user interface software resides in the display memory card (C) which is housed in the palm-top display unit (A). The software that enables communication with DUCATI ECUs resides in the BBAD memory card (D), which is housed in the BBAD self-diagnosis module (B).
Page 111 Diagnostic instruments You can connect a printer to the DDS tester (1) to print test reports: connect the printer to the serial port (COM1) (G) located on the top connection panel of the tester (1). Technical data Power supply: - from the mains - 220 V; - from the motorcycle battery - 12 V.
Page 112 Diagnostic instruments Connection to motorcycle The tester requires a power supply of between 9 and 16 Volts DC. When using the tester, take care never to allow the power supply to fall below the minimum voltage: this situation could occur during engine starting and idling on motorcycles in which the battery is not in perfect working order. If the tester detects a power supply voltage of less than 9 Volts, the current procedures will be aborted;...
Page 113 Diagnostic instruments connect the power and diagnostic cable (2) to the diagnostic connection socket (P) on the tester; then connect the battery socket adapter (8) to the connection socket (R) on the power and diagnostics cable (2) and to the motorcycle battery.
Page 114 Diagnostic instruments Notes For connection of the various devices required for self-diagnostic procedures, consult the instruction handbook supplied with the tester. DDS tester The main functions of the DDS tester can be summarised as follows: retrieval of errors (faults) of the ignition - injection system stored in the engine control unit memory and their subsequent deletion, if required;...
Page 115 Diagnostic instruments green LED that serves to determine that the reader is correctly positioned in front of the belt to be tested. It is also equipped with an infrared transmitter (A) and receiver (B) designed to detect oscillations of the belt when caused to vibrate with the flick of a finger.
Page 116: Tester Power Supply
Diagnostic instruments Remove the belt tension sensor and disconnect the DDS tester from the motorcycle. Operation Section reference Refit the timing belt covers N 4.2, Refitting the timing belt covers Refit the right-hand side fairing E 2, Refitting the side fairings Measuring timing belt tension Switch on the DDS tester (1);...
Page 117 Diagnostic instruments Aim the central green LED of the sensor (15) at the mid-point of the belt run, with the reader parallel to the belt and at a distance of about 1 to 1.5 cm from it. On the DDS tester (1), select the Measurement module function by pressing the corresponding icon; then press the Belt Tension icon followed by the Start icon to access the Mechanical belt tension screen.
Page 118 Diagnostic instruments Flick the belt lightly with your finger and read the frequency value (Hz) on the DDS tester. Notes Do not flick the belt several times repeatedly, as the minimum time necessary for the DDS tester to take a reading is 1 second.
Page 119 Diagnostic instruments Resetting the throttle position sensor (TPS) The linear throttle potentiometer has no facility for positioning adjustment: to ensure that the system functions correctly, proceed as follows: Warning This procedure must precede the first start-up of the vehicle after replacement of the throttle body, the ECU or the wiring.
Page 120 Diagnostic instruments Enter the general functions menu by pressing the icon Menu 1 (C). Press the Select vehicle icon and, on the next screen, press the Select motorcycle icon; select the motorcycle model and confirm, then select the version and confirm. Press the icon Select system to display a list of the bike s systems that can be analysed.
Page 121 Diagnostic instruments Select Engine electronics and press the Confirm icon (D). Next, press the Self-diagnosis icon to access the corresponding function. The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. Notes Make all connections with the motorcycle ignition key in the OFF position.
Page 122 Diagnostic instruments Select the option Reset TPS and then press the icon Apply . On completion of the operation, the message Was the operation was completed successfully? will appear; press Confirm (D). file:///C|/848/wsm/en/848_08_D_5_5_00.19.1.html (15 of 47) [11-6-2008 0:34:24] WWW.PlanDeGraissage.ORG...
Page 123 Adjusting the idle speed Notes Check that the motorcycle is fitted with a genuine Ducati ECU, intake system and exhaust system; if not, fit genuine components. b This adjustment should be carried out in an ambient temperature greater than 16 °C.
Page 124: Resetting The Throttle Position Sensor (Tps)
Diagnostic instruments Make sure that the throttle cable freeplay is correctly adjusted. Reset the TPS to zero as described in the paragraph Resetting the throttle position sensor (TPS) in this section. Screw in fully both bypass screws (20) and (21) and then screw them out by 3/4 of a turn. Check: that the throttle angle value read by the DDS tester with the engine switched off is 2.6°...
Page 125 Connect the Measurement Module cable (3) to the Measurement Module connector on the DDS (see paragraph Description of the Ducati Diagnostic System instrument ). Connect the vacuum/pressure pipes (6) to the connectors (A) and (C) of cable (3) and connect the fittings (7) to the pipes.
Page 126 Diagnostic instruments Switch on the DDS tester; see the paragraph Tester Power Supply . Enter the Measurement module function. Press the Cylinder synchronisation icon. The socket to which the Measurement Module cable (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
Page 127 Diagnostic instruments Warning Press the Reset icon (G), then connect the sensors (4) and (5) to connectors (A) and (C) of the cable (3) and to the vacuum/pressure pipes (6). Press the Start icon to begin the cylinder pressure measurement procedure. The onscreen indicator light (E) will turn red when the function is active.
Page 128: Checking The Engine Oil Pressure
Diagnostic instruments To adjust the balance, turn the bypass screws (20) and (21) until the two lines on the graph coincide, if in graphic mode, or until identical numerical values are displayed, if in numerical mode. Correct balancing is obtained when the two lines of the graph are superimposed or when the two numerical values indicated are equal.
Page 129 Diagnostic instruments Insert the fitting (9) into the connection on the hose (12), interposing the two copper sealing washers (20). Insert the fitting (9) of the pipe (12) in the threaded hole (M10x1 mm) of the right crankcase cover and screw it fully home. Refit the pressure switch (19) on the fitting (9) along with its seal, and reconnect the wiring connector (A).
Page 130 Diagnostic instruments Switch on the DDS tester (1); see paragraph entitled Tester power supply Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (B) on the DDS tester (1). Connect the pressure sensor (5) to socket (A) or (C) of the cable (3). file:///C|/848/wsm/en/848_08_D_5_5_00.19.1.html (23 of 47) [11-6-2008 0:34:24] WWW.PlanDeGraissage.ORG...
Page 131 Diagnostic instruments On the DDS tester (1), select the Measurement module function by pressing the corresponding icon; then press the Pressure Test icon (D) followed by the Start icon (E). The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
Page 132 Diagnostic instruments Start the engine. The values may be displayed in three different ways: one numeric format and two graphic formats; to select the desired display type, press the Value display icon (F). The measured value is indicated alongside the letter (A) or (C) identifying the cable used for the measurement: i.e. if you used connector (A) of the cable (3), the measured value will be displayed next to the letter (A) on the screen.
Page 133 Diagnostic instruments Oil pressure test values: Warm engine (Minimum oil temperature = 80 °C) 1100 to 1300 rpm greater than 0.8 bar 3500 to 4000 rpm greater than 4 bar Important The maximum pressure must never exceed 6.0 bar. Excessively high pressure may indicate that the relief valve is stuck. Excessively low pressure, on the other hand, may be caused by the relief valve being stuck in the open position, the relief valve spring being too weak, or a faulty oil pump.
Page 134: Cylinder Compression Test
Diagnostic instruments Disconnect the DDS tester Refit the RH side fairing (Sect. E 2, Engine torque settings). Cylinder compression test Notes The on-screen icons used during this procedure are explained in a table at the end of this section. Engine performance is directly correlated to the pressure that can be measured in the combustion chambers of the two cylinders.
Page 135 Diagnostic instruments Connect the pressure sensor (5) to socket (A) or (C) of the cable (3). Notes Measure the compression on one cylinder at a time. On the DDS tester (1), select the Measurement module function by pressing the corresponding icon; then press the Cylinder Compression icon (D) followed by the Start icon (E).
Page 136 Diagnostic instruments The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. Turn over the engine with the starter motor until the pressure stops rising. Check the pressure in each cylinder: - standard value: 14.5 bar;...
Page 137: Fuel Pressure Test
Diagnostic instruments Fuel pressure test Notes The on-screen icons used during this procedure are explained in a table at the end of this section. Before doing this check, detach the fuel tank (Sect. L 2, Removal of the fuel tank) from the bike, without removing it. Slightly raise the fuel tank and place a pad underneath it so as to be able to access the fittings on the flange.
Page 138 Diagnostic instruments Switch on the DDS tester (1); see paragraph entitled Tester power supply Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (E) on the DDS tester (1). Connect the pressure sensor (5) to socket (A) or (C) of the cable (3). On the DDS tester (1), select the Measurement module function by pressing the corresponding icon;...
Page 139 Diagnostic instruments The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. The values may be displayed in three different ways: in one numeric form and in two graphic forms; to select the desired display type, press the Value display icon (H).
Page 140: Immobilizer Override Procedure
Diagnostic instruments Immobilizer override procedure Notes The on-screen icons used during this procedure are explained in a table at the end of this section. If the immobilizer system does not work, there is an emergency procedure for starting the engine, by entering the secret code with the aid of the DDS tester.
Page 141 Diagnostic instruments Press the Select vehicle icon and, on the next screen, press the Select motorcycle icon; select the motorcycle model and confirm, then select the version and confirm. Press the icon Select system to display a list of the bike s systems that can be analysed. Select Engine electronics and press the Confirm icon (B).
Page 142 Diagnostic instruments The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. Notes Make all connections with the motorcycle ignition key in the OFF position. Press the Actuators icon (C) to display the actuators and other components connected to the ECU. Select the option Immobilizer Override and then press the icon Apply (D).
Page 143: Guided Diagnosis
Diagnostic instruments A screen will appear in which you can enter the 5 digit secret code. Use the red arrows (E) and (F) to enter each digit: after entering each digit, press the Confirm icon (B). One the entire code has been entered, press the Confirm icon (B) again. On completion of the operation, the message Was the operation completed successfully? will appear;...
Page 144 Diagnostic instruments and documentation for motorcycle components, wiring diagrams for the electronic systems and information on the locations of specific components. Switch on the DDS tester (1); see paragraph entitled Tester power supply Connect the power and diagnostics cable (2) to the diagnostics connector (F) on the tester and to the diagnostics socket (G) on the motorcycle.
Page 145 Diagnostic instruments Select Engine electronics and press the Confirm icon (B). Press the Guided diagnosis icon (C) to access the corresponding function. file:///C|/848/wsm/en/848_08_D_5_5_00.19.1.html (38 of 47) [11-6-2008 0:34:24] WWW.PlanDeGraissage.ORG...
Page 146: Testing The Battery Charging System
Diagnostic instruments A series of screens are displayed indicating the operations required for correct diagnosis. To determine whether the system has any internal problems, you can access the Self-diagnosis function by pressing the corresponding icon. If any errors are present, the symbol (D) will be displayed. To determine the type of errors present, press the Errors icon (E).
Page 147 Diagnostic instruments ammeter clamp (18) detects the magnetic field generated by the current passing through that cable. Remove the right-hand fairing (Sect. E 2, Removal of the side fairings). Switch on the DDS tester (1); see heading Tester Power Supply . Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (D) on the DDS tester (1).
Page 148 Diagnostic instruments The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. file:///C|/848/wsm/en/848_08_D_5_5_00.19.1.html (41 of 47) [11-6-2008 0:34:24] WWW.PlanDeGraissage.ORG...
Page 149: Deactivating The Service Indication On The Instrument Panel
Diagnostic instruments If the measured current is a positive quantity, this means that alternator is powering all the electrical loads and charging battery at the same time. If the current has a negative sign, this means that the charging system is not able to power the electrical loads and a significant amount of the current required must be supplied by the battery, which is therefore discharging.
Page 150 Diagnostic instruments Enter the general functions menu by pressing the Menu 1 icon (B). Press the Select vehicle icon and, on the next screen, press the Select motorcycle icon; select the motorcycle model and confirm, then select the version and confirm. Press the Select system icon.
Page 151 Diagnostic instruments Select Engine electronics . Press the Confirm icon (C). Next, press the Self-diagnosis icon to access the corresponding function. The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. Press the Settings icon to display the special parameters. Select the option Service light OFF and then press the Apply icon.
Page 152: Icons Table
Diagnostic instruments On completion of the operation, the message Was the operation was completed successfully? will appear; press Confirm (C). If any problems were encountered during the operation, the tester will display the relative error messages: each message must be confirmed, (by pressing the Confirm icon (C)), or rejected (by pressing the Exit icon (D)). Notes Once the service indication has been reset with the DDS tester, set the ignition switch to OFF and wait for at least 30 seconds before switching it ON again.
Page 153 Diagnostic instruments Confirm Exit Measurement module Belt tension Start/stop Menu 1 Select vehicle Select motorcycle Self-diagnosis Settings Apply Cylinder synchronisation Value display Reset Pressure test Cylinder compression Actuators Guided diagnosis file:///C|/848/wsm/en/848_08_D_5_5_00.19.1.html (46 of 47) [11-6-2008 0:34:24] WWW.PlanDeGraissage.ORG...
Page 154 Diagnostic instruments Select system Errors Ammeter clamp file:///C|/848/wsm/en/848_08_D_5_5_00.19.1.html (47 of 47) [11-6-2008 0:34:24] WWW.PlanDeGraissage.ORG...
Page 155 E - Fairings 0E - Fairings 1 - Headlight shell - rear-view mirrors Removal of the rear-view mirrors 4 Refitting the rear-view mirrors 5 Removal of the air scoop covers 6 Refitting the air scoop covers 8 Removal of the headlight shell 11 Refitting the headlight shell 13 2 - Fairing panels Removal of the side fairings 17...
Page 156: Headlight Shell - Rear-View Mirrors
Headlight shell - rear-view mirrors 1 - Headlight shell - rear-view mirrors 1 Headlight shell 2 Bolt 3 Washer 4 Bolt 5 Bolt 6 Clip 7 Rivet 8 RH rear-view mirror 9 LH rear-view mirror 10 Nut 11 Nylon washer 12 Special bolt 13 Windshield 14 Splashguard...
Page 157: Removal Of The Rear-View Mirrors
Headlight shell - rear-view mirrors 19 Right heel plate 20 Left heel plate 21 Special bolt 22 Insert Parts catalogue HEADLIGHT FAIRING Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 158: Refitting The Rear-View Mirrors
Headlight shell - rear-view mirrors Refitting the rear-view mirrors Locate the rear-view mirror on the headlight shell, routing the turn indicator wiring through the appropriate hole. Check that the upper gasket (15) is in place on the mirror. Refit the lower gasket (16). Engage the pins (B) in the clips (6) on the headlight shell.
Page 159: Removal Of The Air Scoop Covers
Headlight shell - rear-view mirrors Removal of the air scoop covers Remove the LH (A) and RH (B) bulb covers on the headlight. Undo the three bolts (21) securing the RH air scoop cover (19). file:///C|/848/wsm/en/848_08_E_1_4_00.21.1.html (4 of 14) [11-6-2008 0:34:25] WWW.PlanDeGraissage.ORG...
Page 160 Headlight shell - rear-view mirrors Unscrew the three bolts (21) securing the LH air scoop cover (20). Slide the air scoop covers (19) and (20) towards the front of the motorcycle and when the fittings (A) are clear of the file:///C|/848/wsm/en/848_08_E_1_4_00.21.1.html (5 of 14) [11-6-2008 0:34:25] WWW.PlanDeGraissage.ORG...
Page 161: Refitting The Air Scoop Covers
Headlight shell - rear-view mirrors fairing, lift. Refitting the air scoop covers Refit the air scoop covers (19) and (20), taking care not to mark the fuel tank or break the bulb. Insert the fittings (A) in the slots (B) in the LH and RH fairing panels and slide them towards the fuel tank. file:///C|/848/wsm/en/848_08_E_1_4_00.21.1.html (6 of 14) [11-6-2008 0:34:25] WWW.PlanDeGraissage.ORG...
Page 162 Headlight shell - rear-view mirrors Fit the six bolts (21) securing the RH (19) and LH (20) air scoop covers. Tighten the bolts to the specified torque (Sect. C 3, Frame torque settings). file:///C|/848/wsm/en/848_08_E_1_4_00.21.1.html (7 of 14) [11-6-2008 0:34:25] WWW.PlanDeGraissage.ORG...
Page 163 Headlight shell - rear-view mirrors Refit the LH (A) and RH (B) bulb covers on the headlight. file:///C|/848/wsm/en/848_08_E_1_4_00.21.1.html (8 of 14) [11-6-2008 0:34:25] WWW.PlanDeGraissage.ORG...
Page 164: Removal Of The Headlight Shell
Headlight shell - rear-view mirrors Removal of the headlight shell Operation Section reference Remove the side fairings E 2, Removal of the side fairings To remove the headlight shell, you must first remove the rear-view mirrors and air scoop covers as described above. Unscrew the bolts (18) and remove the splash guard (14).
Page 165 Headlight shell - rear-view mirrors Slide the headlight shell (1) forward, releasing it from the rubber mountings of the lights assembly. If the windshield (13) is to be replaced, unscrew the bolts (12) with washers (11) and remove the windshield (13), recovering the inserts (10).
Page 166: Refitting The Headlight Shell
Headlight shell - rear-view mirrors Refitting the headlight shell Important On refitting the headlight shell, always refit the nylon washers (11) in correspondence with the retaining bolts to avoid damaging the painted parts and the Plexiglas windshield. During reassembly, make sure that the threaded inserts (10) are correctly positioned on the headlight shell. To prevent the bolts (12) and washers (11) from moving while fitting them, hold the inserts (10) pressed against the headlight shell (1).
Page 167 Headlight shell - rear-view mirrors Make sure the turn indicator wiring is correctly routed in the grooves inside the headlight shell supports. Bring the headlight shell up to the lights assembly and locate the pins of the headlight shell in the rubber grommets (C).
Page 168 Headlight shell - rear-view mirrors Refit the bolts (5) (on both sides of the headlight support frame) and the bolt (2) with washer (3) under the light assembly. Tighten the bolts (5) and (2) to the specified torque (Sect. C 3, Frame torque settings).
Page 169 Headlight shell - rear-view mirrors Refit the rear-view mirrors and air scoop covers as previously described. Operation Section reference Refit the side fairings E 2, Refitting the side fairings file:///C|/848/wsm/en/848_08_E_1_4_00.21.1.html (14 of 14) [11-6-2008 0:34:25] WWW.PlanDeGraissage.ORG...
Page 170: Fairing Panels
Fairing panels 2 - Fairing panels 1 Clip 2 Panel (left) 3 Panel (right) 4 Left upper fairing 5 Threaded insert 6 Left lower fairing 7 Left side panel 8 Right side panel 9 Right lower fairing 10 Bolt 11 Right upper fairing 12 Bracket 13 Clip 14 Pin...
Page 171: Removal Of The Side Fairings
Fairing panels 19 Bolt 20 Bolt 21 Nylon washer Parts catalogue FAIRING Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the side fairings Unscrew the screws (20) securing the bottom of the fairing panels, recovering the washers (21).
Page 172 Fairing panels Unscrew the screws (20) and (19) securing the right upper fairing (11) to the bike, recovering the washers (21) and (18). Remove the right side fairing assembly from the motorcycle. Proceed in the same way with the left side fairing, withdrawing the sidestand through the aperture in the fairing. To remove the soundproofing panels (7) and (8), remove the clips (1).
Page 173 Fairing panels Undo the screws (19) securing the upper fairing (11) to the lower (9), recovering the washers (18). Repeat the above steps to disassemble the left-hand side fairing. To reassemble the fairing panels, carry out the steps of the disassembly procedure in reverse order, making sure that the inserts (5) are fitted to the upper fairing (11) and the panel (3).
Page 174: Removal Of The Front Shield
Fairing panels Tighten all the screws to the specified torque (Sect. C 3, Frame torque settings). Removal of the front shield Remove the fairing panels as previously described. Withdraw the drain tube (B) from the guide (C) in the shield. Undo the screws (20) securing the front shield (16) to the oil cooler support bracket.
Page 175: Refitting The Side Fairings
Fairing panels Insert the drain tube (B) in the guide (C) in the shield. Refitting the side fairings Warning If parts that have been removed are not refitted correctly they may become loose suddenly while riding and cause you to lose control of your motorcycle. Important To avoid damage to painted parts, always fit the nylon washers (21) and (18) in correspondence with the fixing screws.
Page 176 Fairing panels Insert the screws (14) and bushes (15) securing the splashguard (A) to the inner panel (3). Fit the inner screw (19) securing the front of the right upper fairing (11). Left fairing mounting bracket If the bracket (12) was removed, refit it and insert the screw (10). Tighten the screw (10) to the specified torque (Sect.
Page 177 Fairing panels In the same way, refit the left fairing (4), taking care when inserting the sidestand through the aperture provided in the fairing panel (6). Fit the left fairing, attaching it to the front shield and to the right fairing at the bottom. Notes The rubber (D) on the lower end of the airbox drain tube (B), must be inserted in the hole provided in the fairing.
Page 178: Seat Seat Cowling And Side Panels
Seat seat cowling and side panels 3 - Seat seat cowling and side panels 1 Seat 2 Bolt 3 Washer 4 Pillion seat 5 Bracket 6 Dual seat cowling 7 Bolt 8 Bolt 9 Left side panel 10 Right side panel 11 Bolt 12 Bolt 13 Threaded insert...
Page 179: Removal Of The Seats
Seat seat cowling and side panels 19 Undertail heat shield 20 Rubber 21 Flange 22 M5 clip 23 M6 clip Parts catalogue Seat Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 180: Removal Of The Side Panels And Seat Cowling
Seat seat cowling and side panels Removal of the side panels and seat cowling Removal of the side panels In order to remove the side panels, you first need to remove the seats as described previously. Unscrew the two bolts (12) securing the rear of the right (10) and left (9) side panels to the rear subframe. Unscrew the four lateral rear retaining bolts (12).
Page 181 Seat seat cowling and side panels Unscrew the two front retaining bolts (11) of the right (10) and left (9) side panels. Remove the two side panels from the bike. Removal of the seat cowling In order to remove the seat cowling, you first need to remove the seats and side panels as described previously. Disconnect the wiring connectors (B) of the rear wiring loom and the connector (C) of the data acquisition wiring.
Page 182 Seat seat cowling and side panels Unscrew the two upper bolts (7) securing the seat cowling (6). Unscrew the two bolts (8) securing the catch for the lock (16). Remove the seat cowling (6) from the heat shield (19), pushing the cowling towards the front of the bike while simultaneously lifting it to disengage the catches (D) on the heat shield (19) from the corresponding locations on the seat cowling (6).
Page 183 Seat seat cowling and side panels Removal of the seat release mechanism The seat release mechanism (14) is located under the seat cowling. Unscrew the two retaining bolts (L) and remove the lever (E). Disconnect the end fitting (F) of the release control cable from the lever (E). Remove the fuel tank/seat assembly.
Page 184 Seat seat cowling and side panels Disconnect the end fitting (M) of the release cable from the catch. Refitting the seat release mechanism Refitting is the reverse of removal. Apply threadlocker to the nut (G) and the bolts (L). Removal of the seat cowling heat shield Remove the exhaust silencers and their clamps as indicated in Sect.
Page 185: Refitting The Side Panels And Seat Cowling
Seat seat cowling and side panels Remove the heat shield (19) from the flanges (21), freeing the wiring (N). Refitting the side panels and seat cowling Make sure that the M5 clips (22), M6 clips (23), rubber mountings (20) and the flanges (21) are all fitted to the bike. file:///C|/848/wsm/en/848_08_E_3_4_00.23.1.html (8 of 14) [11-6-2008 0:34:26] WWW.PlanDeGraissage.ORG...
Page 186 Seat seat cowling and side panels Check that threaded inserts (13) are present on the seat cowling (6) and on side panels (9) and (10). Check that the rubber mountings (20) are present on the heat shield (19). Offer the shield (19) up to the subframe file:///C|/848/wsm/en/848_08_E_3_4_00.23.1.html (9 of 14) [11-6-2008 0:34:26] WWW.PlanDeGraissage.ORG...
Page 187 Seat seat cowling and side panels and feed the wiring (N) through the aperture (P). Refitting the seat cowling heat shield Refit the heat shield (19) to the flanges (21). Position the support (17) and tighten the nuts (18). Refit the lower front bolts (11) securing the heat shield (19).
Page 188 Seat seat cowling and side panels Refit the two upper bolts (7) securing the seat cowling (6). Refit the two bolts (8) securing the catch for the lock (16). Check that the catch of the seat release mechanism (16) is fixed correctly and the release cable is not pinched. Tighten the bolts (7) and (8) to the specified torque (Sect.
Page 189 Seat seat cowling and side panels Refit the two front retaining bolts (11) of the right (10) and left (9) side panels. Fit the four bolts (12) securing the rear of the right (10) and left (9) side panels to the rear subframe. Fit the two lateral rear retaining bolts (12).
Page 190: Refitting The Seats
Seat seat cowling and side panels Refitting the seats Refitting the rider seat Position the seat (1) on the bike pushing it against the fuel tank so that the front catches engage the corresponding locations on the fuel tank. Fit the washers (3) on the bolts (2) and fit them in the rear slots of the seat (1) to secure it to the rear subframe. Tighten the bolts (2) to the specified torque (Sect.
Page 191 Seat seat cowling and side panels file:///C|/848/wsm/en/848_08_E_3_4_00.23.1.html (14 of 14) [11-6-2008 0:34:26] WWW.PlanDeGraissage.ORG...
Page 192: Front Mudguard
Front mudguard 4 - Front mudguard 1 Clip 2 Bolt 3 Nylon washer 4 Front mudguard 5 Rivet 6 Washer Parts catalogue FAIRING Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 193: Refitting The Front Mudguard
Front mudguard Disconnect the brake hose (A) from the clip (1). Remove the retaining bolts (2) and recover the nylon washers (3). Remove the front mudguard (4). Notes The clip (1) is secured to the front mudguard by means of a shear rivet (5) with two washers (6). Refitting the front mudguard Warning Do not ride the motorcycle without the front mudguard.
Page 194 Front mudguard file:///C|/848/wsm/en/848_08_E_4_4_00.24.1.html (3 of 3) [11-6-2008 0:34:27] WWW.PlanDeGraissage.ORG...
Page 195 1 - Throttle twistgrip 3 1 - Throttle twistgrip Adjusting the throttle cable 4 Removal of the throttle twistgrip 4 Refitting the throttle twistgrip 5 2 - Hydraulic clutch control Removal of the clutch master cylinder assembly 8 Refitting the clutch master cylinder assembly 9 Removal of the clutch slave cylinder 10 Refitting the clutch slave cylinder 12 3 - Front brake control...
Page 196: Throttle Twistgrip
Throttle twistgrip 1 - Throttle twistgrip 1 Throttle twistgrip 2 Grips 3 Plug 4 Circlip 5 Throttle opening cable 6 Throttle closing cable 7 Bolt Parts catalogue HANDLEBARS and controls Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 197: Adjusting The Throttle Cable
Throttle twistgrip Adjusting the throttle cable For instructions on how to adjust the throttle cable, see Sect. D 4, Adjusting the throttle cable. Removal of the throttle twistgrip Remove the end plug (3) from the handlebar. Peel back the rubber sleeve (A) protecting the throttle control cables. Undo the screws (7) of the twistgrip (1) and open the housing.
Page 198: Refitting The Throttle Twistgrip
Throttle twistgrip Replacement throttle cables are supplied complete with adjusters. Refitting the throttle twistgrip Lubricate the ends of the throttle cables (5) and (6) and the twistgrip race with the recommended grease. To refit the throttle control components, proceed in inverse order to the disassembly procedure, making sure that the throttle covers locate in the reference hole (C) in the handlebar.
Page 199 Throttle twistgrip file:///C|/848/wsm/en/848_08_F_01_6_00.26.1.html (4 of 4) [11-6-2008 0:34:27] WWW.PlanDeGraissage.ORG...
Page 200: Hydraulic Clutch Control
Hydraulic clutch control 2 - Hydraulic clutch control 1 Clutch master cylinder 2 Lever 3 Bleed valve 4 Dust cap 5 Banjo bolt 6 Clutch control hose 7 Bolt 8 Rubber mounting 9 Bracket 10 Bolt 11 Cover 12 Fluid reservoir assembly 13 Nut 14 Hose clip 15 Hose...
Page 201: Removal Of The Clutch Master Cylinder Assembly
Hydraulic clutch control 19 Microswitch 20 Clutch pushrod 21 O-ring 22 O-ring 23 Clutch slave cylinder 24 Bolt 25 Adjuster screw 26 Circlip 27 Banjo bolt Parts catalogue Clutch control Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 202: Refitting The Clutch Master Cylinder Assembly
Hydraulic clutch control Refer to the exploded view at the beginning of this section for indications on disassembly and replacement of the master cylinder components. Refitting the clutch master cylinder assembly Locate the complete master cylinder assembly (1) on the handlebar, aligning it with the locating grub screw. Tighten the retaining bolts (18) to the specified torque (Sect.
Page 203: Removal Of The Clutch Slave Cylinder
Hydraulic clutch control torque settings). Operation Section reference Fill the clutch system with fluid D 4, Filling the clutch circuit Removal of the clutch slave cylinder Warning The clutch slave cylinder manufacturer advises against servicing the internal components of the slave cylinder (23) due to the safety-critical nature of the unit.
Page 204: Refitting The Clutch Slave Cylinder
Hydraulic clutch control Remove the dust cap (4) and the bleed valve (3) and unscrew the banjo bolt (5), taking care to recover the sealing washers (17): the unit (23) is now disconnected from hose (6). Push in the piston to force out all the fluid from inside the cap. The clutch pushrod (20) can now be removed.
Page 205 Hydraulic clutch control Lubricate the seal (22) and locate it along with the slave cylinder (23) in the crankcase. Tighten the bolts (24) to the specified torque (Sect. C 3, Frame torque settings). Locate the hose (6) on the slave cylinder (23), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder.
Page 206 Hydraulic clutch control Operation Section reference Fill the clutch system with fluid D 4, Filling the clutch circuit Refit the left-hand fairing E 2, Refitting the side fairings Positioning of the clutch hose file:///C|/848/wsm/en/848_08_F_02_6_00.27.1.html (7 of 8) [11-6-2008 0:34:28] WWW.PlanDeGraissage.ORG...
Page 207 Hydraulic clutch control file:///C|/848/wsm/en/848_08_F_02_6_00.27.1.html (8 of 8) [11-6-2008 0:34:28] WWW.PlanDeGraissage.ORG...
Page 208: Front Brake Control
Front brake control 3 - Front brake control 1 Front brake master cylinder 2 Brake lever pedal 3 Banjo bolt 4 Sealing washer, thickness 1 5 Microswitch 6 Hose fitting 7 Pin 8 Upper clamp 9 Bolt 10 Bolt 11 Reservoir bracket 12 Rubber mounting 13 Bolt 14 Fluid reservoir cover...
Page 209: Removal Of The Front Brake Master Cylinder
Front brake control 19 Calipers master cylinder hose Parts catalogue Front brake Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the front brake master cylinder Warning The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical nature of this component.
Page 210: Refitting The Front Brake Master Cylinder
Front brake control Refitting the front brake master cylinder Locate the mounting clamp (8) of the complete master cylinder assembly (1) aligning it with the locating grub screw on the handlebar. Tighten the bolts (9) of the mounting clamp (8) to the specified torque (Sect. C 3, Frame torque settings), in the sequence 1-2-1.
Page 211: Rear Brake Control
Rear brake control 4 - Rear brake control 1 Support 2 Bolt 3 Washer 4 Spring 5 Switch 6 Brake lever pedal 7 Bolt 8 Adjuster screw 9 Pedal pivot bolt 10 Bush 11 O-ring 12 Rubber 13 Pin 14 Banjo bolt 15 Nut 16 Rear brake master cylinder 17 Clamp...
Page 212: Removal Of The Rear Brake Control
Rear brake control 19 Bolt 20 Ball joint 21 Hose 22 Banjo bolt 23 Sealing washer, thickness 1 24 Bolt 25 Fluid reservoir assembly 26 Plug 27 Rear brake hose Parts catalogue Rear brake Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 213: Disassembly Of The Rear Brake Control
Rear brake control Remove the brake fluid reservoir (26) complete with the hose (21) from the frame by unscrewing the bolt (24). Remove the complete rear brake control. Disassembly of the rear brake control The brake master cylinder is supplied only as a complete unit; internal components cannot be replaced. To disassemble the master cylinder's outer parts, follow the indications given in the exploded view at the beginning of this section.
Page 214: Refitting The Rear Brake Control
Rear brake control Refitting the rear brake control To refit the assembly, carry out the removal operations in reverse order, applying the recommended threadlocker to the bolts (2) and (9). Important When refitting the brake master cylinder to the engine, take care to position the brake lever return spring (4) correctly.
Page 215: Gearchange Mechanism
Gearchange mechanism 5 - Gearchange mechanism 1 Gearchange pedal 2 Bush 3 Rubber 4 Bolt 5 Pin 6 O-ring 7 Ball joint 8 Nut 9 Gearchange lever tie-rod 10 Nut 11 Ball joint 12 Gearchange lever tie-rod assembly 13 Bolt 14 Gearchange pedal 15 Nut 16 Washer...
Page 216: Removal Of The Gearchange Mechanism
Gearchange mechanism Parts catalogue FRAME Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the gearchange mechanism Operation Section reference Remove the left-hand fairing E 2, Removal of the side fairings Unscrew and remove the pivot bolt (5) securing the gear pedal (1) and recover the O-ring seals (6).
Page 217: Refitting The Gearchange Mechanism
Gearchange mechanism components. If the bush (2) inside the pedal (1) needs replacing, drive the new bush into place using a press. The bush must be seated 2 mm below the outer face of the pedal. Warning After working on the gearchange mechanism, check the position of the gear pedal. To adjust the position of the gear pedal, follow the instructions provided in Sect.
Page 218 G - Wheels - Suspension - Brakes 0G - Wheels - Suspension - Brakes 1 - Front wheel Removal of the front wheel 4 Overhauling the front wheel 6 Refitting the front wheel 9 2 - Front fork Removal of the front forks 12 Overhauling the front forks 13 Refitting the front forks 20 3 - Hydraulic front brake...
Page 219 G - Wheels - Suspension - Brakes Rear suspension system 56 Removal of the rear shock absorber 56 Overhauling the rear shock absorber 57 Removal of the rear suspension rocker arm 58 Overhauling the rear suspension rocker arm 59 Disassembly of the shock absorber tie-rod 60 Refitting the rear suspension 60 8 - Final drive Inspecting the final drive 64...
Page 220: Front Wheel
Front wheel 1 - Front wheel 1 Nut 2 Washer 3 Left spacer 4 Seal 5 Bearing 6 Front wheel rim 7 Inner spacer 8 Bolt 9 Right spacer 10 Front wheel axle 11 Valve Parts catalogue Front forkS FRONT AND REAR WHEELS file:///C|/848/wsm/en/848_08_G_1_8_00.32.1.html (1 of 7) [11-6-2008 0:34:29] WWW.PlanDeGraissage.ORG...
Page 221: Removal Of The Front Wheel
Front wheel Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the front wheel Remove the front brake calipers complete with hoses by undoing the bolts (A). Warning Do not operate the brake lever when the calipers are removed.
Page 222: Overhauling The Front Wheel
Front wheel Loosen the axle clamp bolts (8) on the ends of the fork legs. Working from the left-hand side, use a plastic mallet to drive the axle (10) out from the opposite side and remove it. Remove the wheel and recover the spacers (3) and (9). Overhauling the front wheel Wheel bearings Before checking the dimensions, check the wear on wheel bearings.
Page 223 Front wheel To remove the bearings (5) and seals (4) from the wheel hub, follow the instructions below. Position a drift (A) against the inner race of the bearing (5). Tap the drift with a hammer to drive out the bearing (5) and the oil seal (4). Apply the drift at different points to keep the bearing square during removal.
Page 224 Front wheel Notes Wheels must be rebalanced after repair, maintenance and overhaul operations. Inspecting the wheel axle Check the wheel axle for straightness. Roll the axle on a reference surface and measure maximum distortion using a feeler gauge (see Sect. C 1.1, Front wheel).
Page 225: Refitting The Front Wheel
Front wheel If the values measured are not within the tolerance limits, renew the wheel. Refitting the front wheel When all the necessary inspections have been completed, refit the wheel as follows. Lubricate and fit the spacers (3) and (9) to the oil seals on the sides of the wheel hub. Install the complete wheel between the fork legs.
Page 226 Front wheel Refit the front brake calipers as described in Sect. G 3, Removal of the front brake system. Check that the brake discs turn freely inside the calipers. Before tightening the axle clamp bolts (8), lower the bike to the ground and press up and down on the handlebars to load the suspension so the fork legs will become properly seated onto the wheel axle.
Page 227: Front Fork
Front fork 2 - Front fork 1 Bolt 2 Bolt 3 Top yoke 4 Bottom yoke 5 Left fork leg assembly 6 Right fork leg assembly 7 Locating ring 8 Damper assembly 9 Oil seal 10 Spring 11 Upper spacer 12 Spacer 13 Washer 14 Top cap assembly...
Page 228: Removal Of The Front Forks
Front fork 19 Adjuster screw 20 Special washer 21 Right inner tube assembly 22 Dust cap 23 Oil seal 24 Circlip 25 Bush 26 Outer tube 27 Bush 28 Left inner tube assembly 29 Ring 30 Bolt 31 Left handlebar 32 Right handlebar Parts catalogue HANDLEBARS and controls...
Page 229: Overhauling The Front Forks
Front fork Loosen the clamp bolts (2) securing the fork legs to the bottom yoke (4). Slacken off the bolts (30) securing the handlebar clamps (31) and (32) to the fork legs. Withdraw the fork legs (5) and (6) downwards in order to carry out to all the necessary overhaul operations. Overhauling the front forks Notes It is advisable to loosen the top cap (14) when the fork is still fitted to the motorcycle.
Page 230 Front fork Loosen the preload adjuster (A) before unscrewing the top cap (14). Unscrew the top cap (14) complete with the rebound damping adjuster. Disassembly of the front fork Fit the service tool no. 88713.0957, engaging its pins (B) in the upper spacer, and secure in place with the screw (C).
Page 231 Front fork Remove the upper cap (14) complete with the collar (12) and washer (13). Fit service tool no. 88713.0958 and screw it onto the damper rod. Push downwards to overcome the force of the spring and remove the spacer (D). file:///C|/848/wsm/en/848_08_G_2_8_00.33.1.html (5 of 13) [11-6-2008 0:34:30] WWW.PlanDeGraissage.ORG...
Page 232 Front fork Remove the service tool no. 88713.0957 and slide out the upper spacer (11). Remove the spring (10) and pump the outer tube (26) and the damper (8) to expel the oil from the fork. Warning This movement generates pressure so that the oil will be rapidly expelled from the fork. Aim the jet of oil into a previously prepared container and avoid contact with fork oil.
Page 233 Front fork Remove the adjuster screw (18) and recover the seal (16). Remove the complete damper assembly (8) and locating ring (7). Slide the dust seal (22) off the outer tube (26), prising it off with a screwdriver. Remove the circlip (29). file:///C|/848/wsm/en/848_08_G_2_8_00.33.1.html (7 of 13) [11-6-2008 0:34:30] WWW.PlanDeGraissage.ORG...
Page 234 Front fork Important Take care not to damage the outer tube (26) or inner tube (21). To separate the outer tube (26) from the inner tube (21), pull the inner tube sharply outwards repeatedly to gradually displace the bottom bush (25). Insert the tip of a screwdriver in the slit in the bush (27) and open it up sufficiently to slide the bush off the inner tube.
Page 235 Front fork Place the spring on a flat surface and measure the free length (L). Service limit: 270 mm. Renew the spring if the length is not within the specified limit. Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes. They must be free from scoring, steps, or dents.
Page 236 Front fork Fit the following components: - spring (10); - upper spacer (11); - spacer (12); - washer (13). Fit service tool 88713.0957 (previously used for removal) into the lateral hole of upper spacer (11). Push the tool down and position the spacer (D) under the lock nut of damper (8). Remove service tool no.
Page 237: Refitting The Front Forks
Front fork Refitting the front forks Refit the fork legs, positioning them at the height shown in the figure relative to the upper surface of the bottom yoke. Locate the fork legs (5) and (6) in the bottom yoke (4) and then fit the handlebars (31) and (32). file:///C|/848/wsm/en/848_08_G_2_8_00.33.1.html (11 of 13) [11-6-2008 0:34:30] WWW.PlanDeGraissage.ORG...
Page 238 Front fork Locate the fork legs (5) and (6) in the top yoke (3). To ensure the handlebars are correctly positioned, check that the end of the pin (A) engages the corresponding slot (B) in the top yoke (3). Tighten to the specified torque (Sect. C 3, Frame torque settings) the clamp bolts (1) and (2) securing the legs to the bottom yoke (4) and to the top yoke (3).
Page 239 Front fork Operation Section reference Refit the headlight shell E 1, Refitting the headlight shell Refit the front wheel G 1, Refitting the front wheel Refit the front mudguard E 4, Refitting the front mudguard Refit the front brake calipers G 3, Refitting the front brake system file:///C|/848/wsm/en/848_08_G_2_8_00.33.1.html (13 of 13) [11-6-2008 0:34:30]...
Page 240: Hydraulic Front Brake
Hydraulic front brake 3 - Hydraulic front brake 1 Banjo bolt 2 Sealing washer 3 Calipers master cylinder hose 4 Bracket 5 Dust cap 6 Bleed valve 7 Banjo bolt 8 Bolt 9 Bolt 10 Right brake caliper 11 Left brake caliper 12 Pair of brake pads 13 Brake disc 14 Bolt...
Page 241: Maintenance Operations
Hydraulic front brake 19 Mudguard 20 Clip 21 Guide 22 Pad retaining pin and clip 23 Clip Parts catalogue Front brake FRONT AND REAR WHEELS FAIRING Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 242 Hydraulic front brake Loosen the bolt (8) and withdraw the hose (3) from the bracket (4). Remove the hose (3) from the brake master cylinder. Warning If the clip (20) is damaged while removing the front brake hose, it must be replaced (Sect. E 4, Removal of the front mudguard).
Page 243: Refitting The Brake Discs
Hydraulic front brake Unscrew the banjo bolts (7) from both calipers and recover the sealing washers (2). Detach the front brake calipers from the hose (3) and (15). Refitting the brake discs The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor. Both parts must be changed together as a pair.
Page 244: Refitting The Front Brake System
Hydraulic front brake of calipers. Incorrect overhaul of this component could endanger rider safety. Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly. Refer to the exploded view at the beginning of this section for indications on renewal of the above components. The brake disc must be clean without any signs of rust, oil, grease or dirt and no deep scoring.
Page 245 Hydraulic front brake Fit the right caliper (10) over the disc. Locate the hose (3) in the grommet (18). Apply recommended grease to the bolts (9). Hand tighten the bolts (9) to secure the calipers to the fork legs. Locate the brake master cylinder-lever assembly (Sect. F 3, Refitting the front brake master cylinder).
Page 246 Hydraulic front brake Insert the front brake hose (15) in the clip (20) on the front mudguard. Operation Section reference Fill the brake circuit D 4, Filling the brake system with fluid file:///C|/848/wsm/en/848_08_G_3_8_00.34.1.html (7 of 7) [11-6-2008 0:34:31] WWW.PlanDeGraissage.ORG...
Page 247: Rear Wheel
Rear wheel 4 - Rear wheel 1 Right-hand wheel nut 2 Washer 3 Bush 4 Valve 5 Wheel 6 Circlip Parts catalogue FRONT AND REAR WHEELS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 248: Overhauling The Rear Wheel
Rear wheel Place the motorcycle on the rear service stand and engage 1 st gear. Remove the circlip (6). Using a suitable socket, loosen the wheel nut (1). Fully unscrew the wheel nut (1), then slide of the washer (2) and the bush (3). Remove the rear wheel from the motorcycle.
Page 249: Refitting The Rear Wheel
Rear wheel Overhauling the wheel Inspect the wheel as follows: Visually inspect the wheel for cracks, scoring and deformation; change the wheel if damaged. Fit the wheel on service tool no. 88713.2951 using the original fasteners. Using a dial gauge, measure rim run-out and out-of-round relative to the wheel axle (see Sect. C 1.1, Rear wheel).
Page 250 Rear wheel file:///C|/848/wsm/en/848_08_G_4_8_00.35.1.html (4 of 4) [11-6-2008 0:34:31] WWW.PlanDeGraissage.ORG...
Page 251: Rear Swingarm
Rear swingarm 5 - Rear swingarm 1 Swingarm pivot shaft 2 Pin 3 Bolt 4 Rear swingarm 5 Nut 6 Washer 7 Upper drive chain slider 8 Lower drive chain slider 9 Bolt 10 Bolt 11 Washer 12 Left spacer 13 Circlip 14 Washer 15 O-ring...
Page 252: Removal Of The Rear Wheel Eccentric Hub And Rear Wheel Axle
Rear swingarm 19 Bearing 20 Spacer 21 Right spacer 22 Bush 23 Seal 24 Plug 25 Roller bearing 26 Rear brake disc 27 Rear wheel axle Parts catalogue rear wheel axle swingarm Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 253 Rear swingarm Remove the circlip (13) on the wheel side of the eccentric hub. Remove the washer (14), the caliper mounting bracket (16) with the O-rings (15). file:///C|/848/wsm/en/848_08_G_5_8_00.36.1.html (3 of 15) [11-6-2008 0:34:32] WWW.PlanDeGraissage.ORG...
Page 254: Refitting The Rear Wheel Eccentric Hub And Rear Wheel Axle
Rear swingarm Remove the other washer (14). Withdraw the eccentric hub (17) from the chain side of the swingarm. Notes The rear hub is a component particularly critical to the dynamic safety of the motorcycle. For this reason, any overhaul of the internal components of the hub is strictly forbidden. The hub is available as complete assembly, part no.
Page 255 Rear swingarm Refit the washers (14) with their square edges facing the eccentric hub. file:///C|/848/wsm/en/848_08_G_5_8_00.36.1.html (5 of 15) [11-6-2008 0:34:32] WWW.PlanDeGraissage.ORG...
Page 256 Rear swingarm Apply an even coating of the recommended grease in the areas (A) of the axle (27). Insert the rear wheel stub axle (27) in the hub. Ensure the stub axle (27) is seated in the hub. Apply the recommended grease to the bolts (3) and tighten to the specified torque (Sect. C 3, Frame torque settings) in the sequence 1-2-1.
Page 257: Removal Of The Swingarm
Rear swingarm Operation Section reference Refit the rear brake caliper G 6, Refitting the rear brake caliper Refit the rear sprocket G 8, Refitting the rear sprocket Refit the rear wheel G 4, Refitting the rear wheel Tension the drive chain as indicated in the paragraph Adjusting the chain tension , in Sect.
Page 258 Rear swingarm Any abnormal movement is a sign of worn bearings that could cause instability when riding. Refer to the indications for checking swingarm bearing play in Sect. G 1, Wheel bearings. Once the play in the swingarm bearings has been checked, the swingarm (4) may be removed from the motorcycle. Restrain the swingarm pivot shaft (1) on the left side of the motorcycle while undoing the bolt (5) on the opposite side: recover the washer (6).
Page 259: Inspecting The Swingarm Pivot Shaft
Rear swingarm Inspecting the swingarm pivot shaft Before refitting the swingarm pivot shaft (1), check it carefully for distortion. Roll the shaft on a reference surface and measure maximum distortion using a feeler gauge (see Sect. C 1.1, Rear wheel). Overhauling the rear swingarm Inside the swingarm (4), at the point at which it pivots on the frame, there are a pair of ball bearing races (19) on the right-hand side and a pair of roller bearings (25), with seal rings (23), on the left-hand side.
Page 260 Rear swingarm To change the bearings, proceed as follows. Remove the spacers (21) from the right-hand side of the swingarm and remove the bush (22) from the left-hand side. Remove the ball bearings (19), seal rings (23) and roller bearings (25) with a suitable punch and press. Support the swingarm and take care not to damage the bearing bores.
Page 261 Rear swingarm Heat the entire swingarm up to 150 °C and support it. Insert the new roller bearings (25) in the service tool no. 88713.1068 and install them from the outside into the bore on the left hand side of the swingarm. Drive them in until the tool is fully seated against the swingarm.
Page 262 Rear swingarm To install the ball bearing races (19) you will need service tool no. 88713.2409 comprised of: drift for internal bearings; drift for external bearings; guide pin. Fit a new bearing (19) with the internal spacer (20) onto the drift (A) and position it on the interior of the right-hand side support of the swingarm.
Page 263 Rear swingarm Remove the spacers (21) and (12) from the right-hand side of the swingarm (4) and remove the bush (22) from the left-hand side. file:///C|/848/wsm/en/848_08_G_5_8_00.36.1.html (13 of 15) [11-6-2008 0:34:32] WWW.PlanDeGraissage.ORG...
Page 264: Refitting The Swingarm
Rear swingarm Refitting the swingarm Refit the upper chain slider (7) securing it with the bolts (9) and (10) and the washers (11). Refit the rear brake hose and speed sensor to the swingarm (4), securing them with the lower chain slider (8) and tightening the bolts (9).
Page 265 Rear swingarm On the opposite side of the bike, secure the swingarm pivot shaft (1) with the nut (5) after applying the recommended grease, interposing the washers (6). Tighten the nut (5) to the specified torque (Sect. C 3, Frame torque settings).
Page 266: Hydraulic Rear Brake
Hydraulic rear brake 6 - Hydraulic rear brake 1 Bolt 2 Pin 3 Bolt 4 Rear brake disc 5 Spacer 6 Speed sensor 7 Bolt 8 Bolt 9 Pad retaining pin and clip 10 Pair of brake pads 11 Rear brake caliper 12 Sealing washer 13 Banjo bolt 14 Dust cap...
Page 267: Removal Of The Rear Brake Caliper
Hydraulic rear brake Rear brake REAR WHEEL AXLE Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the rear brake caliper Important Critical safety components. The brake manufacturer advises against any servicing of the internal components of brake calipers or the master cylinder.
Page 268: Removal Of The Rear Brake Disc
Hydraulic rear brake recover the spacers (5). Only the following parts should be renewed: Caliper: pads, fasteners and bleed valve assembly. Master cylinder: control pedal, bleed valve assembly, reservoir and its parts (Sect. F 4). Refer to the exploded view at the beginning of this section for indications on renewal of the above components. Removal of the rear brake disc Remove the rear eccentric hub (Sect.
Page 269 Hydraulic rear brake caliper (11). After positioning the union correctly, tighten the banjo bolt (13) to the specified torque (Sect. C 3, Frame torque settings). If removed, locate the speed sensor (6) on the caliper mounting bracket (B) with the spacer (5) and tighten the bolt (7) to the specified torque (Sect.
Page 270: Rear Suspension
Rear suspension 7 - Rear suspension 1 Bolt 2 Washer 3 Nut 4 Bolt 5 Spacer 6 Seal 7 Roller bearing 8 Rocker arm assembly 9 Bolt 10 Shock absorber 11 Bush 12 Bolt 13 Ball joint 14 Tie-rod Parts catalogue file:///C|/848/wsm/en/848_08_G_7_8_00.38.1.html (1 of 9) [11-6-2008 0:34:33] WWW.PlanDeGraissage.ORG...
Page 271: Rear Suspension System
Rear suspension Rear suspension Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Rear suspension system The rear suspension uses a fully adjustable progressive hydraulic monoshock (10). The system consists of an upper rocker arm (8) and a non-adjustable tie-rod (14), which is fixed to the single-sided swingarm.
Page 272 Rear suspension Before dismantling the shock absorber, measure the spring preload length (L). The same length must be restored on re-assembly. Disassembly of the rear shock absorber Slacken off locknut (A) and spring adjuster nut (B) with a pin wrench or special tool. Remove the retaining ring (C) and the spring.
Page 273: Removal Of The Rear Suspension Rocker Arm
Rear suspension Removal of the rear suspension rocker arm Disconnect the top of the rear shock absorber from the rocker arm as described in Removal of the rear shock absorber in this section. Separate the tie-rod (14) and the rocker arm (8) by unscrewing the bolt (4) and recover the bushes (11). Before removing the rocker arm (8) from the frame, check the play of its internal needle roller bearings (7).
Page 274: Overhauling The Rear Suspension Rocker Arm
Rear suspension Slide out the bolt (1) and remove the rocker arm assembly (8) from the frame. Overhauling the rear suspension rocker arm Disassembly of the rear suspension rocker arm The rocker arm movement is obtained by needle roller bearings (7) rotating on an internal spacer (5). Two oil seals (6) on the outer sides of the bearings keep the lubricant inside the cages.
Page 275: Disassembly Of The Shock Absorber Tie-Rod
Rear suspension Place two new needle roller bearings (7) on drift part no. 88713.1071 and lubricate with the recommended grease. Support the rocker arm and drive in the needle roller bearings until the tool is seated against rocker arm. Important Make sure that the bearings are installed perfectly square in the hole.
Page 276: Refitting The Rear Suspension
Rear suspension Refitting the rear suspension Lubricate the shank and thread of the bolt (1) and the underside of the head of the nut (3) with the recommended grease. Insert the rocker arm assembly (8) between the frame supports, as shown in the figure. Drive the bolt (1) fully home in the frame.
Page 277 Rear suspension Install the bushes (11) on both the ball joint end fittings. Install the lower end of the tie-rod (14) on the swingarm. Grease the thread, underside and sliding surface of the lower retaining bolt (17) and insert it in the swingarm from the right-hand side. Tighten the bolt (17) to the specified torque (Sect.
Page 278 Rear suspension file:///C|/848/wsm/en/848_08_G_7_8_00.38.1.html (9 of 9) [11-6-2008 0:34:33] WWW.PlanDeGraissage.ORG...
Page 279: Final Drive
Final drive 8 - Final drive 1 Nut 2 Lock washer 3 Front sprocket, Z=15 4 Chain 5 Bolt 6 Front sprocket cover 7 Rear sprocket, Z=38 8 Nut 9 Washer 10 Nut 11 Rear sprocket flange 12 Cush drive bush 13 Bush 14 Bush 15 Spacer...
Page 280: Inspecting The Final Drive
Final drive 19 Washer Parts catalogue Gearbox REAR WHEEL AXLE Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Inspecting the final drive To check wear of the final drive, carry out a visual inspection of the front sprocket (3) and the rear sprocket (7). If the teeth are found to worn as shown in the figure (dotted line), the sprocket must be renewed.
Page 281: Removal Of The Front Sprocket
Final drive Removal of the front sprocket Undo the bolts (5) and remove the sprocket cover (6). Slacken the chain (Sect. D 4, Adjusting the chain tension). Remove the chain with the service tool no 88713.1344. The tool is composed of a holder (A), punch (B), body (C) and two wrenches (D) and (E). Fit the link to be opened into the holder (A).
Page 282: Refitting The Front Sprocket
Final drive Remove the chain. Engage a low gear and unscrew the nut (1). Remove the nut (1) and the safety washer (2). Remove the front sprocket (3) with the chain (4) from the gearbox output shaft. Remove the spacer (15) with the O-ring (16) from the gearbox output shaft. Important The O-ring (15) must be renewed on reassembly.
Page 283 Final drive Check that the splines of the gearbox output shaft and the sprocket are in perfect condition. Fit the front sprocket (3) and install the safety washer (2). Tighten the nut (1) to the specified torque (Sect. C 3, Frame torque settings).
Page 284: Renewal Of The Rear Sprocket
Final drive Adjust the chain tension (Sect. D 4, Adjusting the chain tension). Fit the sprocket cover (6) and tighten the bolts (5) to the specified torque (Sect. C 3, Frame torque settings). Renewal of the rear sprocket Operation Section reference Slacken the chain D 4, Adjusting the chain tension...
Page 285: Refitting The Rear Sprocket
Final drive Fully unscrew the nut (8) and remove the washer (9) and the flange (11) complete with the rear sprocket (7). Recover the collar (A). Using a mallet, tap the sprocket flange (10) with the cush drive bushes (12) off the sprocket (7). Refitting the rear sprocket Check the cush drive bushes (12) for signs of wear and, if necessary, remove from the sprocket flange and renew them.
Page 286: Washing The Chain
Final drive To refit the nut (8) and the circlip (18) securing the sprocket flange, follow the instructions given for tightening the wheel nut in Sect. G 4, Refitting the rear wheel. Operation Section reference Refit the rear wheel G 4, Refitting the rear wheel Adjust the chain tension D 4,...
Page 287 H - Frame 0H - Frame 1 - Handlebars Removal of the handlebars 4 Refitting the handlebars 6 2 - Steering Adjusting the steering head bearings 8 Steering angle adjustment 9 Removal of the steering head components 10 Refitting the steering head components 12 4 - Footrest brackets Removal of the front footrests 16 Refitting the front footrests 17...
Page 288: Handlebars
Handlebars 1 - Handlebars 1 Left handlebar 2 Right handlebar 3 Bolt 4 Plug 5 Bolt 6 Bolt 7 Spring pin 8 Grip Parts catalogue HANDLEBARS and controls Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 289: Removal Of The Handlebars
Handlebars Removal of the handlebars To remove the right handlebar, the following parts must be removed first: Operation Section reference Remove the headlight shell E 1, Removal of the headlight shell Remove the throttle twistgrip F 1, Removal of the throttle twistgrip Remove the right-hand handlebar P 5, Checking the right-hand...
Page 290: Refitting The Handlebars
Handlebars Refitting the handlebars file:///C|/848/wsm/en/848_08_H_1_7_00.41.1.html (3 of 5) [11-6-2008 0:34:34] WWW.PlanDeGraissage.ORG...
Page 291 Handlebars Fit the handlebar onto the fork leg and install the top yoke. Important When refitting the handlebars to the fork legs, position them relative to the top yoke by inserting the end of the handlebar pin (7) into the slot (A) in the top yoke. If the bolts (5) securing the handlebar to the fork leg were removed when removing the handlebars, apply the recommended grease to their threads.
Page 292 Handlebars Refit the headlight shell E 1, Refitting the headlight shell Refit the left-hand handlebar switch P 5, Checking the left-hand handlebar switch Refit the clutch lever F 2, Refitting the clutch master cylinder assembly Refit the top yoke H 2, Refitting the steering head components file:///C|/848/wsm/en/848_08_H_1_7_00.41.1.html (5 of 5) [11-6-2008 0:34:34]...
Page 293: Steering
Steering 2 - Steering 1 Bottom yoke 2 Seal 3 Bearing 4 Nut 5 Bolt 6 Bolt 7 Top yoke 8 Adjuster screw 9 Nut Parts catalogue HANDLEBARS and controls Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the file:///C|/848/wsm/en/848_08_H_2_7_00.42.1.html (1 of 8) [11-6-2008 0:34:35] WWW.PlanDeGraissage.ORG...
Page 294: Adjusting The Steering Head Bearings
Steering exploded view diagram. Adjusting the steering head bearings Notes See Sect. D 4, Adjusting the steering head bearings for steering bearing play adjustment. If this does not solve the problem, check the bearings (3) for wear and, if necessary, renew them as described in Removal of the steering head components in this chapter.
Page 295: Removal Of The Steering Head Components
Steering Turn the front forks to the right until the spacer (A) is seated against the frame top tube. Turn the adjuster screw (8) on the opposite side to bring it into contact with the stop on the steering head. Apply threadlocker to the thread of nut (9).
Page 296 Steering With the service tool no. 88713.1058 loosen the nut (4) and unscrew it from the steering stem. Slide the dust seal (2), the inner race (A) and the ball race (B) of the upper bearing (3) off the steering stem. Remove the bottom yoke (1) complete with the steering stem from the frame tube.
Page 297: Refitting The Steering Head Components
Steering Using a universal puller (of the type shown in the figure) remove the ring (C) from the steering stem, taking care not to damage the seat. Important Once removed, the seals (2) and the bearings (3) must not be refitted. Using a suitable drift, remove the outer bearing races (C) from the steering head.
Page 298 Steering Clean all contact surfaces and lubricate with the recommended grease. To fit the outer races (C) of the bearings (3) to the steering head, use the service tool no. 88713.1062 and proceed as follows: heat the steering head to 150 °C; fit the outer races (C) in their seats on the steering head;...
Page 299 Steering Fit the bottom yoke assembly to frame. Grease the ball race (B) and fit it to outer race (C) of the top bearing. Fit the inner race (A) of the upper bearing (3) to the steering head, with the larger diameter side of the race facing upwards.
Page 300 Steering Operation Section reference Refit the fork legs G 2, Refitting the front forks Refit the headlight shell E 1, Refitting the headlight shell Refit the side fairings E 2, Refitting the side fairings file:///C|/848/wsm/en/848_08_H_2_7_00.42.1.html (8 of 8) [11-6-2008 0:34:35] WWW.PlanDeGraissage.ORG...
Page 301: Footrest Brackets
Footrest brackets 4 - Footrest brackets 1 Right front footrest bracket 2 Left front footrest bracket 3 Spring 4 Pin 5 Right front footrest 6 Left front footrest 7 Bolt 8 Right heel plate 9 Left heel plate 10 Circlip 11 Bolt 12 Bolt 13 Right rear footrest...
Page 302: Removal Of The Front Footrests
Footrest brackets 19 Spring 20 Ball 21 Spacer Parts catalogue FRAME REAR SUBFRAME Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the front footrests The left footrest assembly can be removed after removing gearchange pedal (A) from the bracket (2) (Sect.
Page 303: Refitting The Front Footrests
Footrest brackets Refitting the front footrests Position the spring (3) between the lugs of the footrest (5) or (6) and fit it to the bracket, inserting the straight end (B) of the spring in the hole in the bracket. Grease the pivot bolt (4) and insert it from the front, securing it on the other side with the circlip (10). file:///C|/848/wsm/en/848_08_H_4_7_00.43.1.html (3 of 7) [11-6-2008 0:34:35] WWW.PlanDeGraissage.ORG...
Page 304: Removal Of The Rear Footrests
Footrest brackets Fit the entire assembly to the frame, securing it with the bolts (7) coated with the recommended threadlocker. Tighten the bolts (7) to the specified torque (Sect. C 3, Frame torque settings). Refit the gearchange pedal (Sect. F 5, Refitting the gearchange mechanism) to the left footrest bracket.
Page 305: Refitting The Rear Footrests
Footrest brackets Refitting the rear footrests file:///C|/848/wsm/en/848_08_H_4_7_00.43.1.html (5 of 7) [11-6-2008 0:34:35] WWW.PlanDeGraissage.ORG...
Page 306 Footrest brackets Position the spring (19) and the ball (20) on the rear right footrest bracket (18). Position the footrest (13) with the spacer (21) on the bracket (18) and insert the pivot bolt (16), while pressing the footrest (13). Secure the pivot bolt on the opposite side with the circlip (14).
Page 307 Footrest brackets Locate the footrest brackets (17) and (18) and tighten the bolts (12) to the specified torque (Sect. C 3, Frame torque settings). Refit the rider seat (Sect. E 3, Refitting the seats). file:///C|/848/wsm/en/848_08_H_4_7_00.43.1.html (7 of 7) [11-6-2008 0:34:35] WWW.PlanDeGraissage.ORG...
Page 308: Sidestands
Sidestands 5 - Sidestands 1 Sidestand 2 Bolt 3 Bracket 4 Bolt 5 Switch 6 Inner spring 7 Spring assembly 8 Plate 9 Pin 10 Nut Parts catalogue stand Important file:///C|/848/wsm/en/848_08_H_5_7_00.44.1.html (1 of 4) [11-6-2008 0:34:35] WWW.PlanDeGraissage.ORG...
Page 309: Removal Of The Sidestand
Sidestands Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the sidestand Operation Section reference Remove the left-hand side fairing E 2, Removal of the side fairings Disconnect the wiring connector of the sidestand switch (1) from the main wiring harness.
Page 310 Sidestands Inspecting the sidestand Fit the sidestand leg to the bracket and check that there is no excessive play. Ensure that the ends of the sidestand are not bent with respect to the shank. A stand which shows signs of cracking must be renewed immediately. For details of how to test the switch (5), see Sect.
Page 311: Refitting The Sidestand
Sidestands Refitting the sidestand Position the bracket (3) on the frame, apply recommended threadlocker to the two bolts (2) and insert them. Tighten the bolts (2) to the specified torque (Sect. C 3, Frame torque settings). Connect the sidestand switch connector to the main wiring harness. For correct positioning of the sidestand switch wiring, refer to the plate in Sect.
Page 312: Frame Inspection
Frame inspection 6 - Frame inspection 1 Headlight assembly 2 Frame 3 Rear subframe 4 Bolt 5 Bolt 6 Nut 7 Headlight 8 Instrument panel 9 Spacer 10 Nut 11 Rubber 12 Bolt 13 Spacer 14 Rubber 15 Air temperature sensor 16 Instrument panel shroud 17 Spring washer 18 Bolt...
Page 313: Disassembly Of Structural Components And The Frame
Frame inspection Parts catalogue HEADLIGHT & INSTR. PANEL Frame REAR SUBFRAME Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Disassembly of structural components and the frame Before carrying out dimensional checks on the frame, you must remove all the superstructures fitted, referring to the removal procedures outlined in the sections of this manual.
Page 314 Frame inspection Removal of the headlight assembly Unscrew the bolts (12) to disconnect the headlight (7). Disconnect the various wiring connectors, remove all cable ties from the headlight support (Sect. P 1, Plate 10) and file:///C|/848/wsm/en/848_08_H_6_7_00.45.1.html (3 of 7) [11-6-2008 0:34:36] WWW.PlanDeGraissage.ORG...
Page 315: Checking The Frame
Frame inspection unscrew the bolts (4). Remove the headlight assembly (1). Removal of the rear subframe Disconnect all the wiring connections of the electrical components mounted on the subframe (Sect. P 1, Plate Plate 35) and remove the silencer (Sect. L 8, Removal of the exhaust system).
Page 316 Frame inspection Important Badly damaged frames must be renewed and not repaired. Any work carried out on the frame can give rise to potential danger, infringing the requirements of EC directives concerning manufacturers' liability and general product safety. Frame general dimensions (mm) Rear subframe general dimensions (mm) file:///C|/848/wsm/en/848_08_H_6_7_00.45.1.html (5 of 7) [11-6-2008 0:34:36] WWW.PlanDeGraissage.ORG...
Page 317: Reassembly Of Structural Components And The Frame
Frame inspection Reassembly of structural components and the frame Refitting the rear subframe Locate the rear subframe (3) on the mountings on the frame (2). Insert the bolts (5) from the outside and secure on inside with the nuts (6), applying the specified threadlocker. Tighten the bolts (5) to the specified torque (Sect.
Page 318 Frame inspection Reconnect the wiring connections (Sect. P 1, Plate Plate 35) and refit the silencer (Sect. L 8, Refitting the exhaust system). Refitting the headlight assembly Fit the headlight (7), fit the retaining bolts (12) and tighten to the specified torque (Sect. C 3, Frame torque settings).
Page 319: Number Plate Holder
Number plate holder 7 - Number plate holder 1 Number plate holder 2 Cover 3 Rubber mounting 4 Support 5 Bolt 6 Nut 7 Support 8 Reflector 9 Bracket 10 Washer 11 Bolt 12 Bolt 13 Nut 14 Bolt 15 Nut 16 Number plate light 17 Bolt 18 Rear turn signals...
Page 320: Removal Of The Number Plate Holder
Number plate holder 19 Bulb 20 Rubber mounting 21 Flange 22 Nut 23 Quick-release fastener 24 Tail light 25 Rubber 26 Spacer 27 Bolt 28 Spacer 29 Plate Parts catalogue Number plate holder Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 321: Refitting The Number Plate Holder
Number plate holder Unscrew the bolts (11) and (14) to remove the number plate holder support (7) from the number plate holder (1) and from the bracket (9). Notes On the USA version the bracket (9) is integrated in the number plate holder support (7). Refitting the number plate holder Refit the number plate holder support (7) to the bracket (9) and to the number plate holder by fitting the bolts (14) and (11).
Page 322 Number plate holder Refit the number plate holder (1) with the plate (29) to the support (4) with the bolts (5). Refit the number plate holder cover (2) with the bolts (12). file:///C|/848/wsm/en/848_08_H_7_7_00.46.1.html (4 of 4) [11-6-2008 0:34:36] WWW.PlanDeGraissage.ORG...
Page 323 L - Fuel/Exhaust System 0L - Fuel/Exhaust System 2 - Fuel tank Removal of the fuel tank 4 Removal of the fuel filler cap assembly 6 Refitting the fuel filler cap assembly 7 Renewal of the fuel tank flange 8 Refitting the fuel tank flange 9 Refitting the fuel tank 10 6 - Airbox Throttle Body...
Page 324: Fuel Tank
Fuel tank 2 - Fuel tank 1 Fuel tank 2 Front fuel tank mounting (right) 3 Front fuel tank mounting (left) 4 Bolt 5 Bolt 6 Support 7 Quick-release fastener 8 Bolt 9 Bolt 10 Rubber 11 Spacer 12 Washer 13 Bolt 14 Panel 15 Seal...
Page 325: Removal Of The Fuel Tank
Fuel tank 19 Union 20 Hose 21 Bolt 22 O-ring 23 O-ring 24 Quick-release fitting 25 Flange 26 O-ring 27 Collar 28 Filter 29 Thermistor 30 Collar 31 Plate 32 Plate 33 Bolt 34 Hose 35 Hose 36 Clamp 37 T-fitting Parts catalogue FUEL TANK FUEL SYSTEM...
Page 326 Fuel tank Raise the fuel tank and disconnect the fuel level sensor (A) from the main wiring loom. Disconnect the quick-release fittings (24) from the flange. Withdraw the fuel tank (1) towards the rear of the motorcycle to disengage the front catches from the frame. file:///C|/848/wsm/en/848_08_L2_10_00.48.1.html (3 of 12) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 327: Removal Of The Fuel Filler Cap Assembly
Fuel tank Removal of the fuel filler cap assembly Open the filler cap. Unscrew the outer bolts (9) securing the ring nut to the filler cap recess. Unscrew the anti-theft screw (8) on the inside. Remove the complete filler cap assembly. The rubber breather nozzle (B) is located inside the filler cap.
Page 328: Renewal Of The Fuel Tank Flange
Fuel tank Renewal of the fuel tank flange Unscrew the six bolts (21) securing the fuel tank flange. Remove three of the bolts, leaving three in position in order to help lift the flange. Remove the flange (25) from the fuel tank. Recover the O-ring (A).
Page 329: Refitting The Fuel Tank Flange
Fuel tank Refitting the fuel tank flange Grease the O-ring and locate the flange and refit by reversing the steps of the removal procedure. Tighten the bolts (21) to the specified torque (Sect. C 3, Frame torque settings). Refitting the fuel tank If the fuel tank has been disassembled into its component parts, reposition all the parts as shown in the exploded view.
Page 330 Fuel tank Check that the soundproofing panel (14) is positioned on the tank as shown. file:///C|/848/wsm/en/848_08_L2_10_00.48.1.html (7 of 12) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 331 Fuel tank Reposition the fuel tank (1), inserting the front catches in the corresponding locations on the frame. Connect the quick-release fittings (24) to the flange. file:///C|/848/wsm/en/848_08_L2_10_00.48.1.html (8 of 12) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 332 Fuel tank Connect the wiring connector (A) to the main wiring loom. Insert the hoses (34) and (35) in plates (32) and (31) respectively. Secure the tank to the frame with the bolt (13) and the washer (12). Tighten the bolt (13) to the specified torque (Sect. C 3, Frame torque settings).
Page 333 Fuel tank Positioning of the fuel hoses file:///C|/848/wsm/en/848_08_L2_10_00.48.1.html (10 of 12) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 334 Fuel tank file:///C|/848/wsm/en/848_08_L2_10_00.48.1.html (11 of 12) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 335 Fuel tank file:///C|/848/wsm/en/848_08_L2_10_00.48.1.html (12 of 12) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 336: Airbox Throttle Body
Airbox Throttle Body 6 - Airbox Throttle Body 1 Stepper motor 2 O-ring 3 Bolt 4 Fuel injector support 5 Union 6 Hose 7 Intake manifold 8 Special bolt 9 Seal 10 Seal 11 Throttle body assembly 12 Bolt 13 Injector 14 Hose (vertical) 15 Union 16 Hose (horizontal)
Page 337: Refitting The Airbox And Throttle Body
Airbox Throttle Body 19 Hose 20 Airbox 21 Hose clip 22 Washer 23 Guide 24 Bolt Parts catalogue THROTTLE BODY AIR INTAKE - OIL BREATHER Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 338 Airbox Throttle Body Loosen the clamps (B) securing the throttle body to the intake manifolds (C). Disconnect the connector (D) connecting the main wiring loom to the stepper motor (1). Disconnect the wiring connector (E) connecting the main wiring loom to the throttle position sensor (F). file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (3 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 339 Airbox Throttle Body Slacken off the clamp (21) securing the hose (18) to the blow-by valve. Withdraw the airbox (20) complete with the throttle body (11) and the fuel injectors (13). file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (4 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 340 Airbox Throttle Body Removal of the fuel injectors Unscrew the bolts (3) to remove the fuel injectors (13) complete with hoses (14) and (16) from the airbox. Refitting the injectors Check that the injector O-ring seals (2) are present. Position the hoses and unions (5), (6), (14), (15) and (16) with the fuel injectors (13) on the airbox (20) in the corresponding yellow clips. Tighten the bolts (3) to the specified torque (Sect.
Page 341 Airbox Throttle Body Removal of the stepper motor The stepper motor is installed in the central part of the throttle body: to remove it, unscrew the two bolts (H) and disconnect the hoses (L) and (M) from the airbox. Refer to Sect. M 3, Stepper motor for details of stepper motor operation.
Page 342 Airbox Throttle Body Refitting the stepper motor Reconnect the hoses (L) on the throttle body and the hose (M) to the airbox. Locate the stepper motor with its support on the throttle body, inserting the bolts (H). Tighten the bolts (H). Disassembly of the airbox throttle body Unscrew the six bolts (8) and remove the throttle body (11) from the airbox (20).
Page 343 Airbox Throttle Body Reassembly of the airbox throttle body If removed, refit the fuel hoses (N) with relative quick-release fittings, the hose clamps to the airbox and the cable guide (23) as shown. Fit the cable guide (23) with two bolts (24) and four washers (22) as shown. file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (8 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 344 Airbox Throttle Body If removed, refit the air intake funnels (7) to the throttle body (11) and tighten the bolts (12) to the specified torque (Sect. C 3, Frame torque settings). Check that the throttle closing cable is located under the tab (Z) on the airbox. If previously removed, refit the cable guide (23) and tighten the bolt (24) with the two washers (22).
Page 345 Airbox Throttle Body If removed, refit the throttle cables to the throttle body as indicated: insert the throttle opening cable (P) and the throttle closing cable (Q) in the throttle body plate, as shown in the figure. Secure the throttle cables with two circlips (R).
Page 346: Refitting The Airbox And Throttle Body
Airbox Throttle Body Refitting the airbox and throttle body Locate the hose clamps (B) in their seats on the air intakes (C). Position the airbox (20) and the throttle body (11) on the motorcycle. file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (11 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 347 Airbox Throttle Body Tighten the hose clamps (B) to the specified torque (Sect. C 3, Frame torque settings). Reconnect the wiring connectors connecting the injectors (13) to the main wiring loom. file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (12 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 348 Airbox Throttle Body Connect the wiring connector (D) to connect the main wiring loom to the stepper motor (1). Connect the wiring connector (E) of the main wiring loom to the throttle position sensor (F). Reconnect the hose (18) to the blow-by valve and tighten the clamp (G). Important If the throttle body is renewed, carry out the procedure to reset the TPS (Sect.
Page 349 Airbox Throttle Body Refit the headlight shell E 1, Refitting the headlight shell Refit the fairings E 2, Refitting the side fairings Positioning of the airbox drain hose file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (14 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 350 Airbox Throttle Body Positioning of the blow-by hose file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (15 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 351 Airbox Throttle Body file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (16 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 352 Airbox Throttle Body Positioning the throttle cables file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (17 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 353 Airbox Throttle Body file:///C|/848/wsm/en/848_08_L6_10_00.49.1.html (18 of 18) [11-6-2008 0:34:37] WWW.PlanDeGraissage.ORG...
Page 354: Air Intake
Air intake 7 - Air intake 1 Bolt 2 Rubber 3 Quick-release fastener 4 Spacer 5 Air filter 6 Left air scoop 7 Bolt 8 Seal 9 Left intake hose 10 Right air scoop 11 Right intake hose Parts catalogue AIR INTAKE - OIL BREATHER file:///C|/848/wsm/en/848_08_L7_10_00.50.1.html (1 of 3) [11-6-2008 0:34:38] WWW.PlanDeGraissage.ORG...
Page 355: Removal Of The Air Filters
Air intake Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the air filters Operation Section reference Remove the side fairings E 2, Removal of the side fairings Remove the headlight shell E 1, Removal of the headlight shell...
Page 356 Air intake Reposition the hoses (9) and (11) with the air scoops (6) and (10) on the headlight assembly. Insert the bolts (1) securing the air scoops to the headlight assembly and the bolts (7) securing the air scoops to the airbox.
Page 357: Exhaust System
Exhaust system 8 - Exhaust system 1 Nut 2 Exhaust gasket 3 Spring 4 Horizontal cylinder head exhaust pipe 5 Rubber mounting 6 Spacer 7 Bolt 8 Nut 9 Exhaust manifold 10 Bolt 11 Lambda sensor 12 Seal 13 Quick-release fastener 14 Right-hand clamp 15 Left-hand clamp 16 Clamp rubber...
Page 358: Removal Of The Exhaust System
Exhaust system 20 Cables assembly 21 Vertical cylinder head exhaust pipe 22 Heat shield 23 Washer 24 Bolt 25 Plug 26 Bolt 27 Spacer 28 Rubber 29 Left-hand silencer 30 Right-hand silencer 31 Exhaust valve motor 32 Washer 33 Spacer 34 Heat shield 35 Washer 36 Washer...
Page 359 Exhaust system Remove the springs (3) and slide the silencers (29) and (30) from the vertical cylinder head exhaust pipe (21). Remove the heat shield (22) by unscrewing the bolts (24) and recover the washers (23) and (36). Unscrew the bolt (38) and the bolt (8) securing the cables (20) to the exhaust valve (B). Recover the spacer (41) and the Belleville washer (37).
Page 360 Exhaust system Unscrew the bolt (39) to release the plate (B) of the cables (20) from the plate of the exhaust pipe (21). Unscrew the bolts (26) to remove the exhaust valve motor (31) from the frame and disconnect the wiring (C) from the motor (31).
Page 361 Exhaust system Disconnect the lambda sensor (11) from the wiring (D). Unscrew the bolt (7) and the nut (18) securing the pipe (21) to the frame. file:///C|/848/wsm/en/848_08_L8_10_00.51.1.html (5 of 16) [11-6-2008 0:34:38] WWW.PlanDeGraissage.ORG...
Page 362 Exhaust system Remove the springs (3) and withdraw the vertical cylinder head exhaust pipe (21) from the horizontal cylinder head exhaust pipe (4) and the exhaust manifold (9). Unscrew the bolts (40) and remove the heat shield (34) from the exhaust manifold (9). file:///C|/848/wsm/en/848_08_L8_10_00.51.1.html (6 of 16) [11-6-2008 0:34:38] WWW.PlanDeGraissage.ORG...
Page 363: Refitting The Exhaust System
Exhaust system Unscrew the bolts (1) and remove the exhaust manifold (9) from the vertical cylinder head exhaust pipe and the horizontal cylinder head exhaust pipe (4) from the horizontal cylinder head. Refitting the exhaust system Position the exhaust manifold (9) on the vertical cylinder head and the horizontal head exhaust pipe (4) on the horizontal cylinder head along with the gaskets (2).
Page 364 Exhaust system Refit the heat shield (34) to the exhaust manifold (9), tightening the nuts (40). Connect the vertical cylinder head exhaust pipe (21) to the horizontal cylinder head exhaust pipe (4) and to the exhaust manifold (9) with the springs (3). file:///C|/848/wsm/en/848_08_L8_10_00.51.1.html (8 of 16) [11-6-2008 0:34:38] WWW.PlanDeGraissage.ORG...
Page 365 Exhaust system Secure the vertical head exhaust pipe (21) to the frame with the bolt (7) and nut (18) and tighten the bolt (7) to the specified torque (Sect. C 3, Frame torque settings). file:///C|/848/wsm/en/848_08_L8_10_00.51.1.html (9 of 16) [11-6-2008 0:34:38] WWW.PlanDeGraissage.ORG...
Page 366 Exhaust system Connect the lambda sensor (11) to the wiring (D). Locate the engine (31) on the frame and tighten the bolts (26) to the specified torque (Sect. C 3, Frame torque settings). Connect the motor to the wiring (C). If the cables (20) have been removed from the motor, position them so that the top corner of the pulley race (located between the two cable end fittings) is aligned with the notch.
Page 367 Exhaust system Start the nut (39) with the spacer (33) to secure the plate (B) of the cables (20) to the plate of the exhaust pipe (21). Tighten the nut (39). Position the cables (20) on the exhaust valve (A). Start the bolt (38) with the spacer (41) and the Belleville washer (37) and start the nut (8).
Page 368 Exhaust system To adjust the cables, remove the covers (F) and turn the adjusters. Refit the heat shield (22). Fit the lower bolts (24) with their washers (23) and (36). Tighten the bolts (24) to the specified torque (Sect. C 3, Frame torque settings).
Page 369 Exhaust system Connect the silencers (29) and (30) to the pipe (21) and locate the springs (3). Fit the bolt (17) and the nut (8) to the specified torque (Sect. C 3, Frame torque settings). Insert the bolts (10) with the washers (19) and tighten to the specified torque (Sect. C 3, Frame torque settings).
Page 370 Exhaust system If removed, fit the copper washers (12) to the plugs (25), screw the plugs into the vertical and horizontal head exhaust manifolds and tighten them to the specified torque (Sect. C 3, Frame torque settings). Operation Section reference Refit the fairings E 2, Refitting the side fairings...
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Page 372 Exhaust system file:///C|/848/wsm/en/848_08_L8_10_00.51.1.html (16 of 16) [11-6-2008 0:34:38] WWW.PlanDeGraissage.ORG...
Page 373: Evaporative Emissions Canister
Evaporative emissions canister 10 - Evaporative emissions canister 1 Evaporative emissions canister 2 Hose 3 Hose clip 4 Filter/oil reservoir hose 5 Hose clip 6 Hose 7 Hose clip 8 Tee fitting 9 Hose 10 Hose 11 Hose clip 12 Union 13 Seal 14 Bolt 15 Breather hose...
Page 374: Evaporative Emissions Canister System (Usa Versions Only)
Evaporative emissions canister 19 Spacer 20 Bolt Parts catalogue Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Evaporative emissions canister system (USA versions only) USA models are equipped with an additional system with an evaporative emissions canister that prevents fuel fumes from being discharged into the atmosphere.
Page 375: Removal Of The Evaporative Emissions Canister
Evaporative emissions canister Removal of the evaporative emissions canister Before removing the canister (1) it is first necessary to remove the fairings (Sect. E 2, Removal of the side fairings) and raise the fuel tank (Sect. L 2, Removal of the fuel tank).
Page 376: Refitting The Evaporative Emissions Canister
Evaporative emissions canister Refitting the evaporative emissions canister To refit, carry out the removal operations in reverse order, making sure to locate the hoses as shown in the figures at the end of the chapter. Operation Section reference Reposition the fuel tank L 2, Refitting the fuel tank Refit the fairings...
Page 377 Evaporative emissions canister file:///C|/848/wsm/en/848_08_L10_10_00.52.1.html (5 of 5) [11-6-2008 0:34:39] WWW.PlanDeGraissage.ORG...
Page 378 M - Fuel injection - ignition system 0M - Fuel injection - ignition system 2 - Fuel injection-ignition system 3 - System components Electronic Control Unit (ECU) 4 Removal of the battery support 6 Refitting the battery support 9 Fuel injectors 13 Stepper motor 14 Air pressure sensor 15 Coolant temperature sensor 16...
Page 379: Fuel Injection-Ignition System
Fuel injection-ignition system 2 - Fuel injection-ignition system The electrical components of the fuel injection-ignition system are listed below: the reference next to each component is that shown in the diagram in Sect. P 1, Wiring diagram. 2 Ignition switch 3 Left cooling fan 4 Right cooling fan 5 Starter motor...
Page 380: System Components
System components 3 - System components Electronic Control Unit (ECU) The engine ECU (1) is an electronic digital microprocessor-based unit. It controls both the injectors and the coils, thus controlling fuel injection and ignition in accordance with the engine operating conditions detected by the following sensors: - Absolute pressure sensor (measures atmospheric pressure) - Air temperature sensor (measures intake air temperature) - Engine temperature sensor (measures coolant temperature)
Page 381: Removal Of The Battery Support
System components Warning If the ECU is changed, it will be necessary to follow the procedure for Resetting the throttle position sensor (TPS) , Sect. D 5. For removal and refitting of the ECU, refer to the chapters Removal of the battery support Refitting the battery support in this section.
Page 382 System components Disconnect the battery terminal clamps (5) and (4). Always disconnect the negative terminal clamp (5) first. Remove the battery (6). Remove the clamp (B) and disconnect the regulator wiring connector (7) from the wiring loom. Disconnect the two wiring connectors (8) and (9) from the ECU. Undo the screws (10) and remove the ECU (1), freeing it from the ECU earth lead (C).
Page 383 System components Remove the regulator fuse (14) from the battery support, withdrawing it through the holes provided. Undo the screw (11) and remove the injection and fans relay (12). file:///C|/848/wsm/en/848_08_M_3_3_00.55.1.html (4 of 19) [11-6-2008 0:34:40] WWW.PlanDeGraissage.ORG...
Page 384 System components Release the wiring from any cable ties (D). To remove the regulator/rectifier (15), proceed as described in Sect. P 2, Regulator/rectifier. Undo the bolts (16) securing the battery support (17) to the frame. Recover the spacers (18) and the washer (19). Remove the battery support from the motorcycle.
Page 385: Refitting The Battery Support
System components Refitting the battery support Check the condition of all rubber components and replace them if necessary. Insert the small diameter side of the spacers (18) into their rubbers. file:///C|/848/wsm/en/848_08_M_3_3_00.55.1.html (6 of 19) [11-6-2008 0:34:40] WWW.PlanDeGraissage.ORG...
Page 386 System components For the positioning of the wiring on the battery support, refer to Sect. P 1, Plate Refit the regulator/rectifier (Sect. P 2, Regulator/rectifier) and the contactor (Sect. P 3, Starter contactor). Fit the regulator fuse (14) inserting it through the holes in the battery support. Fit the injection and fans relay (12), tightening the screw (11) to the specified torque (Sect.
Page 387 System components Position the ECU so that the threaded hole (E) is facing upwards; insert the retaining screws (10) with the ECU earth connector (C) under the right-hand screw, and tighten to the specified torque (Sect. C 3, Frame torque settings).
Page 388 System components Rotate the clip to secure the connector (clip in locked position). file:///C|/848/wsm/en/848_08_M_3_3_00.55.1.html (9 of 19) [11-6-2008 0:34:40] WWW.PlanDeGraissage.ORG...
Page 389 System components Important If the ECU is changed, use the DDS tester to set the TPS to zero (Sect. D 5, Resetting the throttle position sensor (TPS)). If it has been removed, refit the rubber mat (20) in its seat, locating the pins in the holes on the battery support.
Page 390: Fuel Injectors
System components Reconnect the battery support wiring to the main wiring loom (Sect. P 1, Plate 35) and refit the left- hand side fairing (Sect. E 2, Refitting the side fairings). Fuel injectors The injectors (1) deliver the correct quantity of fuel required for optimal engine operation. The ECU controls injector opening by feeding current to the coil of an electromagnet which creates a magnetic field to attract the armature, thereby generating fuel spray.
Page 391: Stepper Motor
System components Periodically, after lengthy periods without running the engine, we recommend adding TUNAP 231 to the fuel in the tank to help clean critical sections of the fuel circuit. Notes Electric injectors are only supplied as part of the Injectors and pipes kit, and must not be replaced individually.
Page 392: Air Pressure Sensor
System components Notes The influence of the stepper motor air flow is present to approximately 30° throttle angle; no correction is required for greater angles. The opening of the stepper motor opening is controlled by 2 strategies: Strategy 1) controlled solely by engine temperature (stepper motor opening/closing is determined by engine temperature alone).
Page 393: Air Temperature Sensor
System components Refitting the coolant temperature sensor Refit by reversing the removal operations, securing the sensor to the union with the specified torque (Sect. C 3, Frame torque settings) and applying the recommended threadlocker. Refit the left-hand side fairing (Sect. E 2, Refitting the side fairings).
Page 394: Ignition Coils
System components Ignition coils Raise the fuel tank (Sect. L 2, Removal of the fuel tank). Undo the nut (1) securing the coil to the cylinder head. Remove the connector (2) and remove the coils (3) from the spark plugs on both cylinder heads. Clean the area around the spark plug bores with a compressed air jet before removing the spark plugs themselves.
Page 395: Throttle Position Sensor (Tps)
System components Important Check the gap between the central and side electrodes. If the gap is not as specified or if the spark plug has heavy sooty deposits, renew it. Refit the spark plug in the cylinder head, first tightening it fully by hand. Tighten to the specified torque (Sect.
Page 396: Rpm/Timing Sensor
System components parameters for defining the fuel flow rate and spark advance. Notes To check this component, use the DDS tester following the instructions given in the paragraph Guided diagnosis (Sect. D 5). It is not possible to change the throttle position sensor as a single component. In the event of a fault with this component, it will be necessary to replace the entire throttle body assembly (Sect.
Page 397: Injection Relay
System components paragraph Guided diagnosis (Sect. D 5). For instructions on how to renew the sensor and check the air gap, see the chapter Flywheel- alternator (Sect. N 8). Injection relay The relay (1) is positioned next to the battery and fixed to the battery support. To remove the relay (1), first remove the battery support as described previously in this section.
Page 398 System components superfluous duplications of the sensors on the motorcycle, since their signals are shared by the two nodes and hence the two processing units. The sensors are connected to the nearer of the two units (instrument panel or ECU), which then transmits their signal to the network so that it can be used by the ECUs.
Page 399 N - Engine 0N - Engine 1 - Removal refitting of the engine assembly Removal of the engine 6 Refitting the engine 9 2.1 - Lubrication system: oil pump Removal of the oil pump 11 Disassembly of the oil pump 12 Reassembly of the oil pump 13 Refitting the oil pump 14 2.2 - Lubrication system: oil cooler...
Page 400 N - Engine Removal of the tensioner pulley/timing belt 59 Removal of the camshaft pulleys/idler pulley 59 Removal of the tensioner and idler pulley mounting studs 60 Disassembly of the camshaft pulleys 60 Removal of the timing belt driveshaft pulleys 61 Refitting the timing belt driveshaft pulley 63 Refitting the idler and tensioner pulley mounting studs 65 Reassembly of the timing pulleys 66...
Page 401 N - Engine Removal of the clutch-side crankcase cover 133 Disassembly of the clutch-side crankcase cover 134 Reassembly of the clutch-side crankcase cover 135 Refitting the clutch-side crankcase cover 136 6.3 - Clutch assembly: primary drive gears Removal of the primary drive gears 139 Refitting the primary drive gears and checking backlash 142 7.1 - Gearbox assembly: gearchange mechanism Removal of the gearchange mechanism 146...
Page 402 N - Engine 9.2 - Crankcase assembly: crankcase halves Separation of the crankcase halves 200 Overhaul of the crankcase halves 203 Main bearings 207 Reassembly of the crankcase halves 208 Shimming the shafts 211 Reassembly of the crankcase halves 216 9.3 - Crankcase assembly: crankshaft/connecting rods assembly Removal of the crankshaft/connecting rods assembly 223 Disassembly of the crankshaft/connecting rods assembly 224...
Page 403 Removal refitting of the engine assembly 1 - Removal refitting of the engine assembly 1 Bolt 2 Nut 3 Bolt 4 Swingarm pivot shaft 5 Washer 6 Washer Parts catalogue Frame swingarm Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 404 Removal refitting of the engine assembly Removal of the engine In order to remove engine you must first remove a series of other components from the motorcycle. Most of these removal procedures are described in the relative sections of this manual. The following flow chart illustrates the logical sequence in which the parts are to be removed from the motorcycle and a reference to the section where the removal procedure is described.
Page 405 Removal refitting of the engine assembly Restrain the swingarm pivot shaft (4) from the left side of the motorcycle while undoing the bolt (3) with washer (5) on the opposite side. Using drift 88713.1074, fully extract the swingarm pivot shaft. This frees the swingarm from the engine and therefore it can be left attached to the frame.
Page 406 Removal refitting of the engine assembly Remove the two upper bolts (1). Withdraw the complete engine assembly from the frame by lowering it and pushing it forwards. Refitting the engine Refitting is the reverse of removal. Important Apply the recommended grease to the nuts (2) and tighten to the specified torque (Sect. C 3, Frame torque settings).
Page 407 Removal refitting of the engine assembly file:///C|/848/wsm/en/848_08_N_1_9_00.57.1.html (5 of 5) [11-6-2008 0:34:41] WWW.PlanDeGraissage.ORG...
Page 408 Lubrication system: oil pump 2.1 - Lubrication system: oil pump 1 Complete oil pump assembly 2 O-ring 3 Circlip 4 O-ring 5 Pump body 6 Circlip 7 Reducer bush 8 Spring washer 9 Bolt 10 Bolt 11 Spring washer 12 Pump drive gear 13 Key 14 By-pass plug 15 Locating bush...
Page 409 Lubrication system: oil pump Parts catalogue Filters and oil pump Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the oil pump Operation Section reference Drain the oil from the lubrication D 4, Changing the engine oil and...
Page 410 Lubrication system: oil pump Warning Make sure that vice jaws are faced with soft material. Remove the plug (14) and extract the spring (16) and by-pass valve (17). Check the condition of the above components. Remove the circlip (6) and withdraw the pump drive gear (12). Reassembly of the oil pump Check that the circlip (3) and Woodruff key (13) are both present on the pump.
Page 411: Engine
Lubrication system: oil pump Install in the pump the by-pass valve (17) and the spring (16); screw in the plug (14) and tighten to the specified torque (Sect. C 3, Engine torque settings) after applying a medium strength threadlocker. Refitting the oil pump Position the locating bushes (15) and the O-rings (2) and (4) in correspondence with the crankcase lubrication oilways.
Page 412 Lubrication system: oil pump Check the gear backlash with the driving pinion by fixing a dial gauge (A), equipped with the appropriate stylus, to the crankcase half. Position the dial gauge stylus on one tooth of oil pump gear and set the gauge to zero in this position. Move the gear slightly to measure the backlash;...
Page 413: Lubrication System: Oil Cooler
Lubrication system: oil cooler 2.2 - Lubrication system: oil cooler 1 Oil cooler 2 Rubber mounting 3 Spacer 4 Aluminium gasket 5 Nipple 6 O-ring 7 Oil hose 8 Bolt 9 Bolt 10 Support Parts catalogue OIL COOLER Important file:///C|/848/wsm/en/848_08_N_2B9_00.59.1.html (1 of 6) [11-6-2008 0:34:42] WWW.PlanDeGraissage.ORG...
Page 414 Lubrication system: oil cooler Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the lubrication system Operation Section reference Remove the side fairing panels E 2, Removal of the side fairings Drain the oil from the lubrication D 4,...
Page 415 Lubrication system: oil cooler Unscrew the nuts (D) of the hose unions (7) from the nipples (5) and disconnect the hoses from the cooler. Unscrew the nipples (5) on the cooler and recover the gaskets (6). Oil cooler inspection Visually inspect the cooler. Renew the cooler at any sign of damage or leaks. Refitting the lubrication system Notes Before refitting the hoses (7), check that the O-rings (B) are installed and lubricate them with engine oil.
Page 416 Lubrication system: oil cooler Insert a washer (6) on each nipple (5) and apply the recommended threadlocker to the threads on the cooler side. Notes The washer (6) should be positioned with the square edge side facing the cooler. Fit the nipples (5) to the oil cooler (1) and, while counterholding the hex nuts (E), tighten them to the specified torque (Sect.
Page 417 Lubrication system: oil cooler If removed, refit the support (10) securing it to the horizontal cylinder head with the two bolts (8). Check that the rubber mountings are present on the oil cooler (2). Fit the oil cooler (1), first inserting it in the pin (C) of the support (10). Fit the spacer (3) and the bolt (9).
Page 418 Lubrication system: oil cooler Operation Section reference Fill the lubrication system D 4, Changing the engine oil and filter cartridge Refit the side fairing panels E 2, Refitting the side fairings file:///C|/848/wsm/en/848_08_N_2B9_00.59.1.html (6 of 6) [11-6-2008 0:34:42] WWW.PlanDeGraissage.ORG...
Page 419: Cooling System: Coolant Expansion Tank
Cooling system: coolant expansion tank 3.1 - Cooling system: coolant expansion tank 1 Coolant expansion tank 2 Filler cap 3 Bolt 4 Bracket 5 Hose clip 6 Breather hose 7 Breather hose 8 Bolt 9 Washer Parts catalogue COOLING SYSTEM Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.
Page 420 Cooling system: coolant expansion tank exploded view diagram. Removal of the expansion tank Operation Section reference Drain the cooling system D 4, Changing the coolant Remove the airbox L 6, Refitting the airbox and throttle body Loosen the clamp (5) and remove the hose (6) from the radiator. Unscrew the two bolts (8) and recover the washers (9).
Page 421 Cooling system: coolant expansion tank Refitting the expansion tank Apply liquid gasket to the lower lip of the expansion tank (1). Locate the hoses (6) and (7) on the tank with the clamps (5). Tighten the bolts (3) to the specified torque (Sect. C 3, Frame torque settings) to secure the tank (1) to the bracket (4).
Page 422 Cooling system: coolant expansion tank Attach the hose (6) to the radiator with the clamp (5). Operation Section reference Refit the airbox L 6, Refitting the airbox and throttle body Fill the cooling system D 4, Changing the coolant Positioning of the expansion tank-radiator connection hose file:///C|/848/wsm/en/848_08_N_3A9_00.60.1.html (4 of 5) [11-6-2008 0:34:42] WWW.PlanDeGraissage.ORG...
Page 423 Cooling system: coolant expansion tank file:///C|/848/wsm/en/848_08_N_3A9_00.60.1.html (5 of 5) [11-6-2008 0:34:42] WWW.PlanDeGraissage.ORG...
Page 424: Cooling System: Radiator
Cooling system: radiator 3.2 - Cooling system: radiator 1 Horizontal cylinder coolant outlet union 2 Pump/radiator hose 3 Bolt 4 Spacer 5 Rubber 6 Radiator cap 7 Clip 8 Bolt 9 RH cooling fan 10 Radiator 11 LH cooling fan 12 Bolt 13 Special bolt 14 Clamp...
Page 425 Cooling system: radiator 19 Seal 20 Vertical cylinder coolant outlet union 21 Coolant temperature sensor 22 Thermostat/cylinder head hose Parts catalogue RADIATOR COOLING SYSTEM Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 426 Cooling system: radiator Disconnect the wiring connectors of the main wiring loom (C) from both fans. Remove the radiator (10) from the motorcycle, withdrawing it from the pin (D), on the upper right-hand side of the frame. Radiator inspection Visually inspect the radiator. If it shows signs of damage or leaks, the radiator must be renewed. Check also that the air flow through the radiator core is not obstructed by leaves, insects, mud, etc.
Page 427 Cooling system: radiator Renewal of the cooling fan Unscrew the three fan retaining bolts (8) and remove the fan (11) from the radiator. Repeat the above operation for the other cooling fan (9). Tighten the bolts (8) to the specified torque (Sect. C 3, Frame torque settings).
Page 428 Cooling system: radiator Reconnect the fan wiring to the main wiring loom (C). Connect the cooling system hoses (15) and (2) to their respective unions on the radiator and tighten the clamps (14) to the specified torque (Sect. C 3, Frame torque settings).
Page 429 Cooling system: radiator Attach the expansion tank-radiator connection hose (B) to the inlet on the radiator cap with the clamp (A). Operation Section reference Refit the battery support M 3, Refitting the battery support Fill the cooling system D 4, Changing the coolant Refit the side fairing panels E 2,...
Page 430 Cooling system: radiator Loosen the clamps (14) and (17) securing the thermostat assembly (16) - thermostat/cylinder head hose (18) - thermostat/cylinder head hose (22). Loosen the clamps (14) to dismantle the thermostat assembly (16) - thermostat/cylinder head hose (18) - thermostat/cylinder head hose (22).
Page 431 Cooling system: radiator Unscrew the bolts (12) and remove the union (20). Recover the O-rings (19) located between the union and the vertical cylinder head. Disconnect the wiring connector (A) of the temperature sensor (21) on the horizontal cylinder head union (1) from the main wiring loom.
Page 432 Cooling system: radiator torque settings). Fix the union (20) to the horizontal cylinder head (12) and tighten the bolts to the specified torque (Sect. C 3, Frame torque settings). Reconnect the wiring connector (A) of the temperature sensor (21) on the horizontal cylinder head union (1) to the main wiring loom.
Page 433 Cooling system: radiator Locate the pump/radiator hose (2) and radiator/thermostat hose (15) with the clamps (14) and tighten the clamps to the specified torque (Sect. C 3, Frame torque settings). file:///C|/848/wsm/en/848_08_N_3B9_00.61.1.html (10 of 13) [11-6-2008 0:34:43] WWW.PlanDeGraissage.ORG...
Page 434 Cooling system: radiator Operation Section reference Refit the battery support M 3, Refitting the battery support Fill the cooling system D 4, Changing the coolant Refit the side fairing panels E 2, Refitting the side fairings Positioning of the thermostat hose clamps file:///C|/848/wsm/en/848_08_N_3B9_00.61.1.html (11 of 13) [11-6-2008 0:34:43] WWW.PlanDeGraissage.ORG...
Page 435 Cooling system: radiator Positioning of the radiator hoses file:///C|/848/wsm/en/848_08_N_3B9_00.61.1.html (12 of 13) [11-6-2008 0:34:43] WWW.PlanDeGraissage.ORG...
Page 436 Cooling system: radiator file:///C|/848/wsm/en/848_08_N_3B9_00.61.1.html (13 of 13) [11-6-2008 0:34:43] WWW.PlanDeGraissage.ORG...
Page 437: Cooling System: Water Pump
Cooling system: water pump 3.3 - Cooling system: water pump 1 Bolt 2 Washer 3 Circlip 4 Washer 5 Outer bearing 6 Inner bearing 7 Spacer 8 Locating ring 9 Mechanical seal 10 Water pump impeller 11 Locating dowel 12 Water pump cover assembly 13 Bolt 14 Plug 15 Seal...
Page 438 Cooling system: water pump WATER PUMP-ALTR-SIDE CRANKCASE COVER Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the water pump Operation Section reference Remove the side fairing panels E 2, Removal of the side fairings Drain the cooling system...
Page 439 Cooling system: water pump Recover the ceramic washer (A) and seal ring (B) located on the inner side. Undo and remove the bolts (1) with the washer (2). file:///C|/848/wsm/en/848_08_N_3C9_00.62.1.html (3 of 9) [11-6-2008 0:34:44] WWW.PlanDeGraissage.ORG...
Page 440 Cooling system: water pump Working from the impeller side, use a suitable drift to press on the inner race of end bearing (5) until it can be extracted from the cover. Use the same technique to remove the other bearing (6). Working from the inside of the cover, remove the seat (8) of the mechanical seal (9).
Page 441 Cooling system: water pump Working from the inside of the cover, fit the inner spacer (7) with its square edge (A) facing outwards. Using a suitable drift that bears on the outer race, drive home the bearing (6) against the spacer (7) with the shield side (B) facing the cover.
Page 442 Cooling system: water pump Turn over the cover and fit the locating ring (8) using tool no. 88713.0870. Locate the ring as shown in figure and drive it in until it seats against the spacer (7). Fit the seal ring (B) and the ceramic washer (A). file:///C|/848/wsm/en/848_08_N_3C9_00.62.1.html (6 of 9) [11-6-2008 0:34:44] WWW.PlanDeGraissage.ORG...
Page 443 Cooling system: water pump Insert the impeller shaft (10) with the mechanical seal (9). Turn the cover over. Fit the spacer (4), positioned as shown in the cross-sectional view, and lock the assembly in place with circlip (3). Rotate the impeller (10) and make sure it turns smoothly without sticking. Clean the mating surfaces thoroughly on the pump cover and on the alternator-side crankcase cover.
Page 444 Cooling system: water pump Apply a bead of liquid gasket to the water pump cover (12) as shown in the figure. Fit the locating dowels (11) and position the pump cover (12) on the alternator-side crankcase cover. Start the cover bolts (13) in their threads. Tighten the bolts (13) to the specified torque (Sect.
Page 445 Cooling system: water pump Operation Section reference Refit the alternator-side crankcase N 8, Refitting the alternator-side cover and connect the cooling crankcase cover system hoses to the crankcase cover Refitting the cooling system Refit the cooling system hoses to N 3.2, the water pump cover hoses and unions Fill the cooling system...
Page 446: Cylinder Head Assemblies: Checks And Adjustments
Cylinder head assemblies: checks and adjustments 4.1 - Cylinder head assemblies: checks and adjustments 1 Closing shim 2 Intake side camshaft 3 Opening shim 4 Exhaust side camshaft 5 Valve Parts catalogue Cylinder head: timing system Vertical cylinder head HORIZONTAL cylinder head Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.
Page 447 Cylinder head assemblies: checks and adjustments Checking and adjusting the valve clearances Operation Section reference Remove the side fairing panels E 2, Removal of the side fairings Remove the radiator N 3.2, Removal of the radiator Remove the airbox L 6, Refitting the airbox and throttle body Remove the timing belts...
Page 448 Cylinder head assemblies: checks and adjustments Checking the closing clearance Using a feeler gauge, check the clearance between the closing rocker arm (C) and the highest point of the camshaft lobe (D). The clearance must be within the specified limits (Sect. C 1.1, Timing system/valves).
Page 449 Cylinder head assemblies: checks and adjustments Checking valve lift Put the engine in the condition described in Checking and adjusting the valve clearances above. Locate the tool 88765.1518 on the cylinder head: the part marked A should be on the intake side and the part marked S should be on the exhaust side.
Page 450 Cylinder head assemblies: checks and adjustments Refit following the procedure indicated in the previous paragraph Checking and adjusting the valve clearances Refit the components removed in the procedure. Operation Section reference Refit the timing belts N 4.2, Refitting the timing belts Refit the cylinder head cover N 4.4, Refitting the camshafts...
Page 451 Cylinder head assemblies: checks and adjustments Set the opening valve clearance to zero when the camshaft is in its rest position by fitting a feeler gauge between the upper rocker arm and the opening shim. Check that in this condition the camshaft can rotate. If it moves stiffly, use a thinner feeler gauge. In this condition, with the piston of the horizontal cylinder at TDC with the valves fully closed as confirmed by the reading on gauge (G), set the gauges (H) to zero.
Page 452 Cylinder head assemblies: checks and adjustments Remove all tools installed for the timing check and tension the belts to their prescribed operating tension, as described in Sect. D 5, Measuring timing belt tension. If the values obtained are outside the specified tolerance ranges (Sect. C 1.1, Timing system/valves), loosen the timing pulley bolts (M) and correct the value by turning the camshaft nut with the wrench supplied with service tool...
Page 453 Cylinder head assemblies: checks and adjustments Refit the components removed in the procedure. Operation Section reference Refit the crankshaft inspection cover N 8, Refitting the alternator-side crankcase cover Refit the timing belts N 4.2, Refitting the timing belts Refit the cylinder head cover N 4.4, Refitting the camshafts Refit the airbox...
Page 454: Cylinder Head Assemblies: Timing
Cylinder head assemblies: timing 4.2 - Cylinder head assemblies: timing 1 Vertical cylinder timing belt cover 2 Air filter 3 Horizontal cylinder timing belt cover 4 Bolt 5 Filter cover 6 Bolt 7 Washer 8 Nut 9 Tensioner pulley assembly 10 Circlip 11 Camshaft pulley 12 Tensioner pulley mounting stud...
Page 455 Cylinder head assemblies: timing 19 Driveshaft pulley spacer 20 Spacer 21 Nut 22 Bolt 23 Washer 24 Spacer flange 25 Bolt 26 Idler pulley mounting stud 27 Spacer Parts catalogue Timing system Cylinder head: timing system Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 456 Cylinder head assemblies: timing Removal of the tensioner pulley/timing belt Loosen the nut (8) and remove the washer (7) and the tensioner pulley (9) from its mounting stud (12) on the cylinder head. Remove the timing belt (14) from the horizontal cylinder assembly. Important If the belts are to be re-used, mark the direction of rotation with an arrow and also mark the cylinder they belong to.
Page 457 Cylinder head assemblies: timing Unscrew the bolt (25) and remove the idler pulley (13) from its mounting stud (26). Repeat the same procedure to remove the other pulley. Removal of the tensioner and idler pulley mounting studs Using service tool no. 88713.1821, remove the tensioner pulley mounting studs (12) and (26) from the cylinder heads.
Page 458 Cylinder head assemblies: timing Disassembly of the camshaft pulleys Unscrew and remove the bolts (22). Slide off the washer (23). Withdraw the camshaft pulley (11) from the spacer flange (24). Removal of the timing belt driveshaft pulleys Use the service tool no. 88713.1805 to hold the driving pulley against rotation. Important If this operation is carried out with the engine installed in the frame, hold the driveshaft pulleys against rotation by using service tool no 88713.2011 mounted on the alternator-side crankcase cover.
Page 459 Cylinder head assemblies: timing Remove the nut (15), the spacer (20) and the outer pulley (18). Remove the first Woodruff key (16) from the timing belt driveshaft. Remove the intermediate spacer (19) and the inner pulley (18). Remove the inner spacer (17) and second Woodruff key (16) on the timing belt driveshaft. file:///C|/848/wsm/en/848_08_N_4B9_00.64.1.html (6 of 17) [11-6-2008 0:34:45] WWW.PlanDeGraissage.ORG...
Page 460 Cylinder head assemblies: timing It is now possible to remove the circlip (10) on the driveshaft. Refitting the timing belt driveshaft pulley To fit the circlip (10) to the driveshaft, use the protective cap 88713.2834. Install the inner spacer (17) on the driveshaft, taking care to align the notch in the spacer with the slot for the Woodruff key.
Page 461 Cylinder head assemblies: timing Fit the first Woodruff key (16) on the timing belt driveshaft. Locate the inner pulley (18). Refit the second Woodruff key (16) and the washer (19). file:///C|/848/wsm/en/848_08_N_4B9_00.64.1.html (8 of 17) [11-6-2008 0:34:45] WWW.PlanDeGraissage.ORG...
Page 462 Cylinder head assemblies: timing Locate the outer pulley (18) and the spacer (20). Apply the recommended grease to the threads on the end of the driveshaft. Fit the nut (15). Important To prevent the nuts working loose and consequent serious engine damage, always use new self-locking nuts on all the timing belt pulleys on reassembly.
Page 463 Cylinder head assemblies: timing Insert the idler and tensioner pulley mounting studs (12) and (26) with the spacers (27) in the cylinder heads and tighten them using service tool no. 88713.1821. Tighten the pulley mounting studs to the specified torque (Sect. C 3, Engine torque settings).
Page 464 Cylinder head assemblies: timing Refitting the camshaft pulleys/idler pulleys Check that the keyway on the end of the camshaft is in good condition and without burrs. file:///C|/848/wsm/en/848_08_N_4B9_00.64.1.html (11 of 17) [11-6-2008 0:34:45] WWW.PlanDeGraissage.ORG...
Page 465 Cylinder head assemblies: timing Fit a Woodruff key (B) in the keyway of each camshaft. Fit the pulley (11) on the camshaft, inserting the Woodruff key in the in the slot (C) in the pulley. Apply the recommended grease to the threads on the end of the camshaft. Repeat the procedure on the other camshaft.
Page 466 Cylinder head assemblies: timing Using the bush supplied with service tool 88713.1806 and a torque wrench, tighten the nuts (21) to their specified torque (Sect. C 3, Engine torque settings). Fit the idler pulleys (13), complete with bearings, onto the mounting studs (26) on the cylinder heads and tighten the bolts (25) to their specified torque (Sect.
Page 467 Cylinder head assemblies: timing Refitting the timing belts Rotate the pulleys on the timing belt driveshaft until the timing mark on the outer roller is aligned with the mark on the clutch-side crankcase cover. In this condition, the horizontal cylinder piston will be at top dead centre. Install the service tool 88713.2011 in the alternator-side crankcase cover to hold the crankshaft against rotation and secure it with the relative pin.
Page 468 Cylinder head assemblies: timing Fit the vertical cylinder timing belt around the camshaft pulleys and pass it behind the idler pulley. Repeat the operation for the horizontal cylinder belt. Notes If the used belts are to be refitted, position them in their original direction of rotation and on their original cylinder. Fit the tensioner pulleys (9) and the washers (7) on the mounting studs on the two cylinder heads.
Page 469 Cylinder head assemblies: timing are tightened to the specified torque (Sect. C 3, Engine torque settings). Remove the camshaft holding tool 88765.1524 and the crankshaft holding tool 88713.2011. Refitting the timing belt covers Locate the horizontal cylinder timing belt cover (3) and secure it in place with bolts (4). Do the same with the vertical cylinder outer cover (1).
Page 470 Cylinder head assemblies: timing Reconnect the electrical system P 1, Routing of wiring on frame components on right-hand side of engine Refit the side fairing panels E 2, Refitting the side fairings file:///C|/848/wsm/en/848_08_N_4B9_00.64.1.html (17 of 17) [11-6-2008 0:34:45] WWW.PlanDeGraissage.ORG...
Page 471 Cylinder head assemblies: camshafts 4.4 - Cylinder head assemblies: camshafts 1 Cylinder head 2 Stud bolt 3 Special bolt 4 Seal 5 Horizontal cylinder head cover 6 Vertical cylinder head cover 7 Special bolt 8 O-ring 9 Cylinder head gasket 10 Grub screw 11 Locating dowel 12 Union...
Page 472 Cylinder head assemblies: camshafts 19 Key 20 Vertical cylinder intake camshaft 21 Bolt 22 Timing side support 23 Opposite side support 24 Seal 25 Intake manifold 26 Bolt 27 Washer 28 Seal 29 Bolt 30 Bolt 31 Washer Parts catalogue CYLINDER HEAD: TIMING SYSTEM Vertical cylinder head HORIZONTAL CYLINDER HEAD...
Page 473 Cylinder head assemblies: camshafts Repeat the same procedure for the other cylinder head cover (5). Unscrew the bolts (3) securing the camshaft supports. Withdraw the camshaft supports (22) and (23) straight out from the cylinder head, taking care not to damage the machined faces and locating dowels (11).
Page 474 Cylinder head assemblies: camshafts If necessary, unscrew the stud bolts (2) from the cylinder heads. Checking the camshafts and supports Check the cam contact surfaces for scratches, grooves, steps and waving. Worn cams are frequently the cause of poor timing, which leads to loss of engine power. Place the camshaft between two centres and check the runout on the areas indicated using two dial gauges.
Page 475 Cylinder head assemblies: camshafts Refitting the camshafts If the stud bolts (2) were removed, apply the recommended threadlocker to the short end of the stud bolts (2), i.e. the end that is to be screwed into the cylinder head. Tighten the studs (2) to the specified torque (Sect. C 3, Engine torque settings).
Page 476 Cylinder head assemblies: camshafts Check that the camshafts (marked VA and VS for the vertical cylinder head and OS and OA for the horizontal cylinder head) are clean and in good condition. If the camshafts are not new, use emery cloth to remove signs of wear on the cam and support surfaces, working on a flat surface.
Page 477 Cylinder head assemblies: camshafts Apply sealant (Three Bond 1215 liquid gasket) at the four points of the support (22) shown in red in the photo. Clean off any excess sealant. Notes Only apply sealant to the timing side support (22): do not apply to support (23). Install the camshafts (14) and (15) in the cylinder head, and rotate them to distribute the lubricant evenly.
Page 478 Cylinder head assemblies: camshafts Bed down the supports. Apply engine oil to the threads and undersides of the heads of the bolts (3). Insert the bolts (3). Pre-tighten the bolts (3) to the specified torque (Sect. C 3, Engine torque settings).
Page 479 Cylinder head assemblies: camshafts Check the valve lift as explained in Sect. N 4.1, Checking valve lift. Oil seals Lubricate the oil seals (17) with denatured alcohol. Fit the installation tool supplied with service tool 88713.2861 on the camshaft and install the oil seal on the cylinder head with the spring side.
Page 480 Cylinder head assemblies: camshafts Apply sealant (Three Bond 1215 liquid gasket) at the four points of the cylinder head cover shown in red in the photo. Fit the gaskets (4) and (9) on the cylinder head cover, as shown in the figure. Apply sealant (Three Bond 1215 liquid gasket) at the four points of the cylinder head shown in red in the photo.
Page 481 Cylinder head assemblies: camshafts Locate the cover (6) on the cylinder head, aligning the four fixing holes. Start the bolts (7) with the O-rings (8). Tighten the bolts (7) to the specified torque (Sect. C 3, Engine torque settings) in the indicated sequence. Remove excess sealant from the area of application.
Page 482 Cylinder head assemblies: camshafts come free. Loosen the clamp (A) and remove the hose (B). Remove the union (12) and recover the seal (24). Refitting the intake manifold and coolant union Apply the recommended threadlocker to the union (12), fit the seal (24) and tighten to the specified torque (Sect.
Page 483 Cylinder head assemblies: camshafts Check that the mating surfaces of the cylinder head and manifold are perfectly flat and clean and install the intake manifold (25) on the cylinder head. Relocate the expansion tank support (Sect. N 3.1, Refitting the expansion tank).
Page 484 Cylinder head assemblies: valves - rocker arms 4.5 - Cylinder head assemblies: valves - rocker arms 1 Closing rocker arm shaft 2 Opening rocker arm shaft 3 Opening rocker arm 4 Closing rocker arm (left) 5 Valve opening shim 6 Half rings 7 Valve closing shim 8 Seal 9 Valve guide...
Page 485 Cylinder head assemblies: valves - rocker arms 19 Valve return spring (left) 20 Cylinder head 21 Cylinder head nut 22 Washer Parts catalogue Crankcase halves Vertical cylinder head HORIZONTAL CYLINDER HEAD Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 486 Cylinder head assemblies: valves - rocker arms Remove the cylinder head assembly by lifting it off the engine studs. Repeat the same procedure for the other cylinder head. Removal of the valves Operation Section reference Remove the cylinder head assembly N 4.5, Removal of the cylinder heads from the engine...
Page 487 Cylinder head assemblies: valves - rocker arms Withdraw the valves (14) and (11) from underside of the cylinder head. Repeat the same procedure for the other cylinder head. Removing the valve rocker arms With the cylinder head in the condition described in the previous paragraph, remove the rocker arms. Unscrew the eight plugs (12) and recover the seals (15).
Page 488 Cylinder head assemblies: valves - rocker arms Using an M6 bolt, withdraw the shafts (2) of the opening rocker arms (3) on the exhaust and intake sides. Remove the opening rocker arms (3). Using accessory of the rocker arm spring tensioning kit 88713.2069 installed between the spring and the inner wall of the cylinder head, move the straight end of the rocker arm return spring (19) and (18) and insert it in the drilled shaft.
Page 489 Cylinder head assemblies: valves - rocker arms Use the shaft to slide the end of the spring into its final position. Using an M6 bolt, withdraw the shafts (1) of the closing rocker arms on the exhaust and intake sides. Remove the closing rocker arms (4) and (16), the springs (18) and (19) with the spacers (17).
Page 490 Cylinder head assemblies: valves - rocker arms Remove the seal rings (8) from the ends of the valve guides. Repeat the same procedure for the other cylinder head. file:///C|/848/wsm/en/848_08_N_4E9_00.66.1.html (7 of 24) [11-6-2008 0:34:47] WWW.PlanDeGraissage.ORG...
Page 491 Cylinder head assemblies: valves - rocker arms Overhaul of cylinder head components Cylinder heads Remove any carbon deposits from the combustion chamber and its ducts. Remove any scale from the coolant ducts. Check for cracking and inspect the sealing surfaces for scoring, ridges or other damage. Check that the cylinder barrel mating surfaces of the cylinder head are free of carbon deposits and scale.
Page 492 Cylinder head assemblies: valves - rocker arms Minor damage can be repaired by grinding with special 45° and 60° single-blade grinders. Grind the valves and check the seal. If the valve seats are excessively damaged, fit oversize seats. Replacement seats are available with 0.03 and 0.06 mm oversized outside diameters.
Page 493 Cylinder head assemblies: valves - rocker arms Allow the cylinder head to cool down and grind the seats to the following dimensions: CA = Ø 41.6±0.025 mm. CS = Ø 33.6±0.025 mm. S = 1.2 mm. D = 0.2 to 0.4 mm. Important Do not use any lapping compound after final grinding.
Page 494 Cylinder head assemblies: valves - rocker arms Check the inner surface of the valve guides for cracking or distortion. Thoroughly check the dimensions of the inner surface of the valve guide. Measure the inside diameter with a bore diameter gauge. Measure the diameter at different positions of the valve guide.
Page 495 Cylinder head assemblies: valves - rocker arms Checking the valve Check that the stem and the valve seat contact surface are in good condition. There must be no pitting, cracks, deformations or signs of wear. Warning The valves cannot be ground. Perform the following checks.
Page 496 Cylinder head assemblies: valves - rocker arms Use Prussian blue or a mixture of minium and oil to check that the contact surface (W) between the valve and seat is 1.4 to 1.6 mm (1.05 to 1.35 mm when new). Grind the seat if the dimension measured is greater than the above limit.
Page 497 Cylinder head assemblies: valves - rocker arms Checking the rocker arms Check for signs of wear, grooves or chrome flaking off. Check the condition of rocker arm bore and shaft. Assembly clearance: 0.025 to 0.049 mm. Wear limit: 0.08 mm. Opening and closing shims - Springs Check the condition of the contact surfaces of the valve opening and closing shims: there must be no signs of wear.
Page 498 Cylinder head assemblies: valves - rocker arms Reassembly of the cylinder head The exhaust side can be identified by the three threaded holes on the flange. The intake side can be identified by the presence of four threaded holes on the flange. All the photos in this chapter refer to a vertical cylinder head.
Page 499 Cylinder head assemblies: valves - rocker arms Reassembly of the closing rocker arms Check that the rocker arms are not scored or show signs of breakage in the area of contact with the camshaft and shim. The closing rocker arm shafts are 10 mm in diameter, whereas the opeining rocker arm shafts are 9 mm in diameter. Using an M6 bolt, position the closing rocker shaft (1) towards the exhaust side of the cylinder head.
Page 500 Cylinder head assemblies: valves - rocker arms Locate the spring (18) on the spacer (17). Locate the closing rocker arm (16) and drive the shaft home. Proceed in a similar manner to install the closing rocker arm (4) with the spring (19) from the exhaust side. file:///C|/848/wsm/en/848_08_N_4E9_00.66.1.html (17 of 24) [11-6-2008 0:34:47] WWW.PlanDeGraissage.ORG...
Page 501 Cylinder head assemblies: valves - rocker arms Load the springs (18) and (19) on the closing rocker arms (16) and (4) respectively using service tool no 88713.2069. Proceed to install the closing rocker arms (4) and (16), the relative springs and shafts on the intake side (C) in the same manner as described for the exhaust side (D).
Page 502 Cylinder head assemblies: valves - rocker arms Refitting the valves, closing shims and half rings Carefully clean the two intake valve seats (A) and the two exhaust valve seats (B). Lubricate the stems of the two intake valves (14) and the two exhaust valves (11) with engine oil. Install the valves in respective seats in the cylinde head.
Page 503 Cylinder head assemblies: valves - rocker arms Repeat the procedure with the opposite valve and check that the top of the valve stem is aligned with the surface of the shim (7); if it is not, repeat the half-ring installation procedure. Install the closing shims on the intake valves (14) using the method described above for the exhaust valves.
Page 504 Cylinder head assemblies: valves - rocker arms Locate the opening rocker arm (3) and drive the shaft home. Install the four rocker arms (3) in the manner described above. Raise the opening rocker arm (3) and install the opening shim (5) so it seats against the valve stem. file:///C|/848/wsm/en/848_08_N_4E9_00.66.1.html (21 of 24) [11-6-2008 0:34:47] WWW.PlanDeGraissage.ORG...
Page 505 Cylinder head assemblies: valves - rocker arms Release the rocker arm so that it rests against the shim. Ensure the shim is correctly seated by lightly tapping the rocker arm shoe (A) with plastic mallet. Refit the camshafts (Sect. N 4.4, Refitting the camshafts) to check the valve opening clearances (Sect.
Page 506 Cylinder head assemblies: valves - rocker arms Refit the cylinder head covers N 4.4, Refitting the camshafts Refit the cylinder head assembly N 4.5, Refitting the cylinder head assemblies Refitting the cylinder head assemblies Before fitting the head, check that gasket is installed on the mating surface between head and cylinder (Sect. N 5, Refitting the cylinder/piston assembly).
Page 507 Cylinder head assemblies: valves - rocker arms Tighten the nuts (21) on the studs evenly and gradually in a criss-cross sequence using service tool 88713.2676 in conjunction with a torque wrench. Pre-tighten and tighten the cylinder head nuts (21) to the specified torque (Sect. C 3, Engine torque settings).
Page 508 Cylinder/piston assemblies 5 - Cylinder/piston assemblies 1 Piston 2 Gudgeon pin circlip 3 Gudgeon pin 4 Set of piston rings 5 Cylinder-crankcase gasket 6 Water pump outlet union 7 Hose clip 8 Horizontal cylinder coolant inlet hose 9 Vertical cylinder coolant inlet hose 10 Cylinder barrel 11 Cylinder head gasket 12 Locating bush...
Page 509 Cylinder/piston assemblies Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Removal of the cylinder/piston assembly Loosen the clamps (7) and remove the hoses (8) and (9) from the cylinder barrels (10) and from the alternator-side crankcase cover. If damaged, unscrew the unions (6).
Page 510 Cylinder/piston assemblies Remove the bushes (12). Use service tool no. 88765.1523 to bring the piston of the horizontal cylinder to TDC. Carefully lift the cylinder barrel (10) off the crankcase, keeping it vertical. If necessary, rock the cylinder slightly using both hands or tap its base gently with a rubber mallet. Continue to lift the cylinder until you can access the gudgeon pin (3).
Page 511 Cylinder/piston assemblies Remove the circlip (2) from the gudgeon pin (3) on the clutch side. Working from the opposite side, drive out the gudgeon pin sufficiently to release the connecting rod. Lift the barrel/piston assembly clear of the crankcase studs. If work is to be carried out on the piston, carefully withdraw it from the cylinder.
Page 512 Cylinder/piston assemblies To remove the vertical barrel-piston assembly, bring the vertical piston to TDC and proceed as for removal of the horizontal cylinder barrel. Important Mark the pistons to show from which cylinder they were removed: V= Vertical - H= Horizontal Overhaul of the cylinder barrel/piston components Overhauling the cylinder Check that the walls of the cylinder bore are perfectly smooth.
Page 513 Cylinder/piston assemblies Overhauling the piston Clean the piston crown and piston ring grooves, removing any carbon deposits. Inspect the piston and check its dimensions carefully: there must be no signs of scuffing, scoring, cracks, or other damage. The piston diameter must be measured at 7.5 mm up from the bottom of the skirt at a 90º angle to the gudgeon pin. The pistons must always be renewed as a pair.
Page 514 Cylinder/piston assemblies Overhauling the gudgeon pins Gudgeon pins must be perfectly smooth without signs of scoring, steps, or blueing due to overheating. The well- lubricated gudgeon pin must slide smoothly inside the piston without stiffness. The assembly clearance with the piston at the time of installation must be 0.002 to 0.008 mm. The maximum permissible wear limit is 0.035 mm.
Page 515 Cylinder/piston assemblies Checking the piston ring-grooves clearance The maximum permissible wear limit is 0.15 mm for the top compression ring (1 st ) and 0.10 mm for the others (2 nd and oil control ring). The piston rings must always be installed with markings facing upwards. file:///C|/848/wsm/en/848_08_N_5_9_00.67.1.html (8 of 14) [11-6-2008 0:34:48] WWW.PlanDeGraissage.ORG...
Page 516 Cylinder/piston assemblies Checking the piston ring/cylinder clearance Insert the ring in the cylinder bore so that it is positioned 50 mm from the top face of the cylinder barrel; make sure that the ring is positioned perfectly square to the cylinder walls by checking with a gauge at several points around the ring that the top surface of the ring is exactly 50 mm from the top face of the cylinder barrel.
Page 517 Cylinder/piston assemblies Refitting the cylinder/piston assembly If you are using new cylinders and pistons, combine cylinders and pistons belonging to the same class (see Overhaul of the cylinder barrel/piston components in this section). If the pistons have been separated from their cylinders, before reassembling these components, position the piston ring gaps at 120°...
Page 518 Cylinder/piston assemblies Apply sealant to the gasket (5) then locate the gasket on the crankcase. Using the cap 88713.1920, fit the O-rings (A) on each stud and guide them into their seats in the crankcase. Bring the connecting rod small end close to TDC and slide the barrel-piston assembly (1-10) onto the crankcase studs. Push the connecting rod small end into the piston close to the gudgeon pin (3) bore.
Page 519 Cylinder/piston assemblies The gudgeon pin (3) must slide smoothly in the connecting rod small end bush and in the piston (1). Stuff the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit circlip (2). Important Always use new circlips (2) on reassembly.
Page 520 Cylinder/piston assemblies Fit the cylinder head gasket (11) over the studs. The side marked with the part number must be facing the cylinder head. Notes The shape of the gasket prevents incorrect fitting, provided that the coolant flow holes are aligned with those on the cylinder.
Page 521 Cylinder/piston assemblies file:///C|/848/wsm/en/848_08_N_5_9_00.67.1.html (14 of 14) [11-6-2008 0:34:48] WWW.PlanDeGraissage.ORG...
Page 522 Clutch assembly: clutch 6.1 - Clutch assembly: clutch 1 Bolt 2 Collar 3 Clutch spring 4 Pressure plate 5 Bearing 6 Clutch lifter 7 Nut 8 Belleville washer 9 Clutch plates 10 FCC Belleville washer 11 Flat ring 12 Clutch centre 13 Spacer Parts catalogue Clutch...
Page 523 Clutch assembly: clutch Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram. Description of the clutch assembly The clutch is disengaged by a slave cylinder consisting of a piston (C) housed inside a cylinder mounted to the left- hand side crankcase cover.
Page 524 Clutch assembly: clutch A noisy clutch may be caused by: - excessive backlash between the primary drive gears; - damaged primary drive gear teeth; - excessive play between driving plate tabs and clutch drum; - worn gear/clutch drum bearings; - the presence of metal particles (filings) on the gear teeth. Removal of the clutch Operation Section reference...
Page 525 Clutch assembly: clutch Restrain the clutch centre (12) using service tool no. 88713.2651, insert the socket (D) inside the tool and unscrew the locking nut (7). file:///C|/848/wsm/en/848_08_N_6A9_00.68.1.html (4 of 12) [11-6-2008 0:34:49] WWW.PlanDeGraissage.ORG...
Page 526 Clutch assembly: clutch Remove the nut (7) and the Belleville spring (8), withdraw the clutch centre (12) and the plates (9) from the clutch drum. Slide the clutch plates (9) off the clutch centre (12). When removing the plates, keep them paired in the assembly order and set them aside tied together, if necessary.
Page 527 Clutch assembly: clutch Overhaul of the clutch plates The clutch plates must not show any signs of blackening, grooves or deformation. Measure the thickness of the friction plates. It should not be less than 2.6 mm. Important The total thickness of the clutch plate pack must not be less than 46.1 mm. Place the plate on a flat surface and check the amount of deformation with a feeler gauge.
Page 528 Clutch assembly: clutch Check the condition of spring guide cups (G) and of thepressure plate (4); at each overhaul always renew spring retainer collars (2). Overhauling the pressure plate springs Measure the length L of each spring (3): minimum length: 41 mm. Renew any springs that are shorter than the above limit value.
Page 529 Clutch assembly: clutch Locate the Belleville washer (8). Apply the prescribed grease to the thread of the gearbox input shaft and the mating surface of nut (7), and fit it over Belleville washer (8). Restrain the clutch centre using service tool no. 88713.2651, insert the socket (D) in the tool and tighten the locking nut (7) to the specified torque (Sect.
Page 530 Clutch assembly: clutch Install the clutch plates (9) in the following order: - one friction plate (H) with 48 square tangs; a series of three plain plates (I) thickness 1.6 mm, alternated with three friction plates (L) with 40 rectangular tangs;...
Page 531 Clutch assembly: clutch Notes The last plate must be fitted the opposite way round to the previous plates, as shown in the figure. Lubricate the hole in the gearbox input shaft with engine oil. Fit the clutch lifter (6) in the bearing (5) in the gearbox input shaft. file:///C|/848/wsm/en/848_08_N_6A9_00.68.1.html (10 of 12) [11-6-2008 0:34:49] WWW.PlanDeGraissage.ORG...
Page 532 Clutch assembly: clutch Fit the pressure plate (4). In each cavity, fit a spring (3) and a collar (2). Lubricate the threads of the bolts (1) with oil. Tighten the bolts (1) to the specified torque (Sect. C 3, Engine torque settings), working in a crosswise pattern.
Page 533 Clutch assembly: clutch Operation Section reference Refit the clutch-side crankcase N 6.2, Refitting the clutch-side crankcase cover cover Top up the engine oil D 4, Changing the engine oil and filter cartridge file:///C|/848/wsm/en/848_08_N_6A9_00.68.1.html (12 of 12) [11-6-2008 0:34:49] WWW.PlanDeGraissage.ORG...
Page 534 Clutch assembly: clutch-side crankcase cover 6.2 - Clutch assembly: clutch-side crankcase cover 1 Clutch-side crankcase cover 2 Bolt 3 Bolt 4 Oil level sight glass 5 Bolt 6 Plug 7 Bolt 8 Bush 9 Oil seal 10 Shim 11 Circlip 12 O-ring 13 Locating bush 14 O-ring...
Page 535 Clutch assembly: clutch-side crankcase cover 19 Support 20 Sealing washer, thickness 2 21 Pressure switch Parts catalogue Clutch-side crankcase cover Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 536 Clutch assembly: clutch-side crankcase cover Disassembly of the clutch-side crankcase cover Remove the plug (15) from the cover and the relative O-ring (14), the engine oil pressure switch (21) and its seal (20). Unscrew the bolt (A) securing the inner cover (B). Remove the inner cover (B) and sound-proofing panel (C).
Page 537 Clutch assembly: clutch-side crankcase cover Inspect the oil seal (9) and renew it if necessary. Reassembly of the clutch-side crankcase cover Fit the plug (15) and the seal (14). Install the pressure switch (21) with its seal (20). If the bush has been replaced, fully seat the new bush (8) in the slot in the cover using a suitable drift and a press. If the oil seal (9) needs to be renewed, fit the new seal into the crankcase cover, positioning it so the side without a spring is facing the circlip (11).
Page 538 Clean and degrease mating surfaces on the clutch-side crankcase cover and crankcase and ensure that locating bush (13) and the O-ring (12), located in correspondence with the oil way, are installed in the crankcase. Apply a uniform continuous bead of DUCATI liquid gasket (A) onto crankcase mating surfaces, working around all the holes.
Page 539 Clutch assembly: clutch-side crankcase cover Refit the cable guide (19), the bush (18) and the washer (16). Operation Section reference Connect the oil pressure sensor P 5, Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Top up the engine oil D 4, Changing the engine oil and filter...
Page 540 Clutch assembly: primary drive gears 6.3 - Clutch assembly: primary drive gears 1 Clutch drum/Primary drive gears 2 Spacer 3 Threaded ringnut 4 Lock washer Parts catalogue Clutch Clutch-side crankcase cover Connecting rods Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 541 Clutch assembly: primary drive gears Removal of the primary drive gears Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Remove the clutch-side crankcase N 6.2, Removal of the clutch-side cover crankcase cover Remove the clutch assembly N 6.1, Removal of the clutch...
Page 542 Clutch assembly: primary drive gears wrench part no. 88713.2422. Remove the nut (3) and lockwasher (4). file:///C|/848/wsm/en/848_08_N_6C9_00.70.1.html (3 of 7) [11-6-2008 0:34:50] WWW.PlanDeGraissage.ORG...
Page 543 Clutch assembly: primary drive gears Remove the complete primary drive gear (B) using a commercial puller and placing a brass or aluminium pad between the end of the crankshaft and the puller screw. Do not damage the Woodruff key (D) located on the crankshaft. Refitting the primary drive gears and checking backlash Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear.
Page 544 Clutch assembly: primary drive gears Fit the driving gear (B) onto the crankshaft with the oil pump drive sprocket facing the crankcase. Temporarily secure the gear with the washer (4) and nut (3). Important If fitting a new primary driving gear (B), check the backlash. file:///C|/848/wsm/en/848_08_N_6C9_00.70.1.html (5 of 7) [11-6-2008 0:34:50] WWW.PlanDeGraissage.ORG...
Page 545 Clutch assembly: primary drive gears To check the backlash, temporarily fit the clutch drum (1) complete with the primary driven gear (A) on the gearbox input shaft. Fix a dial gauge to the engine crankcase, positioning the stylus against a gear tooth. Turn the driven gear (A) to mesh the teeth and check with the dial gauge that backlash ranges between 0.05 and 0.07 mm.
Page 546 Clutch assembly: primary drive gears Operation Section reference Refit the complete clutch assembly N 6.1, Reassembly of the clutch Refit the clutch-side crankcase cover N 6.2, Refitting the clutch-side crankcase cover Refill the engine with oil D 4, Changing the engine oil and filter cartridge file:///C|/848/wsm/en/848_08_N_6C9_00.70.1.html (7 of 7) [11-6-2008 0:34:50] WWW.PlanDeGraissage.ORG...
Page 547 Gearbox assembly: gearchange mechanism 7.1 - Gearbox assembly: gearchange mechanism 1 Return spring 2 Washer 3 Special bolt 4 Gear pawl assembly 5 Interlock plunger holder 6 Seal 7 Detent ball spring 8 Ball 9 Circlip 10 Selector claw return spring 11 Shim, thickness 0.5 11 Shim, thickness 0.2 12 Ring...
Page 548 Gearbox assembly: gearchange mechanism 18 Bolt 19 Washer 20 Bolt 21 Washer 22 Locating ring 23 Stop plate 24 Shim, thickness 0.2 24 Shim, thickness 0.5 25 Gearchange mechanism Parts catalogue Gearchange CONTROL Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
Page 549 Gearbox assembly: gearchange mechanism Important Visually inspect the gear selector claw (14) for wear, particularly around the area where it contacts the selector drum. If it proves necessary to change components, disassemble the gear selector lever as shown in the exploded view. Reassemble the gearchange mechanism, orienting the eccentric pin (15) in such a way that the lever arm (16) is positioned centrally with respect to the shoulders of the stop plate (23).
Page 550 Gearbox assembly: gearchange mechanism Disassembly of gear interlock plunger and pawl assembly Unscrew the interlock plunger screw (5) and remove the seal (6), spring (7) and the detent ball (8). Unscrew the clutch-side crankcase half bolt (3) and remove the pawl (4), washer (2) and spring (1). file:///C|/848/wsm/en/848_08_N_7A9_00.71.1.html (4 of 8) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 551 Gearbox assembly: gearchange mechanism Refitting the gear interlock plunger and pawl assembly On the special bolt (3), fit the gear pawl lever (4), orienting it as shown in the figure, the washer (2) with the square edge side (D) facing the clutch-side crankcase, and the spring (1), positioning it so that the hook end (A) is facing the gear pawl lever.
Page 552 Gearbox assembly: gearchange mechanism Grease and then fit the ball (8), spring (7), and seal (6) to the gear interlock plunger (5). Tighten the gear interlock plunger to the specified torque (Sect. C 3, Engine torque settings). Refitting the gearchange mechanism Locate the gearchange mechanism (25) with the shaft, spring, and stop plate, on the chain-side crankcase half.
Page 553 Gearbox assembly: gearchange mechanism Fit the bolts (18) and (20) with the washers (19) and (21). Locate the gearbox drum selector claw in the centre of the drum rollers. Temporarily fit the gearchange lever (or a service lever) and the engine sprocket, and shift to second gear. Fit the plate 88713.2827 in the claw shaft pins (see figure).
Page 554 Gearbox assembly: gearchange mechanism Operation Section reference Refit the primary gear, the clutch N 6.2, Refitting the clutch-side drum and the clutch-side crankcase crankcase cover cover Refit the flywheel/alternator N 8, Refitting the flywheel/alternator assembly and alternator-side assembly crankcase cover file:///C|/848/wsm/en/848_08_N_7A9_00.71.1.html (8 of 8) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 555 Gearbox assembly: gearbox shafts 7.2 - Gearbox assembly: gearbox shafts 1 Shim, thickness 1.2 2 Gearbox input shaft 3 Shim, thickness 0.5 4 Needle roller bearing 5 5 th speed driving gear 6 Splined washer, thickness 0.5 7 Circlip 8 3 rd - 4 th speed driving gear 9 6 th speed driving gear 10 2 nd speed driving gear 11 Shim, thickness 1.6...
Page 556 Gearbox assembly: gearbox shafts 18 1 st speed driven gear 19 Shim, thickness 1 20 5 th speed driven gear 21 4 th speed driven gear 22 3 rd speed driven gear 23 6 th speed driven gear 24 2 nd speed driven gear 25 Gearbox output shaft 26 Shim, thickness 0.8 27 Shim, thickness 0.9...
Page 557 Gearbox assembly: gearbox shafts Withdraw the selector drum (16) taking care not to lose shims (31) and (27) mounted on the shaft. Note that the positions of the shims must not be inverted. Now you can renew the needle roller retaining ring (32) and the special needle rollers (13). Remove gear selector forks (29) and (28).
Page 558 Gearbox assembly: gearbox shafts Disassembly of the gearbox shafts Place the shaft in a vice in such a way as to facilitate the disassembly operations. Important Take care not to invert the positions of the shims on reassembly: this would potentially lead to jamming when using the gear selector control, making it necessary to reopen the engine crankcase.
Page 559 Gearbox assembly: gearbox shafts Withdraw the first speed driven gear (18) with the roller cage (17) and the shim (19). Remove the fifth speed driven gear (20). Use two flat blade screwdrivers to remove the circlip (7) taking care not to damage the shaft surface. Remove the circlip (7) and the splined washer (6).
Page 560 Gearbox assembly: gearbox shafts Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12). Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6). file:///C|/848/wsm/en/848_08_N_7B9_00.72.1.html (6 of 17) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 561 Gearbox assembly: gearbox shafts Remove the circlip (7) and remove the sixth speed driven gear (23). Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24). Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox output shaft (25).
Page 562 Gearbox assembly: gearbox shafts Remove the second speed driving gear (10). Use two screwdrivers to prise out the circlip (7) and the splined washer (6). Important Take care to avoid damaging the surface of the shaft while removing circlip (7). Remove the sixth speed driving gear (9) with its roller cage (4).
Page 563 Gearbox assembly: gearbox shafts Remove the circlip (7) and the splined washer (6). Remove the fifth speed driving gear (5) with the roller cage (4). file:///C|/848/wsm/en/848_08_N_7B9_00.72.1.html (9 of 17) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 564 Gearbox assembly: gearbox shafts Slide the shim (3) off the input shaft (2). Overhaul of the gearbox Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear on the edges of the teeth. The idler gears must rotate freely on their shafts.
Page 565 Gearbox assembly: gearbox shafts Inspection of the gear selector forks Visually inspect the gear selector forks. Bent forks must be renewed as they may lead to difficulties in gear changing or may suddenly disengage when under load. Use a feeler gauge to check the clearance of each fork in its gear groove. If the service limit has been exceeded, check whether or not it is necessary to renew the gear or the fork by referring to the limits specified for each part (Sect.
Page 566 Gearbox assembly: gearbox shafts Reassembly of the gearbox shafts Figure 1 shows all the parts to be reassembled on the gearbox input shaft (2), with the calculated end shims (1) and (11) (Sect. N 9.2, Reassembly of the crankcase halves). file:///C|/848/wsm/en/848_08_N_7B9_00.72.1.html (12 of 17) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 567 Gearbox assembly: gearbox shafts Figure 2 shows all the parts to be reassembled on the gearbox output shaft (25), with calculated end shims (15) and (26) (Sect. N 9.2, Reassembly of the crankcase halves). file:///C|/848/wsm/en/848_08_N_7B9_00.72.1.html (13 of 17) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 568 Gearbox assembly: gearbox shafts Reassemble the gears on the gearbox shafts by reversing the disassembly procedure. Take particular care when installing the idler gears. The assembly of the 3 rd and 4 th speed gears and the relative fixing components on the output shaft is given as an example. Fit the circlip (7), checking that it is fully inserted into its groove on the shaft.
Page 569 Gearbox assembly: gearbox shafts Fit the three-pointed washer (12), which can be distinguished from its counterpart (6) by its bigger outside diameter. Fit another needle roller cage (4) using the method already described. Fit the 4 th speed gear (21). file:///C|/848/wsm/en/848_08_N_7B9_00.72.1.html (15 of 17) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 570 Gearbox assembly: gearbox shafts Fit another 3-pointed washer (6) and another circlip (7) onto the shaft. Seat the circlip using the drift used previously. Reassembly of the gearbox To reassemble gearbox components follow the procedure under Sect. N 9.2, Reassembly of the crankcase halves relating to reassembly of the crankcase halves.
Page 571 Gearbox assembly: gearbox shafts Operation Section reference Reassemble the engine crankcase N 9.2, Reassembly of the crankcase halves halves Refit the engine to the frame N 1, Refitting the engine file:///C|/848/wsm/en/848_08_N_7B9_00.72.1.html (17 of 17) [11-6-2008 0:34:51] WWW.PlanDeGraissage.ORG...
Page 572 Flywheel-alternator 8 - Flywheel-alternator 1 Bolt 2 Cylinder coolant inlet union 3 Ignition inspection plug 4 Oil seal 5 O-ring 6 Cover 7 Bolt 8 Aluminium gasket 9 Cable guide 10 Washer 11 Bolt 12 Bolt 13 Bolt 14 Flange 15 Flanged nut 16 Belleville washer 17 Flywheel...
Page 573 Flywheel-alternator 19 Inner ring 20 Needle roller bearing 21 Electric starter driven gear 22 Starter clutch 23 Flywheel-starter clutch assembly 24 Alternator rotor 25 Bolt 26 Bolt 27 Bearing 28 Circlip 29 Alternator-side crankcase cover 30 Locating bush 31 Bracket 32 Bolt 33 Alternator stator Parts catalogue...
Page 574 Flywheel-alternator Unscrew the two retaining bolts (7) of the centre cap (6) over the end of the crankshaft. Unscrew the bolts (1), (11), (12) and (13) securing the alternator-side crankcase cover (29). file:///C|/848/wsm/en/848_08_N_8_9_00.73.1.html (3 of 18) [11-6-2008 0:34:52] WWW.PlanDeGraissage.ORG...
Page 575 Flywheel-alternator Fix service tool no. 88713.1749 to the holes of the two bolts (7) you have just removed. Turn the tool shaft slowly to separate the cover (29) from the LH crankcase half. There is an oil seal (4) on the cover in correspondence with the gearchange shaft that may be damaged when removing the crankcase cover.
Page 576 Flywheel-alternator cover. Secure the bearing with the circlip (28), ensuring that it is correctly fitted in its seat in the crankcase cover (29). Unscrew the horizontal and vertical cylinder coolant inlet unions (2). When fitting new components, apply the recommended threadlocker and tighten to the specified torque. (Sect. C 3, Engine torque settings).
Page 577 Flywheel-alternator Remove the nut (15), the Belleville washer (16) and the flywheel assembly (23) with the driven gear (21) from the crankshaft. Remove the inner ring (19), the needle roller bearing (20) and the washer (18). Important Check the ring (19), the needle roller bearing (20) and the inner washer (18) for wear. Renew if worn. file:///C|/848/wsm/en/848_08_N_8_9_00.73.1.html (6 of 18) [11-6-2008 0:34:52] WWW.PlanDeGraissage.ORG...
Page 578 Flywheel-alternator Overhaul of the flywheel/alternator assembly Check that the inner part of alternator rotor (24) shows no signs of damage. Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind.
Page 579 Flywheel-alternator Reassembly of the flywheel-alternator assembly Install the starter clutch (22) in the flange (14) to bring the edge (A) of the clutch up against the flange. Important Assemble the components (starter clutch and flange) so that the edge (A) of the starter clutch is positioned on side of the flange with the bevelled edge (B).
Page 580 Flywheel-alternator Seat the flange (14) with the starter clutch (22) in the flywheel (17), aligning the flange locating hole (C) with the flywheel locating hole (D). Notes The flange locating hole (C) is the hole with the countersunk lead-in (E). Notes The locating hole (D) of the flywheel can be either one of the two holes (F).
Page 581 Flywheel-alternator file:///C|/848/wsm/en/848_08_N_8_9_00.73.1.html (10 of 18) [11-6-2008 0:34:52] WWW.PlanDeGraissage.ORG...
Page 582 Flywheel-alternator Important Assemble the components (flange and flywheel) so that edge (A) of the starter clutch (22) is enclosed between the flange and flywheel. Install the rotor (24) on the flywheel (17), aligning one of the the flywheel locating holes (D) with the rotor locating hole (G).
Page 583 Flywheel-alternator Tighten the bolts (26) to the specified torque (Sect. C 3, Engine torque settings), in the indicated sequence. Lubricate the surface (L) of the driven gear (21) with engine oil. Install the driven gear on the starter clutch, ensuring it is properly seated. Notes To facilitate installation, rotate the driven gear in the direction of the green arrow.
Page 584 Flywheel-alternator Refitting the flywheel/alternator assembly file:///C|/848/wsm/en/848_08_N_8_9_00.73.1.html (13 of 18) [11-6-2008 0:34:52] WWW.PlanDeGraissage.ORG...
Page 585 Flywheel-alternator Install the roller cage assembly (20) with the washer (18) and inner ring (19). Install the roller cage assembly (20) with the washer (18) and inner ring (19). Install the flywheel assembly (23) with the gear (21), aligning the notches as shown in the photo. Fit the Belleville washer (16) on the end of the crankshaft.
Page 586 Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the crankcase cover. Fit the two locating bushes (30). Spread a continuous uniform bead of DUCATI liquid gasket on the cover mating surface, ensuring continuity around the holes for the retaining bolts and bushes.
Page 587 Flywheel-alternator Grease the end of the crankshaft and the gearchange shaft to facilitate installation of the cover and to prevent the oil seal (4) from being damaged, if already installed in the cover. While positioning the cover (29) on the crankcase, slightly turn the timing belt drive shaft pulleys to facilitate insertion of the pump control shaft.
Page 588 Flywheel-alternator Moisten the oil seal (4) with alcohol and install it in the alternator-side crankcase cover, in correspondence with the gearchange shaft. Make sure that the O-ring (5) is installed in the cover (6). Apply threadlocker to the bolts (7). Tighten the two retaining bolts (7) of the inspection cover (6) over the end of the crankshaft to the specified torque (Sect.
Page 589 Flywheel-alternator Reconnect the alternator wiring to the main wiring loom (A). Operation Section reference Refit the water pump-radiator N 3.3, Refitting the water pump hose Refit the pump-cylinder hoses N 5, Refitting the cylinder/piston assembly Fit the clutch pushrod F 2, Refitting the clutch slave cylinder Refit the sprocket cover G 8,...
Page 590 Crankcase assembly: external components 9.1 - Crankcase assembly: external components 1 Oil breather valve 2 O-ring 3 Seal 4 Neutral switch 5 Cylinder barrel/head stud 6 Nipple 7 By-pass spring 8 Nipple 9 Aluminium gasket 10 Plug 11 Nut 12 Lock washer 13 Timing gear pair 14 Key 15 Key...
Page 591 Crankcase assembly: external components 20 Washer 21 Gear shaft 22 O-ring 23 Engine sensor 24 Washer 25 Bolt 26 Washer 27 Aluminium gasket 28 O-ring 29 Drilled locating dowel 30 O-ring 31 Seal 32 Ball 33 Spring 34 Special bolt Parts catalogue GEARCHANGE CONTROL Timing system...
Page 592 Crankcase assembly: external components Unscrew and remove the oil inlet and outlet nipples (8) from the clutch-side crankcase half and recover the seals (27). Unscrew and remove the oil filter support nipple (6) and remove also by-pass spring (7). file:///C|/848/wsm/en/848_08_N_9A9_00.74.1.html (3 of 13) [11-6-2008 0:34:53] WWW.PlanDeGraissage.ORG...
Page 593 Crankcase assembly: external components Remove the gauze filter (A) with its seal from the alternator-side crankcase half (Sect. D 4, Changing the engine oil and filter cartridge). Remove the drain plug (10) with its seal (9). Remove the neutral switch (4) with seal (3). Remove the cylinder head studs (5) with the aid of the appropriate tool.
Page 594 Crankcase assembly: external components To remove the engine sensor (23), unscrew the bolt (25) and recover the shim (24) and the washer (26). Check the condition of O-ring (22) and renew it if necessary. file:///C|/848/wsm/en/848_08_N_9A9_00.74.1.html (5 of 13) [11-6-2008 0:34:53] WWW.PlanDeGraissage.ORG...
Page 595 Crankcase assembly: external components Refitting the external components Grease the engine sensor (23) in the part indicated. Fit the engine sensor (23) in its seat in the crankcase. Insert the bolt (25) with the washer (26) and tighten to the specified torque (Sect. C 3, Engine torque settings).
Page 596 Crankcase assembly: external components Install the oil vapour breather valve (1) in the crankcase along with O-rings (2), previously lubricated. Tighten the bolt (17) to the specified torque (Sect. C 3, Engine torque settings). Tighten the two oil hose connection nipples (8) with the seals (27) to the specified torque (Sect. C 3, Engine torque settings).
Page 597 Crankcase assembly: external components Fit the seal (9) on the oil drain plug (10). Position the seal that the side with the square edge (B) is facing the chain side crankcase half. Clean the threasds of the plug; apply THREE BOND TB1215 to the threads. Tighten drain plug (10) and seal (9) to the specified torque (Sect.
Page 598 Crankcase assembly: external components Check the condition of O-rings (28) on the studs (5) and renew them if necessary. Now fit the studs (5) in the crankcase halves, applying threadlocker and tightening to the specified torque value (Sect. C 3, Engine torque settings).
Page 599 Crankcase assembly: external components Relieve the staking on the lock washer (12) of the nut (11). Restrain the driven timing gear by inserting a pin in one of the holes, and unscrew the nut (11). Remove the nut (11), washer (12), driven timing gear (B) and Woodruff key (15) from the timing belt driveshaft shaft.
Page 600 Crankcase assembly: external components Refitting the timing gears Before refitting, check the wear on the timing gear pair (13) and renew if necessary. Important The timing gears (13) must always be renewed as a pair. Refitting is the reverse of removal. Warning When installing the driven gear (B), align the timing mark with that on the driving gear (A).
Page 601 Crankcase assembly: external components Operation Section reference Refit the alternator-side crankcase N 8, Refitting the flywheel/alternator cover and alternator assembly assembly Removal of the starter motor idler gear Operation Section reference Remove the flywheel/alternator N 8, Flywheel-alternator assembly Remove the circlip (18) and the washer (24). Remove the starter motor idler gear (19) and shim (20).
Page 602 Crankcase assembly: external components Refitting the starter motor idler gear Refitting is the reverse of removal. Notes Apply the prescribed threadlocker to the bolt (16) and tighten to the prescribed torque (Sect. C 3, Engine torque settings). Operation Section reference Refit the flywheel/alternator assembly N 8, Flywheel-alternator file:///C|/848/wsm/en/848_08_N_9A9_00.74.1.html (13 of 13) [11-6-2008 0:34:53]...
Page 603 Crankcase assembly: crankcase halves 9.2 - Crankcase assembly: crankcase halves 1 Bearing 2 Bolt 3 Alternator-side crankcase half 4 Bearing 5 Circlip 6 Washer 7 Bearing 8 Oil seal 9 Bearing 10 Retaining plate 11 Bolt 12 Bolt (M8x90) 13 Clutch-side crankcase half 14 Oil seal 15 Bearing 16 Circlip...
Page 604 Crankcase assembly: crankcase halves 19 Plug 20 Bolt 21 Spacer 22 Bush 23 Bearing 24 Bolt (M6x35) 25 Bolt (M8x75) 26 O-ring 27 Bolt (M6x75) 28 Bearing 29 Circlip 30 Timing belt driveshaft 31 O-ring Parts catalogue Timing system Crankcase halves Crankcase halves Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.
Page 605 Crankcase assembly: crankcase halves Unscrew the two bolts (12) on the clutch side near the vertical cylinder. Re-use the alternator-side crankcase cover or a service cover with puller 88713.1749. Secure it to the crankcase half using some of the original bolts and begin separating the crankcase halves by turning the central pin of the tool. Tap the end of the gearbox output shaft with a plastic mallet to separate the crankcase halves.
Page 606 Crankcase assembly: crankcase halves Remove the gearbox shafts and gear selector drum from the crankcase halves as described in Sect. N 7.2, Removal of the gearbox assembly. Drive out the crankshaft (L) using a plastic mallet, taking care not to lose the shims. Remove the timing belt driveshaft (30).
Page 607 Crankcase assembly: crankcase halves Remove the bolts (2), remove the hoses (17) and recover the O-rings (26). Overhaul of the crankcase halves Carefully examine the engine crankcase halves. Check that the surfaces of the crankcases are perfectly flat using a reference surface. Check that the bearings (1) and (18) are in good condition.
Page 608 Crankcase assembly: crankcase halves Notes When overhauling an engine it is good practice to renew all the crankcase bearings. After having renewed the gearbox shaft bearings (28) and (9), secure them in the crankcase with the spacers (21) and the retaining plate (10). At each overhaul it is recommended to renew also the oil seal (8) on the outside of bearing (9).
Page 609 Crankcase assembly: crankcase halves Renew the bearings (7) and (23) on the ends of the gearbox shafts and timing belt driveshaft bearings (4) and (15). Take care not to lose the shim (6) interposed between the bearing (7) on the end of the gearbox input shaft and the chain side crankcase half.
Page 610 Crankcase assembly: crankcase halves The oil seal (14) on the external side of the roller bearing (15) must be renewed at each engine overhaul. Check that the oilways are free of restrictions or clogging. Check the condition of locating bushes (22). In the event of signs of distortion or excessive assembly clearance with the corresponding seats, remove the locating bushes using appropriate tools.
Page 611 Crankcase assembly: crankcase halves Main bearings The main bearings have are of the angular contact type with offset inner races so that the balls transmit loads from one groove to the other along straight lines at an angle to the axis of the bearing. Angular contact thrust bearings are designed to withstand combined loads (radial and axial loads).
Page 612 Crankcase assembly: crankcase halves Important On worn engines, the bearing may no longer be a tight fit in the crankcase half. After having removed the bearing, check that the interference fit between the crankcase and the bearing is no less than 0.03 mm, otherwise the crankcase halves must be renewed.
Page 613 Crankcase assembly: crankcase halves the roller bearing (15) with retaining circlip (16) installed in correspondence with the end of the timing belt driveshaft. Notes Position the circlip so that the side with the square edge (B) is facing upwards (opposite side of the bearing). Refitting the alternator-side crankcase half The following parts must be present on the internal side of the crankcase half: The double race ball bearing (9) supporting the selector fork shaft.
Page 614 Crankcase assembly: crankcase halves Tighten the bolts (11) to the specified torque (Sect. C 3, Engine torque settings). The gearbox input shaft end bearing (7) with the inner spacer (6): apply grease to the bearing rollers. Fit the inner race (A) removed previously from the bearing. Apply grease to the inner race. The main bearing (1) complete with bush (2).
Page 615 Crankcase assembly: crankcase halves Notes None of the bearings except the main bearings have an obligatory assembly direction. it is good practice to install the bearings so that side bearing the writing is facing upwards. Refit the gauze pickup filter as described in Sect. D 4, Changing the engine oil and filter cartridge.
Page 616 Crankcase assembly: crankcase halves Shimming the shafts Before assembling the crankcase halves, calculate the shims required to obtain the correct end float of the crankshaft and gearbox shafts. To determine the correct shim thicknesses proceed as follows. Shimming the crankshaft After fitting the new main bearings, proceed as follows to determine the total shim thickness SA : Measure the distance LA between the bearing contact surfaces on the crankshaft;...
Page 617 Crankcase assembly: crankcase halves In addition to the above procedure, the following is a practical shimming method, providing a guide on how to calculate the crankshaft shim thicknesses accurately. Install a shim of minimum thickness (1.90 mm) on each side of the crankshaft to prevent contact between the crankshaft web and the engine block.
Page 618 Crankcase assembly: crankcase halves Insert a lever (B) between the crankcase and the crank web and force the crankshaft towards the dial gauge. Note the dial gauge reading. This is the crankshaft endfloat. Add a preload of (0.30 mm) plus the thickness of the shims used (1.90x2=3.8 mm).
Page 619 Crankcase assembly: crankcase halves Notes The method described for the crankshaft can also be used to calculate the shim thicknesses for the gear shafts. Shimming the gearbox selector drum To determine the total thickness ST of the gearbox selector drum shims, proceed as described below. Given that: LT1 = clutch-side crankcase half depth LT2 = chain-side crankcase half depth...
Page 620 Crankcase assembly: crankcase halves Reassembly of the crankcase halves Install the O-ring (26) on its seat (A) in the crankcase half. Fit the pipe (17) in the crankcase half, inserting the end (B) fully in the O-ring. Align the hole (L) of the pipe with the threaded hole (M) in the crankcase. Apply threadlocker to the bolt (2) and start it in the threaded hole (M).
Page 621 Crankcase assembly: crankcase halves Notes When refitting used components, make sure that the inner races (C) of the gearbox shaft bearings are fitted into the correct bearings and have not been left on the shafts. Mesh the gearbox shafts and install them on the clutch-side crankcase half with the calculated shims. Notes A figure and a list of the component parts of the gearbox appear in Sect.
Page 622 Crankcase assembly: crankcase halves Notes The two selector forks are identical. Insert the 5 th -6 th speed selector fork (E) in the driven gear of the input shaft. Install the selector drum (F) in the crankcase with calculated shim thickness. Fit the pins (G) in the previously installed selector forks.
Page 623 Crankcase assembly: crankcase halves Fit the shimmed crankshaft into the clutch-side crankcase half, positioning the connecting rods (H) in correspondence with the relative cylinder barrel seats. Important Make sure that the connecting rods (H) are correctly positioned in the respective cylinder seats. Incorrect positioning of the connecting rods at this stage will inevitably lead to the need to re-open the crankcase.
Page 624 Crankcase assembly: crankcase halves Apply a uniform and continuous bead of DUCATI liquid gasket to the mating surfaces of the crankcase halves, going around all the holes as shown in the figure. Bring the crankcase halves (3) and (13) together, tapping with a rubber mallet in the area of the shafts if necessary.
Page 625 Crankcase assembly: crankcase halves Ensure that the crankshaft can be turned with a certain amount of interference with the main bearings (the crankshaft should have a pre-load of 0.2 to 0.30 mm); check also that all the parts you have fitted are free to rotate or move correctly.
Page 626 Crankcase assembly: crankcase halves Install the bush of service tool no. 88713.2060 on the output shaft. Lubricate the new oil seal (8) and seat it. Using the tool's drift, drive the oil seal fully home so it seats against the crankcase bearing. Operation Section reference Refit the clutch assembly...
Page 627 Crankcase assembly: crankshaft/connecting rods assembly 9.3 - Crankcase assembly: crankshaft/connecting rods assembly 1 Special bolt 2 Connecting rod assembly 3 Half bearing 4 Grub screw 5 Key 6 Crankshaft 7 Grub screw 8 Shim 9 Bushes Parts catalogue connecting rods Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.
Page 628 Crankcase assembly: crankshaft/connecting rods assembly exploded view diagram. Removal of the crankshaft/connecting rods assembly Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the cooling system N 3.2, Removal of the radiator Remove the cylinder head assemblies N 4.2, Removal of the timing belt and the timing parts...
Page 629 Crankcase assembly: crankshaft/connecting rods assembly Overhaul of the connecting rods Make the following dimensional checks on the connecting rods: - clearance with gudgeon pin on assembly. In the event of excessive wear (Sect. C 1.1, Crankshaft), renew the connecting rod. The small end bushing must be in good condition and firmly driven into its seat.
Page 630 Crankcase assembly: crankshaft/connecting rods assembly Renewal of the small end bushing To remove the worn bushing, use a suitable drift and a press. Drill lubrication holes into the new bushing in correspondence with the existing lubrication holes on the connecting rod small end.
Page 631 Crankcase assembly: crankshaft/connecting rods assembly Crankshaft The main bearing and big-end journals should not be scored or grooved; the threads, keyways, and slots must be in good condition. Check for fretting or burrs in the fillet between journal and shoulder. Fillet radius: 2 mm.
Page 632 Crankcase assembly: crankshaft/connecting rods assembly Unscrew all the plugs (4) and (7) from the crankshaft, heating the crankshaft, if necessary, to release the threadlocker applied at the time of assembly. Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues that have accumulated and are restricting the oil flow.
Page 633 Crankcase assembly: crankshaft/connecting rods assembly Big-end bearing shell-journal clearance To check the assembly clearance between the bearing shells and crankshaft journals you will lay a strip (A) of GREEN Plastigage PG-1 on the journal. Fit the connecting rod with the original bearings and tighten the bolts to a torque of 50 Nm.
Page 634 Crankcase assembly: crankshaft/connecting rods assembly Check that each connecting rod (2) and cap are fitted with their locating pins (D). Wash the pins and dry them with compressed air. Clean and lubricate the journals and con-rod bearing shells (3) with engine oil and fit the connecting rods in their original mounting positions.
Page 635 Crankcase assembly: crankshaft/connecting rods assembly The grease utilised is an irritant in contact with the skin. Wear protective gloves. Important Lubrication of big-end cap bolts is essential to obtain the correct coupling and to prevent breakage of the parts. The big-end cap bolts may only be used and tightened once, after which they must be discarded. Tighten the bolts (1) by hand.
Page 636 Crankcase assembly: crankshaft/connecting rods assembly described below (observe the same tightening sequence at each step as that of the previous step): 1 first torque each bolt to a value of 20 Nm; 2 now carry out a second tightening stage applying a torque of 35 Nm on each bolt; now tighten each bolt, reading the angle of rotation, to 85 Nm, checking that the final angle is between 55°...
Page 637 Crankcase assembly: crankshaft/connecting rods assembly of the connecting rods at this stage will inevitably lead to the need to re-open the crankcase. Operation Section reference Refit the clutch assembly N 6.1, Reassembly of the clutch Refit the clutch-side crankcase cover N 6.2, Refitting the clutch-side crankcase cover...
Page 638 P - Electrical system 0P - Electrical system 1 - Wiring diagram Key to wiring diagram 5 Wiring colour codes 6 Key to fusebox 6 Routing of wiring on frame 7 Plate 1 9 Plate 2 9 Plate 3 10 Plate 4 10 Plate 5 11 Plate 6 11...
Page 639 P - Electrical system Plate 31 35 Plate 32 36 Plate 33 37 Plate 34 38 Plate 35 38 Plate 36 39 Plate 37 40 Plate 38 41 Plate 39 42 Plate 40 43 Plate 41 44 Plate 42 45 Plate 43 46 2 - Battery charging system Checking the battery charging system 47...
Page 640 P - Electrical system 6 - Protection and safety devices Checking protection and safety device components 86 Checking the fuses 88 7 - Instruments Instrument panel 89 Instrument panel system 90 Display settings and functions 92 8 - Immobilizer and transponder 9 - Diagnostic instruments Using a multimeter to check the electrical systems 123 file:///C|/848/wsm/en/848_08_P_IND_00.77.1.html (3 of 3) [11-6-2008 0:34:56]...
Page 641 Wiring diagram 1 - Wiring diagram file:///C|/848/wsm/en/848_08_P_1A10_00.78.1.html (1 of 5) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 642 Wiring diagram Key to wiring diagram 1 Right-hand handlebar switch 2 Key switch 3 Left cooling fan 4 Right cooling fan 5 Starter motor 6 Starter contactor 7 Battery 8 Regulator fuse 9 Regulator 10 Alternator 11 Rear right turn signal 12 Tail light 13 Number plate light 14 Rear left turn signal...
Page 643 Wiring diagram 47 Front right turn signal 48 EX-UP motor 49 Fan relay 50 Front left sidelight 51 Data Acquisition 52 Lambda sensor Wiring colour codes B Blue Bk Black Bn Brown G Green Gr Grey Lb Light blue O Orange P Pink R Red V Violet...
Page 644 Wiring diagram Position Description Plate 8 Air temperature sensor wiring Plate 8 Lights relay wire Plate 9 Instrument panel wiring Plate 9 Right front indicator wiring branch Plate 9 Left front indicator wiring branch Plate 10 Headlight wiring Plate 10 Right sidelight wiring Plate 10 Left sidelight wiring...
Page 645 Wiring diagram Plate 29 TPS wiring branch Plate 30 Fuel tank flange wiring Plate 31 Sidestand wiring Plate 32 Vertical cylinder injector wiring Plate 33 Exhaust valve motor wiring Plate 34/Plate 35 Data acquisition connector Plate 34/Plate 35 Rear wiring harness connector Plate 35/Plate 36/Plate Battery support wiring branch Plate 38/Plate 39/Plate...
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Page 653 Plate 1 Plate 9 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (8 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 657 Plate 1 Plate 13 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (12 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 658 Plate 1 Plate 14 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (13 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 659 Plate 1 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (14 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 661 Plate 1 Plate 16 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (16 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 662 Plate 1 Plate 17 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (17 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 663 Plate 1 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (18 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 664 Plate 1 Plate 18 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (19 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 665 Plate 1 Plate 19 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (20 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 667 Plate 1 Plate 20 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (22 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 669 Plate 1 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (24 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 670 Plate 1 Plate 22 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (25 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 671 Plate 1 Plate 23 Plate 24 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (26 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 672 Plate 1 Plate 25 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (27 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 677 Plate 1 Plate 28 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (32 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 678 Plate 1 Plate 29 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (33 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 679 Plate 1 Plate 30 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (34 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 681 Plate 1 Plate 32 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (36 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 682 Plate 1 Plate 33 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (37 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 683 Plate 1 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (38 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 684 Plate 1 Plate 34 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (39 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 687 Plate 1 Plate 37 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (42 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 689 Plate 1 Plate 38 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (44 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 691 Plate 1 Plate 40 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (46 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
Page 692 Plate 1 Plate 41 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (47 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 694 Plate 1 Plate 42 file:///C|/848/wsm/en/848_08_P_1B10_00.79.1.html (49 of 51) [11-6-2008 0:34:57] WWW.PlanDeGraissage.ORG...
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Page 697 Battery charging system 2 - Battery charging system Checking the battery charging system To check the current flow in the charging circuit, use the DDS tester, which is equipped with an inductive clamp-type ammeter. see the chapter Testing the battery charging system , Sect.
Page 698 Battery charging system Charge the battery if the open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could damage it. Check the battery charge with a voltmeter. Always check the condition of the battery before recharging and 1 to 2 hours afterwards. Important Pay careful attention to recharging times.
Page 699 Battery charging system Warning Make certain that the electrolyte is of the specific type for your battery. Remove the container with the electrolyte from the vinyl bag. Remove the strip with the caps (3) from the container (2). Important Keep the cap strip (3) to hand because it will be used later as plugs for the battery cells. Warning Do not peel or perforate the sealed areas.
Page 700 Battery charging system Place the electrolyte container (2) upside down. Align the six sealed elements with the six filler holes on the battery. Push the container (2) downwards with sufficient force to break the seals and allow the liquid to flow out. Notes Do not tilt the electrolyte container as this could interrupt the flow temporarily or even permanently.
Page 701 Battery charging system For 3-12 Ah batteries, leave to stand for at least 30 mins. For batteries of over 12 AH, leave to stand for at least 1 hour. Rest the cap strip on the filler holes without fixing it. Recharge the battery as described in the paragraph Recharging the battery .
Page 702 Battery charging system Battery Battery safety rules Warning Read carefully the relevant safety rules before working on the battery (Sect. A 3, General safety rules). When under charge, batteries produce explosive gases. Keep batteries away from heat sources, sparks or open flames. Instructions for use The battery is of the sealed, maintenance-free type and requires no work to be done on it at the time of installation.
Page 703 Battery charging system Refitting the battery Refitting is the reverse of removal. Check the battery terminals (1), which should not show any sign of oxidisation. Tighten the terminal bolts (4) and (5) to the specified torque (Sect. C 3, Frame torque settings) and apply a water repellent spray.
Page 704 Battery charging system Alternator The motorcycle is equipped with a 12 V, 520 W alternator, consisting of a stator (A) located in the left-hand side crankcase cover and a rotor (B) fixed to the crankshaft. Notes To check the charging system for possible faults, use the DDS tester (Sect. D 5, tester).
Page 705 Battery charging system Disconnect the alternator wires from the electrical system (refer to plate in chapter Routing of wiring on frame Sect. P 1). Remove the alternator-side crankcase cover, the stator (A) and rotor (B) (Sect. N 8, Removal of the alternator-side crankcase cover).
Page 706 Battery charging system Regulator/rectifier The regulator (2) is fixed to the battery support (3). The rectifier/regulator consists of an aluminium casing containing the diodes that rectify the current produced by the alternator. It also contains an electronic device that regulates the current supplied by the alternator in accordance with battery voltage.
Page 707 Battery charging system Refitting the regulator Fit the regulator (2) to the battery support (3). Secure it with the bolts (1) and tighten to the specified torque (Sect. C 3, Frame torque settings). Notes Reconnect the regulator cable to the main wiring loom (Sect. P 1, Plate 40).
Page 708 Battery charging system Regulator fuse The 30 A fuse located at the side of the battery protects the electronic regulator. To gain access to the fuse, remove the left-hand fairing (Sect. E 2, Removal of the side fairings) and remove the protective cap (A). A blown fuse can be identified by breakage of the inner filament (B).
Page 709 Electric starting system 3 - Electric starting system Notes The references of the elements shown below are to be found in the Wiring diagram , in Sect. P 1. Electric starting system The key components of the electric starting system are a contactor (6) and a starter motor (5) fed by the battery (7).
Page 710 Electric starting system Starter motor Power: 0.7 kw/12 V Direction of rotation: counterclockwise viewed from power take-off side. file:///C|/848/wsm/en/848_08_P_3_10_00.81.1.html (2 of 9) [11-6-2008 0:34:59] WWW.PlanDeGraissage.ORG...
Page 711 Electric starting system The starter motor is highly compact and reliable and therefore rarely gives any type of problem. In case of malfunction, ensure that the starter motor wiring terminal is properly tightened under the nut and shows no sign of corrosion. If the terminal is properly tightened and free from corrosion, remove the starter motor and test it under no-load conditions (no load applied to the shaft).
Page 712 Electric starting system Notes The starter motor retaining bolts are assembled with threadlocker. Slide out the starter motor and gasket (5). Refitting the starter motor Inspect the condition of the gasket (5) and renew if necessary. Locate the gasket (5) and the starter motor on the crankcase and tighten the bolts (3) to the specified torque (Sect.
Page 713 Electric starting system Locate the insert (2) (if removed) in the crankcase, fit the retaining screw (1) and tighten it to the specified torque (Sect. C 3, Engine torque settings). Connect the starter motor/contactor cable (4). Important Fill the cap with protective grease before fitting it on the starter motor If the starting gears assembly has been renewed, refit the starter motor idler gear and the timing file:///C|/848/wsm/en/848_08_P_3_10_00.81.1.html (5 of 9) [11-6-2008 0:34:59] WWW.PlanDeGraissage.ORG...
Page 714 Electric starting system gears (Sect. N 9.1, Removal of the starter motor idler gear). Refit the alternator-side crankcase cover (Sect. N 8, Refitting the alternator-side crankcase cover). Refit the side fairings (Sect. E 2, Refitting the side fairings). Starter contactor The contactor is elastically mounted to the battery support.
Page 715 Electric starting system Checking operation of the starter contactor Apply 12 V (battery voltage) across the positive terminal (A) and negative terminal (B) of the connector. With a multimeter connected between the two poles (threaded studs (C) and (D)) of the contactor, check for electrical continuity (Sect.
Page 716 Electric starting system Fit the contactor on the fins (A). Route the cable (5) beneath the contactor as shown in the figure. Ensure that the terminals are not oxidized and apply water repellent spray. file:///C|/848/wsm/en/848_08_P_3_10_00.81.1.html (8 of 9) [11-6-2008 0:34:59] WWW.PlanDeGraissage.ORG...
Page 717 Electric starting system Connect the cables (1) and (2) to the contactor terminals (Sect. P 1, Plate Plate 42). Tighten the nuts (4) to the specified torque (Sect. C 3, Engine torque settings). Reconnect the contactor wiring connector to the wiring loom (Sect. P 1, Plate 37).
Page 718 Lights and indicating devices 4 - Lights and indicating devices Changing light bulbs Changing the headlight bulbs Before replacing a burnt out light bulb, ensure that the replacement bulb has the same voltage and power rating as specified for the lighting device in question (Sect. C 1.1, Lights/instrument panel).
Page 719 Lights and indicating devices Remove the bulb lead (2) and remove the bulb from the lead. Notes Do not touch the transparent part of the bulb with your fingers, this will darken it and cause a loss of brightness. Low beam bulb (LO) Repeat the operations for removal of the high beam bulb, but this time working on the right-hand side of the motorcycle.
Page 720 Lights and indicating devices Refitting the bulbs After replacing the bulbs as required, reconnect the bulb holders to the lights assembly. Reposition the covers (1) and secure them to the headlight assembly with the clips (B). Changing the number plate light bulb To access the number plate light bulb, unscrew the two screws (4) securing the cover (5).
Page 721 Lights and indicating devices High beam headlights relay The headlights relay (1) is located on the front subframe. To gain access to this component you must first remove the headlight shell (Sect. E 1, Removal of the headlight shell). A low beam lights relay (1) has been introduced into the system in order to reduce battery power consumption by automatically switching off the headlight.
Page 722 Lights and indicating devices (113) and (133) (small contacts): you should hear a click that confirms that the internal electromagnet has switched. Connect a multimeter to contacts (121) and (122) (big contacts) to check for the full scale reading (analogue tester) or buzzer (digital tester). If this does not occur, the part must be renewed. Headlight aim The motorcycle must be perfectly upright with the tires inflated to the correct pressure and with a rider seated, perfectly perpendicular to the longitudinal axis.
Page 723 Lights and indicating devices beam. Vertical alignment is adjusted by way of the adjuster screws (1) on the rear of the headlight. file:///C|/848/wsm/en/848_08_P_4_10_00.82.1.html (6 of 6) [11-6-2008 0:35:00] WWW.PlanDeGraissage.ORG...
Page 724 Indicating devices 5 - Indicating devices Checking the indicating system components In the event of a fault, the internal connections of the device must be checked in all operating conditions. To do this, disconnect the switch connector from the main wiring loom (Sect. P 1, Routing of wiring on frame).
Page 725 Indicating devices Turn signal switch (TURN) Connect the multimeter to the Orange and Green wires from the turn signal switch and check for electrical continuity when operating the right turn signals (see Sect. P 9, Diagnostic instruments concerning operation of the multimeter). Repeat the above procedure for the left turn signal but connect the multimeter to the green and orange wires.
Page 726 Indicating devices Flasher (PASSING) Check for continuity across the Red/Blue and Brown wires. Refit the left-hand handlebar switch and tighten the bolts (1) to the specified torque (Sect. C 3, Frame torque settings). file:///C|/848/wsm/en/848_08_P_5_10_00.83.1.html (3 of 13) [11-6-2008 0:35:00] WWW.PlanDeGraissage.ORG...
Page 727 Indicating devices Checking the right-hand handlebar switch To remove the right-hand handlebar switch, undo the retaining bolts (1) and disconnect the wiring connector from the electrical system. The colours mentioned in the following descriptions refer to the colours of the wires from the switch and not to the colours of the wires of the main electrical system.
Page 728 Indicating devices Refit the left-hand handlebar switch and tighten the bolts (1) to the specified torque (Sect. C 3, Frame torque settings). Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Brake light switches To check operation of the front (1) and rear (2) brake light switches, use a multimeter to check for electrical continuity (Pos.
Page 729 Indicating devices Neutral indicator light To check the neutral light switch (3) proceed as follows: file:///C|/848/wsm/en/848_08_P_5_10_00.83.1.html (6 of 13) [11-6-2008 0:35:00] WWW.PlanDeGraissage.ORG...
Page 730 Indicating devices The neutral light does not illuminate on the instrument panel. Remove the electric terminal connected to the neutral switch. Switch on the ignition switch (ignition key to ON position) and ensure that the light illuminates when the terminal is earthed. If the light switches on, the neutral light switch should be changed.
Page 731 Indicating devices the ignition key set to OFF, i.e. with instrument panel off). If the engine oil pressure complies with the stated values and the engine oil pressure warning light on the instrument panel is continuously illuminated, switch on the instrument panel (ignition key set to ON) and start the engine, then disconnect the electrical terminal normally inserted on the pressure sensor.
Page 732 Indicating devices Fan relay The fan relay (7) is located on the right-hand side of the battery support. To gain access to the fan relay, first remove the left-hand side fairing (Sect. E 2, Removal of the side fairings). Checking operation of the fan relay Disconnect the relay from the electrical system and apply 12 V (battery voltage) between the small contacts: you should hear a click that confirms that the internal electromagnet has switched.
Page 733 Indicating devices Changing light bulbs Changing the turn signal light bulbs Rear turn signals. To gain access to the rear turn signal bulbs, undo the screw (2) and detach the cover (3) from the turn signal support. Remove the bulb (1) from the bulb holder. Fit a new bulb (1) into the bulb holder.
Page 734 Indicating devices Changing the front turn signals The front turn signals (1) are built into the rear-view mirrors (Sect. E 1, Removal of the rear-view mirrors) and in the event of malfunction, the mirror/turn signal assembly must be renewed as a complete unit.
Page 735 Indicating devices Renewal of the rear side light and brake light Remove the seat cowling as indicated in Sect. E 3, Removal of the side panels and seat cowling. Unscrew the bolts (8) and remove the side light and brake light unit (11). Remove the spacers (9) and grommets (10) from the old unit and fit them to the new unit (11).
Page 736 Indicating devices file:///C|/848/wsm/en/848_08_P_5_10_00.83.1.html (13 of 13) [11-6-2008 0:35:00] WWW.PlanDeGraissage.ORG...
Page 737 Protection and safety devices 6 - Protection and safety devices Checking protection and safety device components Checking the key switch Disconnect the ignition switch (A) from the wiring loom by opening its connector (Sect. P 1, Plate and use a multimeter to check its internal connections as follows: turn the key to OFF and connect a multimeter to contacts (1) and (4) to check electrical continuity (Sect.
Page 738 Protection and safety devices Checking the sidestand switch Remove the switch (1) from the sidestand and disconnect the main wiring loom connector from the switch (Sect. P 1, Plate 31). Use an analogue or digital multimeter (Sect. P 9, Diagnostic instruments) to check operation of the switch (see table).
Page 739 Protection and safety devices The same check can also be performed using the DDS tester (Sect. D 5, tester). Pos. pin (A) Device Val. Multimeter pos. Green/ Green/ Green Yellow White Black 0 = open contact X = Closed contact Checking the fuses The main fusebox (1) is located on the left-hand side of the motorcycle and is accessed by removing the left-hand side fairing (Sect.
Page 740 Protection and safety devices Important Switch the ignition key to OFF before replacing a fuse to avoid possible short circuits. Warning Never use a fuse with a rating other than the specified value. Failure to observe this rule may damage the electric system or even cause fire.
Page 741 Instruments 7 - Instruments Instrument panel Remove headlight shell (Sect. E 1, Removal of the headlight shell). Unscrew the nuts (1). Disconnect the wiring to the instrument panel (2). Remove the instrument panel (3) complete with the cover (4). To remove the cover (4) from the instrument panel, remove the rubber mountings (5). On refitting, tighten the nuts (1) to the specified torque (Sect.
Page 742 Instruments (Controller Area Network) serial communication line. Indicator lights The following indicator lights are mounted on the instrument panel. 3) Neutral light (green): illuminates when the gearbox is in neutral. 4) Low fuel light (yellow): illuminates when there are approximately 3 litres of fuel left in the tank. 5) Turn signal lights (green): illuminate and flash when the corresponding turn signal is in operation.
Page 743 Instruments Display settings and functions On switching on the power (key turned from OFF to ON), the instrument panel activates all the digits of the LCD for 1 second and switches on all the warning lights in sequence. It then reverts to normal display mode and, in place of motorcycle speed, shows the model and, for 2 seconds, also the version (EU, UK, USA, CND, FRA, JAP).
Page 744 Instruments Important This menu is active only if the speed of the motorcycle is less than 20 km/h. If this menu is on the display and the speed of the motorcycle exceeds 20 km/h, the instrument panel automatically exits the menu and returns to the initial display.
Page 745 Instruments Trip meter TRIP B While in this function, if you press switch (1) in position B for 3 seconds, the reading is reset to zero. If the reading exceeds 999.9, it is reset to zero and the count restarts automatically. If the system s units of measurement are changed at any time with the Setting Special function, the reading in this function is reset and the count restarts from zero in the newly set unit of measurement.
Page 746 Instruments TRIP FUEL (distance travelled on reserve fuel) indicator When the fuel warning light (4) comes on, the TRIP FUEL meter is activated automatically, regardless of the function displayed. If the fuel level remains in reserve, the reading is saved even after Key-Off. At the next Key-On, the fuel warning light comes back on after a few seconds and the TRIP FUEL meter is displayed after 60 seconds (although it starts counting the distance travelled as soon as the motorcycle moves off).
Page 747 Instruments Coolant temperature indicator Displays the engine coolant temperature: if the reading is less than or equal to -40 °C (-40 °F), the display shows a series of flashing dashes ( --- ) and the Engine Diagnostics warning light comes on (8); if the reading is between -39 °C (-38 °F) and +39 °C (+102 °F), the message LO is displayed steadily;...
Page 748 Instruments Service indicator (SERV) Indicates that the next service is due. The message SERV appears on the display at the following intervals: after the first 1000 km on the odometer; every 12000 km on the odometer. The messsage is displayed only at Key-On for 5 seconds. After servicing, the system must be reset with the DDS tester.
Page 749 Instruments INJE 12.1 Horizontal cylinder injector error INJE 12.2 Horizontal cylinder injector error INJE 13.1 Vertical cylinder injector error INJE 13.2 Vertical cylinder injector error PUMP 16.0 Fuel pump relay error FAN 18.1 Fan relay error FAN 18.2 Fan relay error STRT 19.1 Starter contactor error STRT 19.2...
Page 750 TILT 6.2 Lambda 2 sensor error Traction control unit error (the error can only occur if the bike has been DTC 8.0 fitted with the traction control kit available from Ducati performance) ECU 30.0 Engine ECU error PK.UP 34.0 Pick-up sensor error SPEE.
Page 751 Instruments Adjusting the engine idle speed (rpm) To display the function, access the menu and select the RPM page. In addition to the upper rev counter scale, the display also shows engine rpm numerically so that you can adjust the idle speed more precisely.
Page 752 Instruments LAP function To activate this function, enter the menu and set the LAP function to On by keeping switch (1) in position B for 3 seconds. The function is now enabled and awaiting the start command. START and STOP the timer by pressing the high beam FLASH switch (2) on the left-hand handlebar switch. Alternatively, these functions can be performed automatically by the MT 906/D and MT 907/D infrared system by Magneti Marelli, by connecting the latter to data acquisition connector (T).
Page 753 Instruments When you switch the LAP function off using the menu, the lap in progress is not saved. If the LAP function is active and the display is suddenly switched off (Key-Off), the LAP function is switched off automatically (even if the timer was ON, the lap in progress is not saved). If the timer is not stopped, when it reaches 99 minutes, 59 seconds and 99 hundredths, it restarts from 0 (zero) and continues until the function is switched off.
Page 754 Instruments LAP Memory display Displays the data saved with the LAP function: lap time, MAX speed and MAX rpm (and limiter if reached). file:///C|/848/wsm/en/848_08_P_7_10_00.85.1.html (14 of 27) [11-6-2008 0:35:03] WWW.PlanDeGraissage.ORG...
Page 755 Instruments To display the saved lap times, enter the menu and select the LAP MEM page. From this page, if you hold switch (1) in position B for 3 seconds, the data for the first lap will appear. The display will show the lap number, lap time, MAX speed and the MAX rpm reached for the lap in question. If you press the switch (1) in position B , the display scrolls through the 30 saved times, before returning to the 1 st lap.
Page 756 Instruments USB DAQ (Switching ON/OFF) This function activates the USB Data Acquisition (DAQ) (can be purchased as replacement parts). In order to acquire data, the DAQ must be connected to the motorcycle wiring loom. To activate the DAQ, enter the menu and set the USB DAQ to On by holding the switch (1) in position B 3 seconds.
Page 757 Instruments Erase USB This function enables you to delete the data saved on the USB DAQ: in order to delete data, the DAQ must be connected to the motorcycle wiring loom. To delete the data, enter the menu and select the Erase USB page. If you hold the switch (1) in position B for 3 seconds and the USB DAQ is OFF, the message WAIT appears on...
Page 758 Instruments Clock setting To set the clock, enter the menu and select the TIME Set page. From this page, if you press the switch (1) in position B for 3 seconds, you enter clock setting mode. On entering this mode, the message AM will flash on the display; pressing the switch (1) in position B will switch the display to PM (flashing);...
Page 759 Instruments Immobilizer override procedure Should the immobilizer become locked, you can perform the Immobilizer Override procedure from the instrument panel by entering the respective function as follows: Select the CODE page from the menu. Notes This menu should be active only if there is at least one immobilizer error. With this page selected, the initial code is always displayed as 00000 .
Page 760 Instruments Entering the code: on entering this function, the first digit on the left starts flashing. Switch (1): each time you press the switch in position B , the number increases cyclically in steps of one digit every second. If you press the switch in position A , you can set the second digit, which will start flashing.
Page 761 Instruments allowing temporary starting of the motorcycle. If the error persists, at the next key-on, the instrument panel will return to an error state and immobilize the engine. Intelligent headlight switch-on This function allows programmed activation of the headlight even with the motorcycle off (Key-Off). Immediately after key-off, the instrument panel remains active for 60 seconds, thus allowing the headlight to be switched on if the switch (1) is pressed in position B or A...
Page 762 Instruments The menu contains three functions: Reprogramming the immobilizer (REPR. CODE); Setting the units of measurement (SET UNIT); Moving the exhaust valve manually (SET EXVL). Reprogramming the immobilizer This function is for reprogramming the immobilizer system in the event of loss or damage to one or both of the keys. To display this function, go into the service menu and select the page Cod.
Page 763 Instruments Loss of the Code Card Without knowing the electronic code on the CODE CARD, it is impossible to: reprogramme the immobilizer system in the event of loss of one or both of the keys; temporarily override the immobilizer in the event of a fault. To restore the entire system to full operation, it is necessary to renew the KEY SET (2 black keys + new CODE CARD) and the instrument panel, and thus programming the immobilizer again.
Page 764 Instruments Special settings (vehicle model and units of measurement) This function allows you to select the units of measurement displayed on the instrument panel. The ECU automatically communicates to the instrument panel the motorcycle model and the units of measurement to be used on the display: to change these parameters, go into the Service Menu and select the SET UNIT function.
Page 765 Instruments Operating the valve motor to facilitate cable fitting With this function, it is possible to operate the motor that moves the exhaust valve to facilitate cable fitting. When renewing cables, if the valve motor is not restrained and the key switch is inadvertently turned to On, the motor will turn over for a few seconds and stop in a random position.
Page 766 Instruments Programming the immobilizer This instrument panel function enables programming of the Immobilizer System. Notes Only 2 keys may be programmed. Insert KEY 1 (one of the two black keys) and turn the ignition switch from Off to On; within 3 seconds turn the ignition switch from On to Off; within 15 seconds insert KEY 2 (the other black key) and turn the ignition switch from Off to On;...
Page 767 Instruments Programming aborted: if you allow the 3 second countdown after Key-On or the 15 second countdown after Key-Off to elapse, or you make a mistake in the programming procedure, the instrument panel will abort the programming operation and display the message OFF for 3 seconds before returning to the normal display mode.
Page 768 Immobilizer and transponder 8 - Immobilizer and transponder The immobilizer allows the vehicle to be started only if the rider uses the special ignition key which sends the identification code to a decoder housed in the instrument panel. The transmission-receiving system is composed of a TRANSPONDER housed in the ignition key heads and an antenna in the vicinity of the ignition switch.
Page 769 Immobilizer and transponder Immobilizer operating principle At key-on (switching on the instrument panel by turning the key) the decoder (incorporated in the instrument panel) activates the antenna, which emits an electromagnetic field that serves to power the transponder in the key grip. The transponder responds by transmitting the code that is stored on its internal ROM memory, and which is picked up by the antenna and relayed to the decoder.
Page 770 Immobilizer and transponder Removal of the immobilizer Set the ignition switch to OFF. Remove the right-hand side fairing (Sect. E 2, Removal of the side fairings). Disconnect the antenna wiring connector (A) from the main wiring loom. Unscrew the two nuts (1) and remove the keyswitch cover (2) with the immobilizer antenna (3). file:///C|/848/wsm/en/848_08_P_8_10_00.86.1.html (3 of 5) [11-6-2008 0:35:03] WWW.PlanDeGraissage.ORG...
Page 771 Immobilizer and transponder Refitting the immobilizer Apply the recommended threadlocker to the inside of the cover (2) in two points of the seat of the immobilizer antenna (3) and install the antenna (3) in the cover (2). Position the cover to the keyswitch block and tighten the nuts (1) to the specified torque (Sect. C 3, Frame torque settings).
Page 772 Immobilizer and transponder file:///C|/848/wsm/en/848_08_P_8_10_00.86.1.html (5 of 5) [11-6-2008 0:35:03] WWW.PlanDeGraissage.ORG...
Page 773 Diagnostic instruments 9 - Diagnostic instruments For information on the DDS tester, refer to Sect. D 5, tester. Using a multimeter to check the electrical systems Introduction This instrument allows you to measure resistances, voltages, and current values. Multimeters can be divided into two basic types: those with an analogue display and those with a digital display Units of the first type are equipped with a dial and needle.
Page 774 Diagnostic instruments The DDS tester (Sect. D 5, tester) can perform the functions of a digital multimeter. Voltage measurement Voltage measurements must be carried out by connecting the terminals of the tester in parallel to the load (e.g. to the wires feeding a light bulb or a relay, the two battery terminals, or the two wires supplying power to a control unit).

Ducati SUPERBIKE 848 MY 2008 Manual

C - Technical Data 1.1 - Technical Specifications

D - Use and Maintenance 1 - Preliminary Checks 3

E - Fairings 1 - Headlight Shell - Rear-View Mirrors

- Throttle Twistgrip

G - Wheels - Suspension - Brakes 1 - Front Wheel

H - Frame 1 - Handlebars 3

L - Fuel/Exhaust System 2 - Fuel Tank

M - Fuel Injection - Ignition System 2 - Fuel Injection-Ignition System

N - Engine 1 - Removal Refitting of the Engine Assembly

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