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Ducati 1098 2007 Manual

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Table of Contents

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GENERAL SUMMARY
General
Information about the model
Technical data
Use and maintenance
Fairings
Controls - Devices
Wheels - Suspension - Brakes
Frame
Fuel / Exhaust System
Injection - ignition system
Engine
Electric system
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Table of Contents
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Summary of Contents for Ducati 1098 2007

  • Page 1 GENERAL SUMMARY General Information about the model Technical data Use and maintenance Fairings Controls - Devices Wheels - Suspension - Brakes Frame Fuel / Exhaust System Injection - ignition system Engine Electric system WWW.PlanDeGraissage.ORG...

  • Page 2: Table Of Contents

    General summary Section A General 1 - How to use this manual Layout of the manual 2 - Symbols - Abbreviations - References Product specifications 3 - Hazardous Products - Warnings General safety rules General maintenance indications Section B Information about the model 1 - Identification data Identification data for the Superbike 1098 Section C...
  • Page 3 Adjusting the front fork Adjusting the rear shock absorber Adjusting the rear ride height 5 - Diagnostic instruments Description of the Ducati Diagnostic System instrument Tester power supply DDS tester Checking and adjusting timing belt tension Resetting the throttle position sensor (TPS)
  • Page 4 General summary Testing the battery charging system Deactivating the “maintenance” indication on the instrument panel Icons table Section E Fairings 1 - Headlight shell - rear-view mirrors Removal of the rear-view mirrors Refitting the rear-view mirrors Removal of the headlight shell Refitting the headlight shell 2 - Fairing panels Removal of the side fairings...
  • Page 5 General summary 5 - Gearchange control Removal of the complete gearchange control Disassembly of the gearchange control Refitting the gearchange control Section G Wheels - Suspension - Brakes 1 - Front wheel Removal of the front wheel Overhauling the front wheel Refitting the front wheel 2 - Front fork (1098) Removal of the front forks...
  • Page 6 General summary 8 - Final drive Inspecting the final drive Removal of the front sprocket Refitting the front sprocket Renewal of the rear sprocket Refitting the rear sprocket Washing the chain Lubricating the chain Section H Frame 1 - Handlebars Removal of the handlebars Refitting the handlebars 2 - Steering...
  • Page 7 General summary 6 - Airbox - Throttle Body Removal of the throttle body Refitting the airbox and throttle body 7 - Air intake Removal of the air filters Refitting the air filters 8 - Exhaust system Removal of the exhaust system Refitting the exhaust system Section M Injection - ignition system...
  • Page 8 General summary 3.2 - Cooling system: radiator Removal of the radiator Renewal of the cooling fan Refitting the radiator Removal of the cooling system hoses and unions Refitting the cooling system hoses and unions 3.3 - Cooling system: water pump Removal of the water pump Refitting the water pump 4.1 - Cylinder head assemblies: checks and adjustments...
  • Page 9 General summary 6.2 - Clutch assembly: right-hand side crankcase cover Removal of the right-hand side crankcase cover Disassembly of the right-hand side crankcase cover Reassembly of the right-hand crankcase cover Refitting the right-hand side crankcase cover 6.3 - Clutch assembly: primary drive gears Removal of the primary drive gears Refitting the primary drive gears and checking backlash 7.1 - Gearbox assembly: gearchange mechanism...
  • Page 10 General summary Section P Electric system 1 - Wiring diagram Key to wiring diagram Wiring colour codes Key to fusebox Routing of wiring on frame Plate 1 Plate 2 Plate 3 Plate 4 Plate 5 Plate 6 Plate 7 Plate 8 Plate 9 Plate 10 Plate 11...
  • Page 11 General summary 3 - Electric starting system Electric starting system Starter motor Starter contactor 4 - Lights and indicating devices Changing light bulbs High beam headlights relay Headlight aim 5 - Indicating devices Checking the indicating system components Coolant temperature sensor Fan relay Checking operation of the fan relay Changing light bulbs...
  • Page 12 WWW.PlanDeGraissage.ORG...
  • Page 13 General WWW.PlanDeGraissage.ORG...

  • Page 14: How To Use This Manual

    section General 1 - How to use this manual Layout of the manual 2 - Symbols - Abbreviations - References Product specifications 3 - Hazardous Products - Warnings General safety rules General maintenance indications WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 15 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 16 Some of the sections of this manual are not included, since the motorcycle in question is not equipped with the relevant parts. Important 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.
  • Page 17 section General 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 18: Product Specifications

    section General Product specifications Symbols in the diagram show the type of threadlocker, sealant or lubricant to be used at the points indicated. The table below shows the symbols used and the specifications of the various products. Symbol Specifications Recommended product Engine oil (for specifications, see Sect.
  • Page 19 LOCK 11 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel LOCK DUCATI liquid gasket. 942470014 Exhaust pipe paste. Self-sealing paste, hardens when Holts Firegum heated; resists temperatures exceeding 1000 °C. Spray used to protect electrical systems.

  • Page 20: C 3 - Hazardous Products - Warnings

    section Generalità 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 21 section Generalità Coolant (ethylene glycol) is an irritant and is poisonous when ingested. Keep away from children. Never remove the radiator cap when the engine is hot. The coolant is under pressure and will cause severe burns if it comes into contact with the skin.

  • Page 22: General Maintenance Indications

    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 23: Information About The Model

    Information about the model WWW.PlanDeGraissage.ORG...

  • Page 24: Identification Data Identification Data For The Superbike 1098

    section Information about the model 1 - Identification data Identification data for the Superbike 1098 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 25 Information about the model 1 - Identification data Identification data for the Superbike 1098 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 26 Information about the model Data stamped on the frame Europe version 1 Manufacturer: Ducati Motor Holding 2 Type, same on all 1098 models. 3 Variant 4 Version 5 Year of manufacture (7=2007) 6 Manufacturing facility 7 Progressive serial No.
  • Page 27 Information about the model Data stamped on engine Europe version 1 Manufacturer: Ducati Motor Holding 2 Engine type 3 Progressive production No. Data stamped on engine Europe version ZDM 1098W4*000002* Data stamped on engine US version 1 Engine type 2 Model year 3 Progressive production No.
  • Page 28 WWW.PlanDeGraissage.ORG...

  • Page 29: Technical Data

    Technical data WWW.PlanDeGraissage.ORG...

  • Page 30: Technical Specifications

    section Technical data 1.1 - Technical specifications General Colours Transmission Timing system/valves Crankshaft Cylinder/Piston Gearbox Cooling system Front wheel Front suspension (1098) Front suspension (1098S) Rear wheel Rear suspension (1098) Rear suspension (1098S) Hydraulic brakes Charging system/alternator Injection - ignition system Fuel system Lights/instrument panel 1.2 - Dimensions...

  • Page 31: General

    section Technical data C 1.1 1.1 - Technical specifications General Reference Technical specifications Motorcycle dimensions Total length 2100 ± 20 mm Total width 730 ± 20 mm Total height 1110 ± 20 mm Wheelbase 1430 ± 20 mm Handlebar height 875 ±...

  • Page 32: Colours

    Cooling system Liquid cooling Air filter Two filter units Crankshaft type One-piece Colours Description Part no. 1098/1098S Ducati Anniversary Red F_473.101 (PPG) Transparent 228.880 (PPG) Red frame with black wheels Transmission Reference Technical specifications Clutch Dry multi-plate clutch Clutch control...

  • Page 33: Timing System/Valves

    section Technical data C 1.1 Timing system/valves Reference Adjusting clearance Checking clearance Timing diagram With 1 mm valve clearance Intake Opening 15° B.T.D.C. Closing 58° A.B.D.C Exhaust Opening 60° B.B.D.C. Closing 20° A.T.D.C. Intake valve diameter 42 mm Exhaust valve diameter 34 mm With 0 mm valve clearance Intake 11.8 mm...

  • Page 34: Gearbox

    section Technical data C 1.1 Reference Standard value Service limit Engine cylinder compression 13÷15 bar 11 bar (MIN.), difference measured with DDS instrument between the two cylinders: 2 bar (MAX.) Gearbox Reference Standard value Service limit Endfloat 0.05 to 0.25 mm Gearbox shafts Selector drum Endfloat...

  • Page 35: Front Suspension (1098S)

    section Technical data C 1.1 Front suspension (1098S) Reference Technical specifications Type Öhlins: FG315 hydraulic upside-down radially mounted fork with external adjusters for adjustment of rebound, compression, and preload (for inner springs of fork legs). Fork Stanchion diameter: 43 mm Travel along leg axis: 120 mm.

  • Page 36: Hydraulic Brakes

    section Technical data C 1.1 Hydraulic brakes Reference Standard value Service limit FRONT Brake disc Type Semi-floating drilled dual disc Shim 4.5 ± 0.1 mm 4 mm (min.) Braking surface material Steel Flange material Aluminium Disc diameter 330 mm Brake caliper Make Brembo Type...

  • Page 37: Lights/Instrument Panel

    section Technical data C 1.1 Lights/instrument panel Reference Technical specifications Headlight Bulb type 2 x H11 (12 V-5 W) Side light Bulb type 2 x H16W (12 V-5 W) Bulb type Front: A LED turn indicators Rear: R10W (12 V-10 W)-orange. Tail light and brake light A LED Number plate light...

  • Page 38: Dimensions

    section Technical data C 1.2 1.2 - Dimensions 730±20 1430±20 2100±20 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 39: Fuel, Lubricants And Other Fluids

    section Technical data 2 - Fuel, lubricants and other fluids Fuel, lubricants and other fluids Type dm³ (litres) Fuel tank, including a reserve of 3 dm (litres) Unleaded fuel with 95 fuel octane rating (at least) 15.5 Lubrication circuit SHELL Advance Ultra 4 Front/rear brake and clutch circuits SHELL Advance Brake DOT 4 Protection for electrical contacts...

  • Page 40: Torque Settings

    section Technical data 3 - Torque settings Frame torque settings Part Thread (mm) Nm ±10% Tolerance Notes WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 41 section Technical data Engine torque settings Part Thread (mm) Min. Max. Notes Idler and tensioner pulley bolts M20x1 LOCK 2 or TB1324 Camshaft pulley retaining nut M17x1 GREASE A Rocker arm shaft covers M12x1.25 LOCK 2 or TB1324 Coolant temperature sensor on coolant outlet M12x1.5 LOCK 4 –...
  • Page 42 section Technical data Part Thread (mm) Min. Max. Notes Outer crankcase screw M6x1 Oil pick-up gauze filter bolt M6x1 Left-hand side crankcase cover screw M6x1 Bosch sensor bolt M6x1 Right-hand side crankcase cover screw M6x1 Chain cover oil circuit blanking screw M6x1 LOCK 5 Right-hand side crankcase cover screw...
  • Page 43 section Technical data Part Thread (mm) Min. Max. Notes Dry clutch drum bolts M8x1.25 LOCK 4 Right-hand side crankcase cover screw M6x1 Clutch spring bolt M5x0.8 Coolant inlet union M30x1.5 LOCK 5 Coolant outlet union M22x1.5 LOCK 5 Pick-up sensor inspection screw M12x1 LOCK 2 or TB1324 Water pump cover plug...
  • Page 44 section Technical data 4 - Service tools Special tools for the engine Part 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 Wrench for tightening timing belt tensioner 88713.1821 pulley shafts...
  • Page 45 Technical data Part No. Designation 88713.1806 Tool for tightening Z=20 camshaft pulley 88713.2069 Rocker spring tensioning kit DDS (Ducati Diagnosis System) + cylinder 97900.0215 negative pressure measuring kit 88765.1524 Timing belt pulley timing tools 88765.1518 Valve lift gauge Fork-type feeler gauge 0.1 mm, 0.2 mm, 88713.2878...
  • Page 46 section Technical data Part No. Designation 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 88713.2133 Clutch centre wrench 88700.5665 Clutch cover assembly tool...
  • Page 47 section Technical data Part No. Designation 88713.1886 Engine cover sheet 88713.1010 Exhaust gases pick-up connector 88713.1805 Tool for tightening timing belt driveshaft pulley 88765.1188 Top Dead Centre test gauge 88713.2102 Wrench for tightening primary sprocket ringnut 88713.0869 Water pump front seal installer Installation tool for counter plate for water 88713.0870 pump front seal...
  • Page 48 section Technical data Part No. Designation 88700.5749 Crankcase assembly cap 88713.2877 Sparkplug wrench 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 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 49 section Technical data Part No. Designation 88713.2832 Timing belt tensioner pulley wrench WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 50 section Technical data Special tools for the frame Part no. Designation 88713.1072 Drift for installing half bearing in bottom yoke 88713.1213 Chain assembly tool 8000.70139 Front wheel axle wrench 88713.1040 Engine/frame support 88713.1058 Wrench for steering stem nut 88713.1062 Tool for installing steering head bearings 88713.1071 Drift for installing rocker arm roller bearings WWW.PlanDeGraissage.ORG...
  • Page 51 section Technical data Part no. Designation 88713.1073 Real wheel balancing tool 88713.1038 Wrench for adjustment of the eccentric hub Tool for overhauling SHOWA forks/fitting oil 88713.1096 seals 677.4.003.1A Chain joining link 88713.1074 Swingarm pivot shaft removal tool 88713.0957 SHOWA fork spacer holder 88713.1057 Steering damper bearing installer WWW.PlanDeGraissage.ORG...
  • Page 52 section Technical data Part no. Designation 88713.1077 Seat lock nut wrench 88713.1068 Swingarm roller bearing installer 88713.2409 Swingarm bearing installer WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 53 Use and maintenance WWW.PlanDeGraissage.ORG...
  • Page 54 Adjusting the front fork Adjusting the rear shock absorber Adjusting the rear ride height 5 - Diagnostic instruments Description of the Ducati Diagnostic System instrument Tester power supply DDS tester Checking and adjusting timing belt tension Resetting the throttle position sensor (TPS)

  • Page 55: 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 comply with these rules will release Ducati Motor Holding S.p.A. from any liability whatsoever for any engine damage or shorter engine life.

  • Page 56: Pre-Ride Checks

    section Use and maintenance Pre-ride 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 necessary (Sect. C 2, Fuel, lubricants and other fluids). Engine oil level Check the oil level in the sump through the sight glass.

  • Page 57: Starting - Engine Warmup

    section Use and maintenance 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. Turn the ignition switch to ON.

  • Page 58: Routine Maintenance Table

    section Use and maintenance 3 - Routine maintenance table Programmed maintenance plan: operations to be carried out by the dealer List of operations and frequency km x1000 (distance or time interval *) miles x1000 22.5 37.5 Months • • • •...
  • Page 59 section Use and maintenance List of operations and frequency km x1000 (distance or time interval *) miles x1000 22.5 37.5 Months • Change the front fork oil • • • • • Check the forks and rear shock absorber for oil leaks •...

  • Page 60: Programmed Maintenance Plan: Operations To Be Carried Out By The Dealer

    section Use and maintenance Programmed maintenance plan: operations to be carried out by the dealer List of operations and frequency km x1000 (distance or time interval *) miles x1000 Months • Check the engine oil level • Check the brake and clutch fluid levels •...

  • Page 61: Maintenance Operations

    section Use and maintenance 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 62: Changing The Engine Oil And Filter Cartridge

    section Use and maintenance Changing the engine oil and filter cartridge Notes Change the oil when the engine is warm (but with the engine stopped). In these conditions the oil is more fluid and will drain more rapidly and completely. Remove the side fairings (Sect.
  • Page 63 section Use and maintenance Every two oil changes, clean the oil pickup gauze filter. Undo the four bolts (5) securing the outer cap (6) and plug. Take care not to damage the gasket (7). Take out the filter element (8), check the O-rings (9) and replace if necessary. Clean the filter with petrol and compressed air.
  • Page 64 section Use and maintenance Remove the filler plug (2) and fill with oil of the recommended type (Sect. C 2) up to the MAX line in the sight glass. Refit the filler plug (2). Run the engine at idle speed for a few minutes. Check for oil leaks.

  • Page 65: Checking Valve Clearances

    section Use and maintenance Checking valve clearances Proceed as described in Sect. N 4.1. With the valve in the rest position, slide a feeler gauge between rocker arm and the cam to measure the clearance: The clearances must be within the specified limits: Opening rocker arm Intake: Operation...

  • Page 66: Adjusting The Valve Clearances

    section Use and maintenance With the valve in the rest position, slide a feeler gauge between the closing rocker arm and the closing shim 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 0.05 to 0.10 mm...

  • Page 67: Checking The Coolant Level

    section Use and maintenance Checking the coolant level At the intervals specified in the “Routine Maintenance” chart (Sect. D 3), check the coolant level in the expansion tank, located on the right-hand side of the motorcycle. The coolant level must be between the MAX and MIN marks on the tank. If the level is low, top up with the recommended coolant.

  • Page 68: Change The Coolant

    section Use and maintenance Change 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. E 2). Remove the expansion tank filler cap (1).

  • Page 69: Changing And Cleaning The Air Filters

    section Use and maintenance Changing and cleaning the air filters The air filter must be changed at the intervals indicated in the “Routine maintenance” table (Sect. D 3). Operation Section reference Remove the side fairings Remove the headlight shell Notes The images show the motorcycle without the fuel tank: the operation described is possible also with the fuel tank fitted.
  • Page 70 section Use and maintenance Reinstall the filter cartridge in its seat in the filter housing and refit all removed parts and structures. Important If the motorcycle is used in very damp or dusty conditions, the air filter element must be changed more frequently. Check the air filter (5) located in the horizontal cylinder timing belt cover (6): to remove the filter, remove the cover (Sect.

  • Page 71: Changing The Brake Fluid

    section Use and maintenance 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. Changing the fluid in the front brake circuit Unscrew the screws (2) and remove the cap (1) and membrane from the front brake fluid reservoir.
  • Page 72 section Use and maintenance Notes Repeat this operation on each brake caliper. Refit the cap (1), carrying out the removal operations in reverse order. Changing the rear brake circuit fluid Unscrew the cap (4) of the rear brake fluid reservoir (B). Aspirate the brake fluid from inside the reservoir (B).
  • Page 73 section Use and maintenance Attach a length of transparent plastic tubing to the bleed valve (5) and insert the other end of the tubing in a container placed on the floor. 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 (5) until it changes colour.

  • Page 74: Draining The Braking Circuit

    section Use and maintenance Draining the braking circuit Warning Brake 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. Undo the screws (2) and remove the cap (1) and membrane from the front brake fluid reservoir.
  • Page 75 section Use and maintenance Connect a commercially available brake bleeder to the bleed valve (3) or (5). Loosen the bleed valve (3) or (5) and pump with the bleeder until no more fluid is draining off. Notes Follow the manufacturer's instructions when using a commercial brake bleeding tool. If you do not have a bleeder available, attach a length of transparent plastic tubing to the bleed valve (3) or (5) and insert the other end of the tubing in a container of old brake fluid placed on the floor.

  • Page 76: Fill The Brake System With Fluid

    section Use and maintenance Fill the brake system with fluid Warning Brake 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. Fill the reservoir (A) or (B) with the recommended fluid taken from a previously unopened container.
  • Page 77 section Use and maintenance Operate the brake lever (or pedal) several times to allow the fluid to reach all points of the circuit and expel any air. Connect the bleed tool to bleed valve (3) or (5). Notes Follow the manufacturer's instructions when using a commercial brake bleeding tool. Pump with the bleeder and loosen off the bleed valve (3) or (5).
  • Page 78 section Use and maintenance 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 loosen off the bleed valve by at least a 1/4 of a turn. Wait a few seconds, then release the lever gradually while simultaneously closing the bleed valve (3) or (5).

  • Page 79: Changing The Clutch Fluid

    section Use and maintenance Changing the clutch fluid Warning 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 80: Draining The Clutch Hydraulic Circuit

    section Use and maintenance Draining the clutch hydraulic circuit 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. Remove the dust cap to expose the bleed valve (2).
  • Page 81 section Use and maintenance To help drain the circuit fully, unscrew the three retaining screws (3) and remove the slave cylinder cap from the engine. 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.

  • Page 82: Filling The Clutch Circuit

    section Use and maintenance Filling the clutch circuit 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. Fill the reservoir with the recommended fluid (Sect.
  • Page 83 section Use and maintenance 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). Pull the lever fully in and then slacken off the bleed valve by at least a 1/4 turn. Wait for a few seconds, then release the lever gradually while simultaneously closing the bleed valve (2).

  • Page 84: Adjusting The Steering Head Bearings

    section Use and maintenance Adjusting the steering head bearings Excessive handlebar play or shaking forks in the steering head indicate that the play in the steering head bearings requires adjustment. Proceed as follows: 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).

  • Page 85: Adjusting The Chain Tension

    section Use and maintenance Adjusting the chain tension 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 one finger in correspondence with the mid point of the swingarm (see label). The lower run of the chain should deflect by approximately 33÷35 mm.
  • Page 86 section Use and maintenance If the clamp bolts (1) are removed, lubricate the threads and the underside of the head of each bolt, then tighten the bolts (1) to the specified torque in the sequence 1-2-1. Warning For the safety of the rider, it is essential that the eccentric hub clamp bolts are correctly tightened (Sect. C 3). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 87: Checking Brake Pad Wear And Changing Brake Pads

    section Use and maintenance 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. Important When the motorcycle is consigned to the customer after changing the brake pads, inform the customer that the brake must be used gently for the first 100 km to allow the pads to bed in completely.
  • Page 88 section Use and maintenance Checking rear brake pad wear Check through the slot between the two caliper halves that there is at least 1 mm of friction material on the pads. Important If either of the pads is worn, both pads must be renewed as a set. 1 mm Change the brake pads as follows: Remove the safety clip (1) (on the inner side of the caliper) from the pad retaining pin.
  • Page 89 section Use and maintenance Insert the new pads and clip (3). Fit the retaining pin (2) from the outer side and secure it with the safety clip (1), positioning the lip (A) so that it faces the wheel. Operate the brake pedal repeatedly so that the pads are bedded in against the disc by the force of the brake fluid. Check that the brake fluid level in the reservoir (4) is between the MIN and MAX marks.

  • Page 90: Adjusting The Throttle Cable

    section Use and maintenance Adjusting the throttle cable The throttle cable should have freeplay of 1.5 to 2.0 mm (measured in terms of rotation of the twistgrip) in all steering positions. 1,5÷2 mm If necessary, adjust using the adjusters (1 and 2) located on the steering tube on the left side of the motorcycle. Adjuster (1) adjusts the throttle opening control, while adjuster (2) adjusts the throttle closing control.
  • Page 91 section Use and maintenance Operate the throttle to make sure the inner cable slides smoothly inside the outer cable. If you feel excessive resistance or stiffness, renew the cable. To lubricate the throttle twistgrip, peel back the rubber sleeve (A), unscrew the screws (3) and remove the twistgrip housings (4) and (5).

  • Page 92: Adjusting The Clutch Lever And Front Brake Lever

    section Use and maintenance 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. Lever distance is adjusted by 10 clicks of the knob (2). Turn the knob clockwise to move the lever away from twistgrip, or counter clockwise to move it closer.

  • Page 93: Adjusting The Position Of The Gearchange And Rear Brake Pedals

    section Use and maintenance 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. To adjust the position of the gearchange pedal, proceed as follows: Restrain the tie-rod (1) and slacken the locknuts (2) and (3).

  • Page 94: Adjusting The Front Fork

    section Use and maintenance Adjusting the front fork The front fork can be adjusted for rebound, compression and spring preload. The settings are adjusted by way of external adjuster screws: 1) to adjust rebound damping; 2) to adjust spring preload; 3) to adjust compression damping.

  • Page 95: Adjusting The Rear Shock Absorber

    section Use and maintenance Adjusting the rear shock absorber The shock absorber has external adjusters that enable you to adapt the rear suspension to suit the load conditions. Adjuster (1), located on the left-hand side at the point at which the shock absorber is fixed to the swingarm, controls rebound damping. The adjuster (2) located on the rear shock absorber reservoir is used to adjust compression damping.
  • Page 96 section Use and maintenance The two nuts (3) on the upper part of the shock absorber serve to adjust the preload on the outer spring. To adjust the spring preload, unscrew the upper adjuster nut using a pin wrench. Screw the lower nut in or out to increase or reduce the preload. Once the desired spring preload has been set, lock down the upper ring nut.

  • Page 97: Adjusting The Rear Ride Height

    Modifying the frame geometry is a very critical operation, and can be dangerous if carried out by untrained persons. Given that this motorcycle is often used in competition, DUCATI has decided to equip this motorcycle with the means to alter the geometry of the rear suspension and the steering head to suit the needs of different circuits and track conditions.
  • Page 98 section Use and maintenance Warning The maximum distance that the UNIBALL end fitting (A) can be unthreaded from the tie-rod body is 5 threads, or 7.5 mm (B). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 99: Diagnostic Instruments

    Use and maintenance 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 100: 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 line 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 101 section Use and maintenance The display unit is equipped with two connection panels: one at the top of the instrument and one at the bottom. The top connection panel has 6 connection sockets with the following functions: - one VGA output (E); - one port for connection of the measurement module (F);...

  • Page 102: Tester Power Supply

    section Use and maintenance Tester power supply The DDS tester (1) may be powered in any one of the following ways: - from the mains power supply by connecting the mains adapter (14) to the power connection socket (N); - from the motorcycle by connecting the specific cables (see paragraph “Connection to motorcycle”); - from the tester's internal battery: the battery (Q) is housed in the top part of the tester.
  • Page 103 section Use and maintenance 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.
  • Page 104 section Use and maintenance - 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. Notes For connection of the various devices required for self-diagnostic procedures, consult the instruction handbook supplied with the tester.

  • Page 105: Dds Tester

    section Use and maintenance 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. - Reading of engine parameters (rpm, coolant and air temperature, atmospheric pressure, throttle opening, battery voltage, injection times and ignition advance, etc.).

  • Page 106: Checking And Adjusting Timing Belt Tension

    section Use and maintenance Checking and adjusting timing belt tension Notes The on-screen icons used during this procedure are explained in a table at the end of this section. Notes This operation, which is performed using the DDS tester, has the advantage that it can be carried out on both timing belts with the engine still installed on the frame.
  • Page 107 section Use and maintenance 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 (F) on the DDS tester (1). Connect the belt tension sensor (15) to the connector (V) of the power and diagnostics cable (Measurement Module) (3). Fix the mounting bracket of the belt tension sensor (15) using the timing belt cover screw (21).
  • Page 108 section Use and maintenance 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. 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 109 section Use and maintenance Warning Check the tension on the belt runs (22) and (23) indicated in the figure. The tension values are specified in Sect. C 1.1, Timing system/valves. Vertical Idler Tensioner Horizontal Idler Driveshaft Tensioner Warning The timing belts can become slack during normal operation. When checking belt tension, if the reading is less than 70 Hz, restore to the specified tension (Sect.

  • Page 110: Resetting The Throttle Position Sensor (Tps)

    section Use and maintenance 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. Make sure the butterfly valve is seated against the stop (throttle twistgrip fully closed).
  • Page 111 section Use and maintenance Enter the general functions menu by pressing the “Menu 1” icon (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 “Select system”...
  • Page 112 section Use and maintenance 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 the connections with the motorcycle ignition key in the OFF position.
  • Page 113 section Use and maintenance 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). 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”...

  • Page 114: Adjusting The Idle Speed

    section Use and maintenance Adjusting the idle speed Notes This adjustment should be carried out in an ambient temperature equal to or greater than 19 °C. Connect the inserts of the Exhaust Gas analyser part no. 88713.1010 to the outlets on the exhaust pipes, using the connection fittings (19).
  • Page 115 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 116 section Use and maintenance Close the bypass screws (20) completely. 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 117 section Use and maintenance The values can be reset by pressing the “Reset” icon. If the cylinders are not balanced, turn the bypass screw (20) of the cylinder with the lowest vacuum level (the highest value) backing it off slightly (a 1/4 turn at a time) until the two lines on the graph coincide, or until identical numerical values are displayed, if numerical display is selected.

  • Page 118: Checking The Engine Oil Pressure

    section Use and maintenance Checking the engine oil pressure Notes The on-screen icons used during this procedure are explained in a table at the end of this section. To measure the pressure of the lubrication circuit, use the engine oil pressure test point (19) as follows: Remove the RH side fairing (Sect.
  • Page 119 section Use and maintenance Connect the pressure sensor (5) to the pipe (12) to transform the pressure signal into an electrical signal. 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).
  • Page 120 section Use and maintenance 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 121 section Use and maintenance 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 122 section Use and maintenance Remove the tool and refit the pressure switch (19) along with its seal. Tighten the pressure switch to the specified torque (Sect. C 3, Engine torque settings). Reconnect the electrical system connector (A) to the pressure switch. Disconnect the DDS tester.

  • Page 123: Cylinder Compression Test

    section Use and maintenance 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. Excessive or insufficient pressure, or an excessive difference between the two cylinders, will result in a reduction in engine performance and can lead to component failure.
  • Page 124 section Use and maintenance 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”...
  • Page 125 section Use and maintenance 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: 13 to 15 bar;...

  • Page 126: Fuel Pressure Test

    section Use and maintenance Fuel pressure test Notes The on-screen icons used during this procedure are explained in a table at the end of this section. Before carrying out this procedure, you need to detach the fuel tank-seat–cowling assembly (Sect. E 3) from the motorcycle but without removing it.
  • Page 127 section Use and maintenance 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”...
  • Page 128 section Use and maintenance 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”...

  • Page 129: Immobilizer Override Procedure

    section Use and maintenance Immobilizer override procedure Notes The on-screen icons used during this procedure are explained in a table at the end of this section. In the event of a malfunction of the immobilizer system, it is possible to start the engine using an emergency procedure: this procedure, which is described in full in Sect.
  • Page 130 section Use and maintenance 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 to display a list of the bike’s systems that can be analysed. Select “Engine electronics”...
  • Page 131 section Use and maintenance Press the “Actuators” icon (C) to display the actuators and other components connected to the ECU. Select the “Immobilizer Override” option and then press the “Apply” icon. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 132 section Use and maintenance 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 was completed successfully?”...

  • Page 133: Guided Diagnosis

    section Use and maintenance Guided diagnosis Notes The on-screen icons used during this procedure are explained in a table at the end of this section. The DDS tester guides the operator step-by-step through the various diagnostic procedures, providing descriptions and documentation for motorcycle components, wiring diagrams for the electronic systems and information on the locations of specific components.
  • Page 134 section Use and maintenance 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 to display a list of the bike’s systems that can be analysed. Select “Engine electronics”...
  • Page 135 section Use and maintenance 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”...

  • Page 136: Testing The Battery Charging System

    section Use and maintenance Testing the battery charging system Notes The on-screen icons used during this procedure are explained in a table at the end of this section. You can determine the engine rpm required for the alternator to produce sufficient current to charge battery, power the injection/ ignition system and all the electrical equipment on the motorcycle.
  • Page 137 section Use and maintenance On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Ammeter” icon (F) followed by the “Start” icon. 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 138 section Use and maintenance If the measured current is a positive quantity, this means that alternator is powering all the electrical equipment and charging the 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 139: Deactivating The "Maintenance" Indication On The Instrument Panel

    section Use and maintenance Deactivating the “maintenance” indication on the instrument panel The message “SERV” is displayed on the instrument panel, indicating that the motorcycle should be serviced in accordance with programmed maintenance plan. This indication is activated after the first 1000 km and thereafter at intervals of 12000 km. After the scheduled service has been carried out, the indication must be switched off as follows: Notes The on-screen icons used during this procedure are explained in a table at the end of this section.
  • Page 140 section Use and maintenance Press the “Select system” icon. A list of the motorcycle’s systems that can be analysed will appear on the display. 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.
  • Page 141 section Use and maintenance Select the option “Mainten. light OFF” and then press the “Apply” icon. 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”...

  • Page 142: Icons Table

    section Use and maintenance Icons table Symbol Designation 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 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 143 section Use and maintenance Symbol Designation Guided diagnosis Select system Errors Ammeter clamp WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 144 WWW.PlanDeGraissage.ORG...
  • Page 145 Fairings WWW.PlanDeGraissage.ORG...
  • Page 146 section Fairings 1 - Headlight shell - rear-view mirrors Removal of the rear-view mirrors Refitting the rear-view mirrors Removal of the headlight shell Refitting the headlight shell 2 - Fairing panels Removal of the side fairings Removal of the front shield Refitting the front shield Refitting the side fairings 3 - Seat - seat cowling and side panels...

  • Page 147: Headlight Shell - Rear-View Mirrors

    section Fairings 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 screw 13 Windshield 14 Splashguard 15 Upper gasket...
  • Page 148 section Fairings Removal of the rear-view mirrors Unscrew the rear-view mirror (9) retaining bolt (4). Release the rear view mirror (9) by disengaging the pins (B) from the clips (6). Remove the lower rubber gasket (16) and disconnect the turn indicator wiring connector (A) from the wiring loom. During removal, take care not to lose or damage the gasket (16).

  • Page 149: Refitting The Rear-View Mirrors

    section Fairings Refitting the rear-view mirrors Locate the rear view mirror on the headlight shell, routing the turn indicator wiring through the hole in the headlight shell. 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 150: Removal Of The Headlight Shell

    section Fairings Removal of the headlight shell Operation Section reference Remove the side fairings To remove the headlight shell, you must first remove the rear view mirrors as described above. Unscrew bolts (18) and remove the splash guard (14). Unscrew the bolts (5) (on both sides of the headlight support frame) and the bolt (2) with washer (3) under the light assembly. Slide the headlight shell (1) forward, releasing it from the rubber mountings of the lights assembly.
  • Page 151 section Fairings If the windshield (13) is to be replaced, unscrew the bolts (12) with washers (11) and remove the windshield (13), recovering the inserts (10). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 152: Refitting The Headlight Shell

    section Fairings 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 153 section Fairings Check that the threaded inserts (17) are present on the headlight shell (1) and on th elower part of the lights assembly (A) and its support (B). 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 rubbers (D).
  • Page 154 section Fairings 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). Refit the windshield (14) and tighten the bolts (18) to the specified torque (Sect. C 3). Refit the rear-view mirrors as described above.

  • Page 155: Fairing Panels

    section Fairings 2 - Fairing panels 19 18 5 21 1 Clip 12 Bracket 2 Panel (left) 13 Clip 3 Panel (right) 14 Washer 4 Left upper fairing 15 Bush 5 Threaded insert 16 Front air scoop 6 Left lower fairing 17 Bush 7 Left side panel 18 Nylon washer...

  • Page 156: Removal Of The Side Fairings

    section Fairings Removal of the side fairings Unscrew the screws (22) securing the bottom of the fairing panels, recovering the washers (21). Unscrew the inner screw (19) securing the front of the right upper fairing (11). Unscrew the inner screws (19) securing the splashguard (A) to the inner panel (3).
  • Page 157 section Fairings Disassembly of the fairing Remove the screws (19) securing the panel (3) and remove it from the upper fairing (11). 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 158: Removal Of The Front Shield

    section Fairings Removal of the front shield After removing the side fairings as described above, unscrew the screws (22) securing the front shield (16) to the oil cooler support bracket. Remove the front shield (16) from its seat and recover the washers (21). Refitting the front shield When refitting the shield, tighten the screws (22) to the specified torque (Sect.

  • Page 159: Refitting The Side Fairings

    section Fairings Refitting the side fairings Warning Failure to replace or incorrect refitting of any of the components removed could cause parts of the fairing to come loose when riding and the consequent loss of control of the motorcycle. Important To avoid damage to painted parts, always fit the nylon washers (21) and (18) in correspondence with the fixing screws.
  • Page 160 section Fairings Left fairing mounting bracket If the bracket (12) was removed, refit, in order, bush (17), bush (15), washer (14), bracket (12) and secure then with the screws (20) and (10). Tighten the screws (20) and (10) to the specified torque (Sect. C 3). make sure that the clip (13) is fitted. In the same way, refit the left fairing (4), taking care when inserting the sidestand through the aperture provided in the fairing panel (6).

  • Page 161: Seat - Seat Cowling And Side Panels

    section Fairings 3 - Seat - seat cowling and side panels 1 Seat 13 Threaded insert 2 Bolt 14 Seat lock 3 Washer 15 Control cable 4 Passenger seat 16 Seat catch 5 Seat cover 17 Support 6 Dual seat cowling 18 Nut 7 Bolt 19 Seat cowling heat shield...

  • Page 162: Removal Of The Seat

    section Fairings Removal of the seat Removal of the pillion seat Release the pillion seat (4) by opening the lock (A) at the rear of the rider seat (1). Remove the pillion seat (4) from the bike by pulling it backwards slightly and lifting. Removal of the rider seat Undo the bolts (2) securing the seat to the subframe and recover the washers (3).

  • Page 163: Removal Of The Side Panels And Seat Cowling

    section Fairings 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 screws (12) securing the rear of the right (10) and left (9) side panels to the rear subframe. Unscrew the four lateral rear retaining screws (12).
  • Page 164 section Fairings 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 (A) of the rear wiring loom and the connector (B) of the data acquisition wiring. Unscrew the two upper bolts (7) securing the seat cowling (6).
  • Page 165 section Fairings Removal of the seat cowling heat shield Remove the exhaust silencers and the relative clamps as indicated in Sect. L 8. In order to remove the seat cowling heat shield, you first need to remove the seats, side panels and seat cowling as described previously.

  • Page 166: Refitting The Side Panels And Seat Cowling

    section Fairings 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. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 167 section Fairings 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 and insert the wiring (D) in the aperture (E).
  • Page 168 section Fairings Refitting the seat cowling Refit the seat cowling (6) to the heat shield (19), pushing the cowling towards the rear of the bike so that it engages the catches (C) on the shield (19). Refit the two upper bolts (7) securing the seat cowling (6). Refit the two bolts (8) securing the catch for the lock (16). Tighten the bolts (7) and (8) to the specified torque (Sect.
  • Page 169 section Fairings Refitting the side panels Position the left side panel (9) on the bike first and then the right (10) and fit the screw (11) that connects the two side panels together and to the fuel tank. Fit the washers (3) on the screws (2) and secure the central parts of the side panels to the rear subframe.

  • Page 170: Refitting The Seats

    section Fairings 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 screws (2) and fit them in the rear slots of the seat (1) to secure it to the rear subframe. Tighten the screws (2) to the specified torque (Sect.

  • Page 171: Refitting The Pillion Seat

    section Fairings Refitting the pillion seat Refit the pillion seat (4) and fit the catches (F) on the seat base under the frame cross tube. Press down on the pillion seat until you hear the catch engage with an audible click. Make sure that the pillion seat (4) is fully engaged by lightly pulling it upwards.

  • Page 172: Front Mudguard

    section Fairings 4 - Front mudguard Removal of the 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). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 173: Refitting The Front Mudguard

    section Fairings Refitting the front mudguard Warning Do not ride the motorcycle without the front mudguard. The front mudguard also acts as a brake hose support and prevents the brake hose from fouling the wheel when braking. Position the front mudguard (4) and refit the retaining bolts (2) with the washers (3). Locate the front brake hose grommet (A) in the mudguard clip (1).
  • Page 174 WWW.PlanDeGraissage.ORG...
  • Page 175 Controls - Devices WWW.PlanDeGraissage.ORG...
  • Page 176 section Controls - Devices 1 - Throttle and choke controls Adjusting the throttle cable Removal of the throttle cable Refitting the throttle twistgrip 2 - Hydraulic clutch control Removal of the clutch master cylinder assembly Refitting the clutch master cylinder assembly Removal of the clutch slave cylinder Refitting the clutch slave cylinder 3 - Front brake control...

  • Page 177: Throttle And Choke Controls

    section Controls - Devices 1 - Throttle and choke controls 1 Throttle twistgrip 2 Handlebar grips 3 Plug 4 Circlip 5 Throttle opening cable 6 Throttle closing cable 7 Bolt Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
  • Page 178 section Controls - Devices 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 cable 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 179: Refitting The Throttle Twistgrip

    section Controls - Devices 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, reverse the removal procedure, making sure that the twistgrip housings locate in the reference hole (C) in the handlebar.
  • Page 180 section Controls - Devices Throttle cable routing WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 181: Hydraulic Clutch Control

    section Controls - Devices 2 - Hydraulic clutch control 20 21 22 23 24 1 Clutch master cylinder 15 Hose 2 Lever 16 Banjo bolt 3 Bleed valve 17 Sealing washer 4 Dust cap 18 Bolt 5 Banjo bolt 19 Microswitch 6 Clutch control hose 20 Clutch pushrod 7 Bolt...

  • Page 182: Removal Of The Clutch Master Cylinder Assembly

    section Controls - Devices Removal of the clutch master cylinder assembly Warning The clutch master cylinder manufacturer advises against servicing of the internal parts of clutch master cylinder (1) due to the safety-critical nature of this component. Incorrect overhaul of this critical safety component can endanger the rider and passenger.

  • Page 183: Refitting The Clutch Master Cylinder Assembly

    section Controls - Devices Refitting the clutch master cylinder assembly Fit the clutch master cylinder (1), locating the pin on the cylinder body in the hole (A) in the handlebar. Tighten the retaining bolts (18) to the specified torque (Sect. C 3), in the sequence 1-2-1. Locate the hose (6) and sealing washers (17) on the master cylinder (1) and secure with the banjo bolt (16), but do not tighten at this stage.
  • Page 184 section Controls - Devices For routing of the clutch hose (6) and retaining clips, see the illustration at the end of this section. Locate the hose (6) as shown in the figure, then tighten down the special bolt (16) to the specified torque (Sect. C 3). Operation Section reference Fill the clutch system with fluid...

  • Page 185: Removal Of The Clutch Slave Cylinder

    section Controls - Devices 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. Incorrect overhaul of this critical safety component can endanger the rider and passenger. The only components that should be renewed are the complete clutch slave unit, the bleed valve, the O-ring seal and the clutch pushrod assembly.
  • Page 186 section Controls - Devices The clutch pushrod (20) can now be removed. Check both O-rings (21) for wear and renew them if necessary. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 187: Refitting The Clutch Slave Cylinder

    section Controls - Devices Refitting the clutch slave cylinder Grease and refit the clutch pushrod (20) with two O-rings (21). Lubricate seal (22) and locate it along with the slave cylinder (23) on the crankcase. Tighten the bolts (24) to the specified torque (Sect. C 3). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 188 section Controls - Devices Locate the hose (6) on the slave cylinder (23), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder. Warning If the clutch hose end fitting is incorrectly positioned, the hose may interfere with moving parts and lead to clutch faults. Locate the two sealing washers (17) and tighten the banjo bolt (5) to the specified torque (Sect.
  • Page 189 section Controls - Devices Routing the clutch hose WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 190: Front Brake Control

    section Controls - Devices 3 - Front brake control 1 Front brake master cylinder 2 Brake lever pedal 3 Banjo bolt 4 Sealing washer, thickness 1 5 Microswitch 6 Elbow fitting 7 Pivot bolt 8 Upper clamp 9 Bolt 10 Bolt 11 Reservoir bracket 12 Rubber mounting 13 Bolt...

  • Page 191: Removal Of The Front Brake Master Cylinder

    section Controls - Devices Removal of the front brake master cylinder Warning The manufacturer of the brake master cylinder advises against the servicing of its internal parts due to the safety critical nature of this component. Incorrect overhaul of this safety–critical component can endanger rider safety. Maintenance operations on these units are limited to renewal of the following parts: control lever, fluid reservoir assembly and relative fasteners and master cylinder fasteners.

  • Page 192: Refitting The Front Brake Master Cylinder

    section Controls - Devices Refitting the front brake master cylinder Locate the mounting clamp (8) of the complete master cylinder assembly (1) aligning it with the locating grub screws on the handlebar. Tighten the bolts (9) of the mounting clamp (8) to the specified torque (Sect. C 3), in the sequence 1-2-1. Warning An incorrectly positioned hose can affect brake operation and foul moving parts.

  • Page 193: Rear Brake Control

    section Controls - Devices 4 - Rear brake control 1 Support 15 Nut 2 Bolt 16 Rear brake master cylinder 3 Washer 17 Clamp 4 Spring 18 Pushrod 5 Switch 19 Bolt 6 Brake lever pedal 20 Ball joint 7 Bolt 21 Hose 8 Adjuster screw 22 Banjo bolt...

  • Page 194: Removal Of The Complete Rear Brake Control

    section Controls - Devices Removal of the complete rear brake control Operation Section reference Drain the braking system Remove the right-hand fairing Warning The manufacturer of the brake master cylinder advises against the servicing of its internal parts due to the safety critical nature of this component.

  • Page 195: Disassembly Of The Rear Brake Master Control

    section Controls - Devices Disassembly of the rear brake master control The brake master cylinder is supplied only as a complete unit; internal components cannot be replaced. To disassemble the external parts of master cylinder assembly, refer to the exploded view at the beginning of this chapter. If the bush (10) inside the brake pedal (6) needs to be renewed, drive the replacement bush into place using a press.

  • Page 196: Refitting The Rear Brake Control

    section Controls - Devices 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). LOCK LOCK Important When refitting the brake master cylinder to the engine, take care to position the brake lever return spring (4) correctly. Notes If the master cylinder-caliper hose (27) and the master cylinder–reservoir hose (21) are to be renewed, take care to position the hose unions on the master cylinder correctly.

  • Page 197: Gearchange Control

    section Controls - Devices 5 - Gearchange control 1 Gearchange pedal 2 Bush 3 Pedal rubber 4 Bolt 5 Pivot bolt 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...

  • Page 198: Removal Of The Complete Gearchange Control

    section Controls - Devices Removal of the complete gearchange control Operation Section reference Remove the left-hand fairing Unscrew and remove the pivot bolt (5) securing the gear pedal (1) and recover the O-ring seals (6). Unscrew and remove the bolt (13) securing the lever to the gearbox shaft. Withdraw the lever (14) complete with the gearchange control assembly.

  • Page 199: Disassembly Of The Gearchange Control

    section Controls - Devices Disassembly of the gearchange control Refer to the exploded view at the beginning of this section for indications on disassembly and renewal of gearchange control components. If the bush (2) inside the pedal (1) needs replacing, drive the replacement bush into place using a press. The bush must be seated 2 mm below the outer face of the pedal.

  • Page 200: Refitting The Gearchange Control

    section Controls - Devices Refitting the gearchange control To refit the gearchange control, reverse the operations of the removal procedure. In particular, grease the O-rings 6), apply threadlocker to the bolt (13), pivot bolt (5) and bolt (17) and then tighten them to the specified torque (Sect.
  • Page 201 Wheels - Suspensions - Brakes WWW.PlanDeGraissage.ORG...
  • Page 202 section Wheels - Suspensions - Brakes 1 - Front wheel Removal of the front wheel Overhauling the front wheel Refitting the front wheel 2 - Front fork (1098) Removal of the front forks Overhauling the front forks Refitting the front forks 3 - Hydraulic front brake Maintenance operations Removal of the front brake system...

  • Page 203: G Wheels - Suspensions - Brakes

    section Wheels - Suspensions - Brakes 1 - Front wheel 1 Nut 2 Washer 3 Left spacer 4 Oil seal 5 Bearing 6 Front wheel rim 7 Inner spacer 8 Bolt 9 Right spacer 10 Front wheel axle 11 Valve Important Bold reference numbers in this section identify parts not shown in the figures next to the text.
  • Page 204 section Wheels - Suspensions - Brakes 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. This could cause the brake pistons to be expelled from their bores. Support the bike so that the front wheel is raised from the ground.
  • Page 205 section Wheels - Suspensions - Brakes Loosen the axle clamp bolts (8) on the ends of the fork legs. Working from the left side, use a plastic mallet to drive the wheel axle (10) out from the opposite side. Remove the wheel and recover the spacers (3) and (9). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 206: Overhauling The Front Wheel

    section Wheels - Suspensions - Brakes Overhauling the front wheel Wheel bearings Before checking the dimensions, check the wear on wheel bearings. Check for wear by hand after cleaning and degreasing the bearings in their seats. Turn the inner race. Check the amount of radial and axial play.
  • Page 207 section Wheels - Suspensions - Brakes Grease the bearing seat and then push the new bearing into its seat. Using a tubular drift (B) that only bears on the outer race of the bearing, drive the bearing (5) fully into its seat. Use the same method to install the oil seals (4).
  • Page 208 section Wheels - Suspensions - Brakes Overhauling the wheel After you have checked the bearings, check the rim as follows. Visually inspect the rim for cracks, scoring and deformation; change the wheel if damaged. Insert the axle in the wheel and mount it on two fixed reference blocks. Using a dial gauge, measure rim runout and out-of-round relative to the axis of the axle (see Sect.

  • Page 209: Refitting The Front Wheel

    section Wheels - Suspensions - Brakes 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 210 section Wheels - Suspensions - Brakes 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. Lubricate the bolts (8).

  • Page 211: Front Fork (1098)

    section Wheels - Suspensions - Brakes 2 - Front fork (1098) 21 23 1 Bolt 17 Dust cap 2 Bolt 18 Bolt 3 Top yoke 19 Adjuster screw 4 Bottom yoke 20 Special washer 5 Left fork leg assembly 21 Right inner tube assembly 6 Right fork leg assembly 22 Dust cap 7 Locating ring...

  • Page 212: Removal Of The Front Forks

    section Wheels - Suspensions - Brakes Removal of the front forks Before removing the front forks, it is necessary to remove the following parts: Operation Section reference Removal of the front brake calipers Removal of the front mudguard Removal of the front wheel Removal of the headlight shell Important Not all the components described in this chapter are available as individual replacement parts: however they are indicated for...

  • Page 213: Overhauling The Front Forks

    section Wheels - Suspensions - Brakes Overhauling the front forks Notes It is advisable to loosen the top cap (14) when the fork is still fitted to the motorcycle. Notes The special tools required for front fork overhaul are listed in Sect. C 4. Loosen the preload adjuster (A) before unscrewing the top cap (14).
  • Page 214 section Wheels - Suspensions - Brakes Push the tool downwards to compress the spring and then slide the spacer (D) under the damper lock nut (8). Apply a wrench to the flats (E) and hold the lock nut steady to loosen the top cap (14). Remove top cap assembly (14) complete with the collar (12) and the washer (13).
  • Page 215 section Wheels - Suspensions - Brakes Fit the service tool part no. 88713.0958 and screw it onto the damper rod. 88713.0958 Push downwards to overcome the force of the spring and remove the spacer (D). 88713.0958 Remove the service tool part 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.
  • Page 216 section Wheels - Suspensions - Brakes Clamp the inner tube (28) in a vice with soft-faced jaws. Unscrew the screw (18). 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.
  • Page 217 section Wheels - Suspensions - Brakes 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).
  • Page 218 section Wheels - Suspensions - Brakes Inspection of the adjustable 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.
  • Page 219 section Wheels - Suspensions - Brakes Fit the service tool part no. 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 the tool part no.

  • Page 220: Refitting The Front Forks

    section Wheels - Suspensions - Brakes Refitting the front forks Refit the fork legs, positioning them at the height shown in the figure relative to the bottom yoke. Locate the fork legs (5) and (6) in the bottom yoke (4) and then fit the handlebars (31) and (32). Locate the fork legs (5) and (6) in the top yoke (3).
  • Page 221 section Wheels - Suspensions - Brakes Tighten to the specified torque (Sect. C 3) the clamp bolts (2) and (1) securing the legs to the bottom yoke (4) and to the top yoke (3) in the sequence 1-2-1. Tighten the handlebar clamp bolts (30) to the specified torque (Sect. C 3). Important If the clamp bolts (1) and (2) were removed on disassembly, smear the threads with the specified grease before tightening.

  • Page 222: Hydraulic Front Brake

    section Wheels - Suspensions - Brakes 3 - Hydraulic front brake 1 Banjo bolt 11 Left brake caliper 2 Sealing washer 12 Set of 4 brake pads 3 Calipers–master cylinder hose 13 Brake disc 4 Clamp 14 Bolt 5 Dust cap 15 Front brake hose 6 Bleed valve 16 Washer...

  • Page 223: Maintenance Operations

    section Wheels - Suspensions - Brakes Maintenance operations Warning Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In case of accidental contact, wash the affected area with abundant running water and consult a doctor if necessary. For maintenance instructions (brake pad wear check and replacement, brake fluid change, etc.) refer to Sect.

  • Page 224: Removal Of The Front Brake System

    section Wheels - Suspensions - Brakes Removal of the front brake system Operation Section reference Drain the braking system Unscrew the banjo bolt (2) securing the brake hose to the master cylinder and recover the sealing washers (1). Remove the hose (15) from the grommet (18) on the mudguard and release the hose (3) from the clip (20). Withdraw the hose (3) from the clamp (4) on the bottom yoke.
  • Page 225 section Wheels - Suspensions - Brakes Remove the brake master cylinder (Sect. F 3). Unscrew the two retaining bolts (9) securing the left front brake caliper (11) to the fork leg. Repeat the operation for the right brake caliper (10). Recover the spacers (8).

  • Page 226: Refitting The Brake Discs

    section Wheels - Suspensions - Brakes 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. Remove the front wheel (Sect. G 1). Undo the bolts (14) securing the brake discs to the wheel and remove the discs (13) from both sides of the wheel.

  • Page 227: Overhauling The Front Brake Components

    section Wheels - Suspensions - Brakes Overhauling the front brake components Important Critical safety components. The brake caliper manufacturer advises against any servicing of the internal components of calipers. Incorrect overhaul of this safety-critical component can 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.

  • Page 228: Refitting The Front Brake System

    section Wheels - Suspensions - Brakes Refitting the front brake system Before refitting the brake disc to the wheel, clean all contact surfaces thoroughly and smear a medium strength threadlocker on the threads of retaining screws (14). Screw in the bolts (14) securing the front brake disc (13) to the front wheel in this sequence: 1-3-5-2-4. LOCK Tighten the bolts to the specified torque (Sect.
  • Page 229 section Wheels - Suspensions - Brakes Fit the right caliper (10) over the disc. Locate the hose (3) in the grommet (18). Apply the recommended grease to the bolts (9). Hand tighten the bolts (9) with their spacers (8) to secure the calipers to the fork legs. Repeat the procedure to refit the other brake caliper.

  • Page 230: Rear Wheel

    section Wheels - Suspensions - Brakes 4 - Rear wheel 1 Right-hand wheel nut 2 Washer 3 Bush 4 Valve 5 Wheel Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.

  • Page 231: Removal Of The Rear Wheel

    section Wheels - Suspensions - Brakes Removal of the rear wheel Place the motorcycle on the rear service stand and engage 1 gear. 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 232: Overhauling The Rear Wheel

    section Wheels - Suspensions - Brakes Overhauling the rear wheel Proceed with inspection of the rear wheel. As the rear wheel has no bearings, it should be supported on the service tool part no. 88713.1073. Notes This service tool can also be used to install the wheel on a balancing machine. 88713.1073 Overhauling the wheel Inspect the wheel as follows:...

  • Page 233: Refitting The Rear Wheel

    section Wheels - Suspensions - Brakes Refitting the rear wheel Clean the mating surfaces and grease the threaded end of the stub axle with the recommended grease. Fit the wheel, aligning it with the stub axle and the driving pins. Fit the tapered bush (3) and the washer (2), and hand tighten the wheel nut (1).

  • Page 234: Rear Swingarm

    section Wheels - Suspensions - Brakes 5 - Rear swingarm 13 14 15 16 15 14 20 4 1 Swingarm pivot shaft 14 Washer 2 Pin 15 O-ring 3 Bolt 16 Caliper mounting bracket 4 Rear swingarm 17 Eccentric hub 5 Nut 18 Spacer 6 Washer...

  • Page 235: Removal Of The Rear Eccentric Hub

    section Wheels - Suspensions - Brakes Removal of the rear eccentric hub Before removing the eccentric hub, you must first remove the following parts: Operation Section reference Remove the rear wheel Remove the rear sprocket Remove the rear brake caliper Slacken off the bolts (3).
  • Page 236 section Wheels - Suspensions - Brakes Remove the washer (14), the caliper mounting bracket (16) with the O-rings (15). Remove the other washer (14). Withdraw the eccentric hub (17) from the chain side of the swingarm. Chain side 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.
  • Page 237 section Wheels - Suspensions - Brakes Removal of the rear eccentric hub Refitting is the reverse of removal, with attention to the following points. Before refitting, apply the recommended grease to the seat on the eccentric hub (17) of the caliper mounting bracket (16) on which the rings (15), also greased, will be located.
  • Page 238 section Wheels - Suspensions - Brakes Refit the washers (14) with their square edges facing the eccentric hub. Square edge Square edge Apply the recommended grease to the bolts (3) and tighten to the specified torque (Sect. C 3) in the sequence 1-2-1. Operation Section reference Refit the rear brake caliper...

  • Page 239: Removal Of The Swingarm

    section Wheels - Suspensions - Brakes Removal of the swingarm Before removing the parts in question, you must first remove the following parts: Operation Section reference Remove the rear wheel Remove the rear sprocket Remove the rear brake caliper Remove the shock absorber and tie-rod from the swingarm Remove the rear hub as described in “Removal of the rear eccentric hub”...
  • Page 240 section Wheels - Suspensions - Brakes 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). Use the drift 88713.1074 to drive out the swingarm pivot shaft. Remove the swingarm (4) assembly from the frame.

  • Page 241: Inspecting The Swingarm Pivot Shaft

    section Wheels - Suspensions - Brakes 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). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 242: Overhauling The Rear Swingarm

    section Wheels - Suspensions - Brakes 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 side and a pair of roller bearings (25), with seal rings (23), on the left side. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 243 section Wheels - Suspensions - Brakes To change the bearings, proceed as follows. From the right-hand side of the swingarm, remove the spacers (21) and (12) and the two bushes (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 244 section Wheels - Suspensions - Brakes Heat the entire swingarm up to 150 °C and support it. Fit the new roller bearings (25) on to service tool part no. 88713.1068 and, working from the outer side, install them in their bores on the left side of the swingarm.
  • Page 245 section Wheels - Suspensions - Brakes To install the ball bearing races (19) you will need tool part no. 88713.2409, composed of: (A) – drift for internal bearings; (A) – drift for external bearings; (C) – 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 246: Refitting The Swingarm

    section Wheels - Suspensions - Brakes Refitting the swingarm Refit the upper chain slider (7) securing it with the bolts (9) and (10) and the washers (11). LOCK 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 247 section Wheels - Suspensions - Brakes Locate the swingarm (4) on the frame. Lubricate the swingarm pivot shaft (1) with the recommended grease and drive it home in the frame. 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).

  • Page 248: Hydraulic Rear Brake

    section Wheels - Suspensions - Brakes 6 - Hydraulic rear brake 14 15 1 Bolt 2 Locating dowel 3 Bolt 4 Rear brake disc 5 Spacer 6 Speed sensor 7 Bolt 8 Bolt 9 Spring washer 10 Washer 11 Rear brake caliper 12 Sealing washer 13 Banjo bolt 14 Dust cap...

  • Page 249: Removal Of The Rear Brake Caliper

    section Wheels - Suspensions - Brakes 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. Incorrect overhaul of these critical safety components can endanger rider and passenger safety. Before removing the parts in question, you must first remove the following parts: Operation Section reference...

  • Page 250: Removal Of The Rear Brake Disc

    section Wheels - Suspensions - Brakes Removal of the rear brake disc Remove the rear eccentric hub (Sect. G 5). Unscrew and remove the four bolts (3) securing the brake disc to the stub axle and remove the rear brake disc (4). If they are to be renewed, unscrew the bolts (1) from the hub and remove the locating pins (2).

  • Page 251: Refitting The Rear Brake Caliper

    section Wheels - Suspensions - Brakes Refitting the rear brake caliper If the brake hoses are renewed or if one of the components of the rear brake system have been removed, make sure that the hose connection fittings on the master cylinder and the caliper are correctly positioned. Warning An incorrectly positioned hose can affect brake operation and foul moving parts.

  • Page 252: Rear Suspension

    section Wheels - Suspensions - Brakes 7 - Rear suspension 1 Bolt 2 Washer 3 Nut 4 Bolt 5 Spacer 6 Oil seal 7 Roller bearing 8 Rocker arm assembly 9 Bolt 10 Shock absorber 11 Collar 12 Nut 13 Ball joint 14 Tie-rod 15 Nut 16 Ball joint...

  • Page 253: Rear Suspension System

    section Wheels - Suspensions - Brakes Rear suspension system The rear suspension uses a fully adjustable progressive hydraulic monoshock (10). The system consists of an upper rocker arm (8) and an adjustable tie-rod (14), which is fixed to the single-sided swingarm. The swingarm pivots on the frame and the engine to achieve maximum rigidity;...

  • Page 254: Removal Of The Rear Shock Absorber

    section Wheels - Suspensions - Brakes Removal of the rear shock absorber Operation Section reference Remove the seat cowling Remove the rear wheel To remove the rear shock absorber (10) from the swingarm and from the rocker arm (14), remove the upper (9) and lower (17) mounting bolts.

  • Page 255: Overhauling The Rear Shock Absorber

    section Wheels - Suspensions - Brakes Overhauling the rear shock absorber Before dismantling the shock absorber, measure the spring preload length (L). The same length must be restored on re-assembly. Removal 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 256: Removal Of The Rear Suspension Rocker Arm

    section Wheels - Suspensions - Brakes 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 collars (11) from either side of the ball joint (13).

  • Page 257: Overhauling The Rear Suspension Rocker Arm

    section Wheels - Suspensions - Brakes 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 seals (6) on the outer sides of the bearings keep the lubricant inside the cages.

  • Page 258: Disassembly And Overhaul Of The Shock Absorber Tie-Rod

    section Wheels - Suspensions - Brakes Disassembly and overhaul of the shock absorber tie-rod Unscrew and remove the upper bolt (4) and lower bolt (18). Remove the tie-rod assembly (14). The tie–rod (14) is comprised of a central shaft (19), two nuts (12) and (15), and two ball joints (13) and (16). Two mounting collars (11) are located at the sides of each ball joint.

  • Page 259: Refitting The Rear Suspension

    section Wheels - Suspensions - Brakes 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 260 section Wheels - Suspensions - Brakes Grease the thread and underside of the head of the lower mounting bolt (17), and tighten it to the specified torque (Sect. C 3). Install the collars (11) on both the ball joints end fittings. Install the lower end of the tie-rod (14) on the swingarm.

  • Page 261: Final Drive

    section Wheels - Suspensions - Brakes 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 Inner ring 14 Spacer...

  • Page 262: Inspecting The Final Drive

    section Wheels - Suspensions - Brakes Inspecting the final drive To check wear of the final drive, carry out a visual inspection of the front sprocket (3) and rear sprocket (7). If the teeth are found to worn as shown in the figure (dotted line), the sprocket must be renewed. Normal Worn Normal...

  • Page 263: Removal Of The Front Sprocket

    section Wheels - Suspensions - Brakes Removal of the front sprocket Undo the bolts (5) and remove the sprocket cover (6). Slacken the chain (Sect. D 4). Remove the chain with the service tool part 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 264 section Wheels - Suspensions - Brakes 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 reasembly.

  • Page 265: Refitting The Front Sprocket

    section Wheels - Suspensions - Brakes Refitting the front sprocket Refit the ring (17) (Sect. N 9.2). Grease the O-ring (16) and install it on the front sprocket spacer (15). Fit the spacer, from the seal side, on the output shaft and seat it against the inner ring of the bearing. Before fitting the front sprocket, check that the spacer (15) is installed on the gearbox output shaft.
  • Page 266 section Wheels - Suspensions - Brakes Fit the chain and join it with the service tool part no. 88713.1344, previously used for split it. The tool is composed of a holder (A), punch (B), body (C) and two wrenches (D) and (E) and link plate holder (F). Connect the two halves of the chain with the external link and manually fit the plate onto the pins.

  • Page 267: Renewal Of The Rear Sprocket

    section Wheels - Suspensions - Brakes Renewal of the rear sprocket Operation Section reference Slacken the chain Remove the rear wheel Hold the stub axle against rotation and, using a socket wrench, loosen the nut (8). Fully unscrew the nut (8) and remove the washer (9) and the flange (11) complete with the rear sprocket (7). Recover the spacer (14).

  • Page 268: Refitting The Rear Sprocket

    section Wheels - Suspensions - Brakes 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. Refitting is the reverse of removal. If it was necessary to remove the cush drive bushes (12), grease all the mating surfaces and the undersides of the retaining nuts (10) of the cush drive bushes (12) with the recommended grease.

  • Page 269: Washing The Chain

    section Wheels - Suspensions - Brakes Washing the chain Chains with O-rings must be washed in oil, diesel fuel or paraffin (kerosene). Do not use petrol, trichloroethylene or other solvents, which could damage the rubber O-rings. For the same reason use only sprays specifically formulated for use with O-ring chains.
  • Page 270 WWW.PlanDeGraissage.ORG...
  • Page 271 Frame WWW.PlanDeGraissage.ORG...
  • Page 272 section Frame 1 - Handlebars Removal of the handlebars Refitting the handlebars 2 - Steering Adjusting the steering head bearings Steering angle adjustment Removal of the steering head components Refitting the steering head components 3 - Steering damper (1098) Removal of the steering damper Refitting the steering damper 4 - Footrest brackets Removal of the footrests...

  • Page 273: Handlebars

    section Frame 1 - Handlebars 1 Left handlebar 2 Right handlebar 3 Bolt 4 Plug 5 Bolt Important Bold reference numbers in this section identify parts not shown in the figures next to the text. Refer to the exploded view diagram.
  • Page 274 section Frame Removal of the handlebars To remove the right handlebar, the following parts must be removed first: Operation Section reference Remove the headlight shell Remove the throttle twistgrip Remove the right-hand handlebar switch Remove the front brake lever Remove the top yoke To remove left handlebar, the following parts must be removed first: Operation Section reference...

  • Page 275: Refitting The Handlebars

    section Frame Refitting the 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 (A) into the slot (B) in the top yoke.

  • Page 276: Steering

    section Frame 2 - Steering 1 Bottom yoke 2 Oil seal 3 Bearing 4 Nut 5 Bolt 6 Bolt 7 Top yoke 8 Adjuster screw 9 Nut Important Bold reference numbers in this section identify parts not shown in the figures next to the text. Refer to the exploded view diagram.

  • Page 277: Adjusting The Steering Head Bearings

    section Frame Adjusting the steering head bearings Notes See Sect. D 4 for steering bearing play adjustment. If correct steering bearing play cannot be achieved, check the wear of the steering bearings (3) and if necessary replace them as described in “Removal of the steering head components” in this section. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 278: Steering Angle Adjustment

    section Frame Steering angle adjustment Loosen the nuts (9). Loosen the adjuster screws (8) on both sides of the bottom yoke. Use a 6 to 6.5 mm spacer (A) fitted to the fork outer tube, or use a gauge. 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.

  • Page 279: Removal Of The Steering Head Components

    section Frame Removal of the steering head components Operation Section reference Remove the side fairings Remove the headlight shell Remove the fork legs Remove the steering damper Notes All parts fitted to the top and bottom yokes, wires and control cables included, can remain on motorcycle provided they do not hinder the following operations.
  • Page 280 section Frame Remove the bottom yoke (1) complete with the steering stem from the frame tube. Remove the ball race (B) of the lower bearing (3). The inner race (A) of the lower bearing (3) and the relative oil seal (2) will remain on the steering stem. 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.

  • Page 281: Refitting The Steering Head Components

    section Frame Refitting the steering head components Important The steering tube bearings (3) are identical but in no case may their components be swapped around during reassembly. 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 part no. 88713.1062 and proceed as follows: heat the steering head to 150 °C;...
  • Page 282 section Frame Fit the oil seal (2) (with the rim facing upwards) and inner race (A) of bottom bearing (3) onto the steering stem after heating it for about 10 minutes to 120 °C. Fit drift part no. 88713.1072 into steering stem. Keep the inner race (A) pressed against the oil seal (2) manually for at least 10 - 15 seconds.
  • Page 283 section Frame Tighten the steering stem nut (4) by hand until it seats against the oil seal (2). Fit service bush part no. 88713.1058 to the steering stem nut (4) and fit the torque wrench to the bush. Tighten the steering stem nut (4) to the specified torque (Sect. C 3). 88713.1058 88713.1058 Fit the top yoke (7) onto the steering stem nut (4), aligning the fork leg bores with the corresponding bores on the bottom yoke.

  • Page 284: Steering Damper

    section Frame 3 - Steering damper (1098) 1 Steering damper 2 Bolt 3 Bolt 4 Mounting clamp 5 Bolt 6 Ball joint 7 Spacer 8 O-ring 9 Spacer Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.

  • Page 285: Removal Of The Steering Damper

    section Frame Removal of the steering damper Unscrew and remove the bolt (2) securing the steering damper rod (1) to the frame. Loosen the bolt (5) securing the steering damper to the mounting clamp (4) on the top yoke. Remove the steering damper (1) from the mounting clamp (4). Recover the spacer (7).

  • Page 286: Refitting The Steering Damper

    section Frame Refitting the steering damper Lubricate the spacer (9) with the O-ring (8) and fit to the seat on the top yoke. Apply threalocker to the thread of bolt (3) and insert it in the hole of the mounting clamp (4). Tighten the bolt (3) on the top yoke to the specified torque (Sect.

  • Page 287: Footrest Brackets

    section Frame 4 - Footrest brackets 1 Right footrest bracket 2 Left footrest bracket 3 Spring 4 Pivot bolt 5 Right front footrest 6 Left front footrest 7 Bolt 8 Right heel plate 9 Left heel plate 10 Circlip 11 Bolt Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.

  • Page 288: Removal Of The Footrests

    section Frame Removal of the footrests The left footrest assembly can be removed after removing gearchange pedal (A) from the bracket (2) (Sect. F 5). Undo the two bolts (7) securing the bracket to the frame and remove the complete footrest and bracket assembly. To separate the footrest and the bracket, remove the circlip (10) and withdraw the pin (4) to release the footrest and the spring (3).

  • Page 289: Refitting The Footrests

    section Frame Refitting the 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. Insert the pin (4) from the front side of the bracket, securing it on the other side with circlip (10). Fit the entire assembly to the frame, securing it with the bolts (7) coated with the recommended threadlocker.

  • Page 290: Stands

    section Frame 5 - Stands 1 Sidestand 2 Bolt 3 Bracket 4 Bolt 5 Switch 6 Inner spring 7 Spring assembly 8 Plate 9 Pivot bolt 10 Nut Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.

  • Page 291: Removal Of The Sidestand

    section Frame Removal of the sidestand. Operation Section reference Remove the left-hand side fairing Disconnect the wiring connector of the sidestand switch (1) from the main wiring harness. Unscrew the two bolts (2) securing the sidestand bracket (3) to the engine and remove the complete sidestand assembly. Disassembly of the sidestand.
  • Page 292 section Frame 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. See Sect.

  • Page 293: Refitting The Sidestand

    section Frame Refitting the sidestand Position the plate (3) on the frame, apply recommended threadlocker to the two bolts (2). Tighten the bolts (2) to the specified torque (Sect. C 3). LOCK Connect the side stand switch connector (A) to the main wiring harness. For correct routing of the sidestand switch wiring, refer to the plates in Sect.

  • Page 294: Frame Inspection

    section Frame 6 - Frame inspection 10 11 13 11 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 mounting 12 Bolt 13 Spacer 14 Rubber mounting 15 Air temperature sensor Important...

  • Page 295: Disassembly Of Structural Components And The Frame

    section Frame 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. The structural components of the frame (2) are the headlight assembly (1) and the rear subframe (3). Both serve to support motorcycle superstructures and must therefore be in perfect condition.
  • Page 296 section Frame The flow chart below illustrates the logical sequence in which the parts are to be removed from the motorcycle and gives a reference to the section of the manual in which the removal procedure is described. COMPLETE MOTORCYCLE HEADLIGHT GEARCHANGE REAR...
  • Page 297 section Frame Removal of the headlight assembly Unscrew the bolts (12) to disconnect the headlight (7). Disconnect the various wiring connectors and remove all cable ties from the headlight support (Sect. P 1), unscrew the bolts (4). Remove the headlight assembly (1). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 298 section Frame Removal of the rear subframe Disconnect all the wiring connections of the electrical components mounted on the subframe (Sect. P 1) and remove the silencer (Sect. L 8). Unscrew the bolts (5) securing the rear subframe (3) to the frame (2). Separate the rear subframe (3) from the frame (4).

  • Page 299: Checking The Frame

    section Frame Checking the frame Check the dimensions of the frame against the dimensions shown here to determine whether it needs to be realigned or renewed. 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.
  • Page 300 section Frame Rear subframe general dimensions (mm) 564,6 568,1 72,6 320,3 393,3 613,9 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 301: Reassembly Of Structural Components And The Frame

    section Frame 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 302 section Frame Install the headlight assembly (1) complete with accessories to the mounting on the front of the steering head, making sure the holes are aligned. Insert the bolts (4) in the front mounting. Apply the prescribed threadlocker and tighten the bolts (4) to the specified torque (Sect. C 3). LOCK Reconnect and refit the wiring connectors (Sect.

  • Page 303: Number Plate Holder

    section Frame 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 Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.

  • Page 304: Removal Of The Number Plate Holder

    section Frame Removal of the number plate holder Undo the bolts (12) and remove the number plate holder cover (2). Undo the bolts (5) securing the number plate holder (1) to the frame (4). Disconnect the rear turn signal connectors from the main wiring loom (Sect. P 1) and remove the number plate holder assembly. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 305 section Frame Unscrew the bolts (11) and (14) to remove the number plate support (7) from the number plate (1) and from the bracket (9). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 306 section Frame Refitting the number plate holder Refit the number plate support (7) to the bracket (9) and to the number plate holder by fitting the bolts (14) and (11). Reconect gthe turn signal wiring connectors to the main wiring loom (Sect. P 1). Refit the number plate holder (1) to the support (4) with the bolts (5).
  • Page 307 section Frame Refit the number plate holder cover (2) with the bolts (12). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 308 WWW.PlanDeGraissage.ORG...
  • Page 309 Fuel / Exhaust System WWW.PlanDeGraissage.ORG...
  • Page 310 section Fuel / Exhaust System 2 - Fuel tank Removal of the fuel tank Removal of the fuel filler cap assembly Refitting the fuel filler cap assembly Renewal of the fuel tank flange Refitting the fuel tank flange Refitting the fuel tank 6 - Airbox - Throttle Body Removal of the throttle body Refitting the airbox and throttle body...

  • Page 311: Fuel Tank

    section Fuel / Exhaust System 2 - Fuel tank 32 35 21 20 19 18 5 36 37 36 1 Fuel tank 20 Hose 2 Front fuel tank mounting (right) 21 Bolt 3 Front fuel tank mounting (left) 22 O-ring 4 Bolt 23 O-ring 5 Bolt...
  • Page 312 section Fuel / Exhaust System Removal of the fuel tank Remove the seat and the side panels (Sect. E 3, Removal of the seat - Removal of the side panels and seat cowling). Remove the bolt (13) and recover the washer (12). Detach the hoses (34) and (35) from respectively plates (32) and (31).
  • Page 313 section Fuel / Exhaust System Withdraw the fule tank (1) towards the rear of the motorcycle to disengage the front catches from the frame. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 314: Removal Of The Fuel Filler Cap Assembly

    section Fuel / Exhaust System 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 315: Refitting The Fuel Filler Cap Assembly

    section Fuel / Exhaust System Refitting the fuel filler cap assembly Grease the new O-ring and its groove in the fuel tank. Refit the filler cap assembly in its seat in the tank and tighten the bolts (8) and (9) to the specified torque (Sect. C 3). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 316: Renewal Of The Fuel Tank Flange

    section Fuel / Exhaust System 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 317: Refitting The Fuel Tank Flange

    section Fuel / Exhaust System 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). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 318: Refitting The Fuel Tank

    section Fuel / Exhaust System 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. In particular: apply the recommended threadlocker to the bolts (4); tighten the bolts (4), (5) and (33) and the unions (16) to the specified torque (Sect.
  • Page 319 section Fuel / Exhaust System Connect the quick-release fittings (24) to the flange. Connect the wiring connector (A) to the main wiring loom. Insert the hoses (34) and (35) in respectively plates (32) and (31). Secure the tank to the frame with the bolt (13) and the washer (12). Tighten the bolt (13) to the specified torque (Sect.
  • Page 320 section Fuel / Exhaust System Positioning of the fuel tank breather and drain hoses and the water overflow hose and expansion tank. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 321 section Fuel / Exhaust System Positioning of the fuel pipes WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 322: Airbox - Throttle Body

    section Fuel / Exhaust System 6 - Airbox - Throttle Body 1 Stepper motor 11 Throttle body assembly 2 O-ring 12 Bolt 3 Bolt 13 Injector 4 Fuel injector support 14 Hose (vertical) 5 Union 15 Union 6 Hose 16 Hose (horizontal) 7 Air intake funnel 17 Fuel injector cap 8 Special screw...

  • Page 323: Removal Of The Throttle Body

    section Fuel / Exhaust System Removal of the throttle body Operation Section reference Remove the side fairings Remove the headlight shell Remove the fuel tank Remove the air scoops Disconnect the throttle cable Disconnect the fuel injectors (13) from the main wiring harness. Remove the retaining clips (A).
  • Page 324 section Fuel / Exhaust System 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). Slacken off the clamp (G) dsecuring the hose (18) to the blow-by valve.
  • Page 325 section Fuel / Exhaust System Withdraw the airbox (20) complete with the throttle body (11) and the fuel injectors (13). Removal of the fuel injectors Undo the screws (3) to remove the fuel injectors (13) complete with hoses (14) and (16) from the airbox. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 326 section Fuel / Exhaust System 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.
  • Page 327 section Fuel / Exhaust System Removal of the stepper motor The stepper motor is installed in the central part of the throttle body: to remove it, unscrew the two screws (H) and disconnect the hoses (L) and (M) from the airbox. Refer to Sect. M 3 for details of stepper motor operation.
  • Page 328 section Fuel / Exhaust System Disassembly of the airbox – throttle body Unscrew the six bolts (8) and remove the throttle body (11) from the airbox (20). Reassembly of the airbox – throttle body If removed, refit the fuel hoses (N) with relative quick-release fittings and hose clamps to the airbox as shown. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 329 section Fuel / Exhaust System 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). 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.
  • Page 330 section Fuel / Exhaust System If removed, refit the throttle cable stop (S) tightening the screws (T). Refit the throttle body (11) to the airbox (20). Tighten the six screws (8) to the specified torque (Sect. C 3, Frame torque settings). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 331: Refitting The Airbox And Throttle Body

    section Fuel / Exhaust System 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. Tighten the hose clamps (B) to the specified torque (Sect. C 3). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 332 section Fuel / Exhaust System Reconnect the wiring connectors connecting the injectors (13) to the main wiring loom. Connect the wiring connector (D) on the main wiring loom to the stepper motor (1). Connect the wiring connector (E) to connect the main wiring loom to the throttle position sensor (F). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 333 section Fuel / Exhaust System 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. D 5). Operation Section reference Connect the throttle cable Refit the air intake funnels Refit the fuel tank Refit the headlight shell...
  • Page 334 section Fuel / Exhaust System Positioning of the airbox drain hose WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 335 section Fuel / Exhaust System Positioning of the blow-by hose WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 336 section Fuel / Exhaust System Positioning throttle cables WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 337: Air Intake

    section Fuel / Exhaust System 7 - Air intake 1 Bolt 2 Rubber grommet 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 Important Bold reference numbers in this section identify parts not shown in the figures next to the text.

  • Page 338: Removal Of The Air Filters

    section Fuel / Exhaust System Removal of the air filters Operation Section reference Remove the side fairings Remove the headlight shell Undo the bolts (7) securing the air scoops to the airbox. Unscrew the bolts (1) securing the air scoops to the headlight assembly and withdraw the intake hoses (9) and (11) with the air scoops (6) andd (10) from the headlight assembly.

  • Page 339: Refitting The Air Filters

    section Fuel / Exhaust System Refitting the air filters If removed, refit the seals (8) to the air scoops (6) and (10), positioning the locating nib in the relative motch on the air scoop. Reposition the hoses (9) and (11) with the air scoops (6) and (10) on the headlight assembly. Insert the bolts (1) securing the air scoppos to the healdight assembly and the bolts (7) securing the air scoops to the airbox.

  • Page 340: Exhaust System

    section Fuel / Exhaust System 8 - Exhaust system 10 17 29 1019 26 13 7 28 1 Nut 18 Nut 2 Exhaust gasket 19 Washer 3 Spring 20 Cables assembly 4 Horizontal cylinder head exhaust pipe 21 Vertical cylinder head exhaust pipe 5 Rubber mounting 22 Heat shield 6 Spacer...

  • Page 341: Removal Of The Exhaust System

    section Fuel / Exhaust System Removal of the exhaust system Operation Section reference Remove the side fairings Unscrew the bolts (10) and recover the seals (19). Unscrew the bolt (17) and the nut (8). Remove the springs (3) and slide the silencers (29) and (30) from the vertical cylinder head exhaust pipe (21). Unscrew the bolts (24) to remove the heat shield (22).
  • Page 342 section Fuel / Exhaust System Remove the circlips (A) from the cables assembly (20) for the exhaust valve motor (B). Remove the cables (20) from the exhaust valve (B). Unscrew the bolts (33) to remove the exhaust valve motor (31) from the frame and disconnect the wiring (C) from the motor (31). Disconnect the lambda sensor (11) from the wiring (D).
  • Page 343 section Fuel / Exhaust System Unscrew the bolt (7) and the nut (18) securing the pipe (21) to the frame. 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). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 344 section Fuel / 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. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 345: Refitting The Exhaust System

    section Fuel / Exhaust System 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). Tighten the nuts (1) to the specified torque (Sect. C 3, Frame torque settings). 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).
  • Page 346 section Fuel / 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). Connect the lambda sensor (11) to the wiring (D). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 347 section Fuel / Exhaust System Locate the motor (31) on the frame and tighten the bolts (33) 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 348 section Fuel / Exhaust System To adjust the cables, turn the adjusters (F). Refit the heat shield (22) and tighten the bolts (24) to the specified torque (Sect. C 3, Frame torque settings). Connect the silencers (29) and (30) to the pipe (21) and locate the springs (3). Refit the bolt (17) with the nut (8) and tighten to the specified torque (Sect.
  • Page 349 section Fuel / Exhaust System Insert the bolts (10) with washers (19) and tighten the bolts (10) to the specified torque (Sect. C 3, Frame torque settings). Operation Section reference Refit the fairings WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 350 section Fuel / Exhaust System Positioning the control cables of the exhaust valve motor WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 351 Injection - ignition system WWW.PlanDeGraissage.ORG...
  • Page 352 section Injection - ignition system 2 - Fuel injection-ignition system 3 - System components Electronic Control Unit (ECU) Removal of the battery support Refitting the battery support Electric injector Air pressure sensor Coolant temperature sensor Air temperature sensor Ignition coils Throttle Position Sensor (TPS) Rpm/timing sensor Injection relay...

  • Page 353: Fuel Injection-Ignition System

    section 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. Ignition switch Left cooling fan Right cooling fan Starter motor Starter contactor...

  • Page 354: Electronic Control Unit (Ecu)

    section Injection - ignition system 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)
  • Page 355 section Injection - ignition system There are two kinds of ECU connector, one with a grey terminal block (Body), and one with a black terminal block (Engine). Grey Black Warning If the ECU has been renewed, it will be necessary to reset the throttle position sensor (TPS) (Sect. D 5). Notes For removal/refitting of the ECU, refer to “Removal of the battery support”...

  • Page 356: Removal Of The Battery Support

    section Injection - ignition system Removal of the battery support To remove the battery support, you first need to remove the left-hand side fairing (Sect. E 2) and disconnect the sidestand wiring connector (A) from the main wiring loom (Sect. P 1). Unscrew the bolt (2) and remove the battery retaining bracket (3).
  • Page 357 section Injection - ignition system Disconnect the two wiring connectors (8) and (9) from the ECU. Undo the screws (10) and remove the ECU (1), freeing from the ECU earth lead (C). Detach the wiring connector of the contactor (13) with the fixing device from the battery support. To remove the contactor, proceed as described in Sect.
  • Page 358 section Injection - ignition system Release the wiring from any cable ties (D). To remove the rectifier (15), proceed as described in Sect. P 2. 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 359: Refitting The Battery Support

    section Injection - ignition system 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. Notes If the regulator/rectifier and the contactor were removed, refit following instructions in Sect. P 2. Fit the regulator fuse (14) inserting through the holes in the battery support.
  • Page 360 section Injection - ignition system Refit the injection and fans relay e (12), insert the screws (11) and tighten to the specified torque (Sect. C 3). Fasten the main branch of the wiring loom to the battery support with the relative clips (D). Position the ECU so that the threaded hole (E) is facing upwards;...
  • Page 361 section Injection - ignition system Make sure the clip (A) for the connector (8) is in its “open” position (as shown in the diagram). Push the connector firmly into the ECU. Rotate the clip (F) to secure the connector (clip in “locked” position). Repeat the procedure for the other connector (9).
  • Page 362 section Injection - ignition system Connect the regulator wiring connector (7) and secure with the wiring clip (B) along with the sidestand wiring connector (A). Fasten the main branch of the wiring loom to the battery support as shown in the illustration. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 363 section Injection - ignition system If it has been removed, refit the rubber mat (20) in its seat, locating the pins in the holes (C) on the battery support. Refit the battery in the support and refit the support to the motorcycle by reversing the removal operations. Reconnect the sidestand wiring (A) to the main wiring loom (Sect.

  • Page 364: Electric Injector

    section Injection - ignition system Electric injector 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 365: Air Pressure Sensor

    section Injection - ignition system Air pressure sensor This sensor is integrated in the instrument panel and indicates the atmospheric air pressure. This information is sent to the ECU by a serial line (CAN line), and is used to correct the calibrations stored in the Flash Eprom. Notes To test the operation of this component, use the DDS tester and follow the instructions given under the heading “Guided diagnosis”, Sect.

  • Page 366: Coolant Temperature Sensor

    section Injection - ignition system Coolant temperature sensor This sensor is mounted to the horizontal cylinder head coolant outlet union and measures the coolant temperature. This information is sent to the ECU and used to correct the calibrations stored in the Flash Eprom so as to ensure optimal ignition and fuel supply at all times.

  • Page 367: Air Temperature Sensor

    section Injection - ignition system Air temperature sensor The sensor (1) is located on the right-hand side of the instrument panel and measures the external air temperature: the temperature signal is sent to the ECU integrated in the instrument panel for display and sent over the CAN line to the engine ECU which uses it to make mapping corrections.

  • Page 368: Ignition Coils

    section Injection - ignition system Ignition coils Remove the seat cowling and the fuel tank (Sect. E 3). Undo the nut (1) securing the coil to the cylinder head. Remove the connector (2) and extract 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 369 section Injection - ignition system Spark plugs Check the colour of the ceramic insulation around the central electrode: an even, light brown colour indicates the engine is in good condition and running at the right temperature. The motorcycle may be fitted with either plugs with earth electrodes (4) or plugs without earth electrodes (5). On spark plugs with earth electrodes, check the central electrode for wear and the gap between the electrodes, which should be: 0.6 to 0.7 mm.
  • Page 370 section Injection - ignition system Checking the coils The coils used on this model are known as “cigar” coils. They are similar in appearance to a spark plug cap. They transform the low voltage from the ECU into high voltage for the spark plugs.

  • Page 371: Throttle Position Sensor (Tps)

    section Injection - ignition system Throttle Position Sensor (TPS) The TPS is powered by the ECU to which it sends a signal indicating the throttle position. This information is the indirect measure of the engine load and is used by the ECU as one of the main parameters for determining 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”...

  • Page 372: Rpm/Timing Sensor

    section Injection - ignition system Rpm/timing sensor This sensor (1) is of the inductive type: it faces the timing gear and is capable of reading the 46 teeth and the 2-tooth gap. The signal from the pickup on the timing driveshaft driving gear is used by the ECU to determine the engine speed and as a timing reference point.

  • Page 373: Injection Relay

    section Injection - ignition system 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. Disconnect the relay from the electrical system and apply 12 V (battery voltage) between contacts (86) and (85) (small contacts): you should hear a click that confirms that the internal electromagnet has switched.

  • Page 374: Can Line

    section Injection - ignition system CAN Line This model utilises a CAN line (Controller Area Network) which has made it possible to greatly simplify the layout of the electrical system and consequently reduce its overall weight. The CAN line is connected to two nodes: the instrument panel and the Magneti Marelli engine ECU (I.A.W.
  • Page 375 Engine WWW.PlanDeGraissage.ORG...
  • Page 376 section Engine 1 - Removal–refitting of the engine assembly Removal of the engine Refitting the engine 2.1 - Lubrication system: oil pump Removal of the oil pump Disassembly of the oil pump Reassembly of the oil pump Refitting the oil pump 2.2 - Lubrication system: oil cooler Removal of the lubrication system Oil cooler inspection...
  • Page 377 section Engine Overhaul of cylinder head components Reassembly of the cylinder head Fitting the cylinder head assemblies 5 - Cylinder/piston assemblies Disassembly of the cylinder/piston Overhaul of the cylinder barrel/piston components Refitting the cylinder/piston assembly 6.1 - Clutch assembly: clutch Description Disassembly of the clutch Inspection and overhaul of the clutch components...
  • Page 378 section Engine 9.2 - Crankcase assembly: crankcase halves Separation of the crankcase halves Overhaul of the crankcase halves Main bearings Reassembly of the crankcase halves Shimming the shafts Reassembly of the crankcase halves 9.3 - Crankcase assembly: connecting rods Removal of the connecting rods assembly Disassembly of the connecting rods Overhaul of the connecting rods Reassembly of the connecting rods...

  • Page 379: Removal-Refitting Of The Engine Assembly

    section Engine 1 - Removal–refitting of the engine assembly 1 Bolt 2 Nut 3 Bolt 4 Swingarm pivot shaft 5 Washer 6 Washer Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
  • Page 380 section Engine 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 381 section Engine Place a stand beneath the engine to support it during removal from the frame. Unscrew the nuts (2) on the right-hand side of the frame, on the two upper engine bolts (1) and recover the washers (6). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 382 section Engine 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. Use the drift 88713.1074 to fully extract the swingarm pivot shaft. This frees the swingarm from the engine and therefore it can be left attached to the frame. Remove the two upper bolts (1).

  • Page 383: Refitting The Engine

    section Engine 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, engine tightening torques). Refit the removed parts by performing the steps shown in the table and in the specific sections of the manual in reverse order. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 384: Lubrication System: Oil Pump

    section Engine N 2.1 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 dowel...

  • Page 385: Removal Of The Oil Pump

    section Engine N 2.1 Removal of the oil pump Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the right-hand side crankcase N 6.2, Removal of the right-hand side cover crankcase cover Undo and remove the bolts (9) and (10) securing the pump assembly. Remove the oil pump assembly (1) and extract O-rings (2) and (4) from the crankcase half together with two locating bushes (15).

  • Page 386: Disassembly Of The Oil Pump

    section Engine N 2.1 Disassembly of the oil pump Hold the oil pump (1) in a vice taking care not to damage the drive gear (12). Warning Make sure that vice jaws are faced with soft material. Remove plug (14) and extract the spring (16) and by-pass valve (17). Check the condition of the above components.

  • Page 387: Reassembly Of The Oil Pump

    section Engine N 2.1 Reassembly of the oil pump Check that the circlip (3) and Woodruff key (13) are both present on the pump. Fit the pump drive gear (12) on to the oil pump and secure it by installing the circlip (6) in its groove. Install in the pump the by-pass valve (17) and the spring (16);...

  • Page 388: Refitting The Oil Pump

    section Engine N 2.1 Refitting the oil pump Position the locating bushes (15) and the O-rings (2) and (4) in correspondence with the crankcase lubrication oilways. Position the oil pump on the crankcase and tighten the bolts (9) and (10) to the specified torque (Sect. C 3, Engine torque settings).

  • Page 389: Lubrication System: Oil Cooler

    section Engine N 2.2 2.2 - Lubrication system: oil cooler 11 3 1 Oil cooler 2 Rubber mounting 3 Spacer 4 Aluminium gasket 5 Nipple 6 O-ring 7 Oil hose 8 Plate 9 Bolt 10 Support 11 Bolt Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.

  • Page 390: Removal Of The Lubrication System

    section Engine N 2.2 Removal of the lubrication system Operation Section reference Remove the side fairings Drain the oil from the lubrication system Undo the nuts (A) on the feed and return hoses (7) and the nipples (5) and disconnect them from the engine. Unscrew the nipples (5) on the crankcase and recover the gaskets (4).
  • Page 391 section Engine N 2.2 Unscrew and remove the bolt (11) with the spacer (3) securing the oil cooler to the support (10). Remove the oil cooler, withdrawing the pin (B) of the support (10). The support (10) can now be removed by unscrewing the bolts (9). Unscrew the bolt (9) securing the plate (8) to the oil cooler (1).

  • Page 392: Oil Cooler Inspection

    section Engine N 2.2 Oil cooler inspection Make a visual inspection of the oil cooler. Renew the cooler in the presence of damage or leaks. Refitting the lubrication system Notes Before installing the hoses (7), check that the O-rings (6) are installed and lubricate them with engine oil. Locate the feed and return hoses (7) on the cooler with the plate (8) and tighten the bolt (9) to secure.
  • Page 393 section Engine N 2.2 If removed, refit the support (10) securing it to the horizontal cylinder head with the two bolts (9). Fit the oil cooler (1), firsts inserting it in the pin (B) of the support (10). Fit the spacer (3) and the bolt (11). Tighten the bolt (11) to the specified torque (Sect.

  • Page 394: Cooling System: Radiator

    section Engine N 3.2 3.2 - Cooling system: radiator 3 4 5 1 Horizontal coolant outlet union 12 Bolt 2 Pump/radiator hose 13 Special screw 3 Bolt 14 Clamp 4 Spacer 15 Radiator/thermostat hose 5 Rubber 16 Thermostat 6 Radiator cap 17 Clamp 7 Spacer 18 Thermostat/cylinder head hose...

  • Page 395: Removal Of The Radiator

    section Engine N 3.2 Removal of the radiator Operation Section reference Drain the cooling system Remove the side fairings Remove the battery support Loosen the clamps (14) on the coolant hoses (15) and (2); disconnect the hoses from the unions on the radiator (10). Loosen the clamp (A) and remove the expansion tank-radiator hose (B).
  • Page 396 section Engine N 3.2 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 Make a visual inspection of the radiator.

  • Page 397: Renewal Of The Cooling Fan

    section Engine N 3.2 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). When refitting the fan, tighten the bolts (8) to the specified torque (Sect. C 3). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 398: Refitting The Radiator

    section Engine N 3.2 Refitting the radiator Check that the rubber mountings (5) are present on the upper radiator brackets (10) and that the special screw (13) is fitted. Insert the support of radiator (10) on the pin (A) on the right-hand side of the frame and then fit the screw (3) with the spacer (4) on the left-hand side.
  • Page 399 section Engine N 3.2 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). Connect the expansion tank-radiator hose (B) to the inlet on the radiator cap and tighten the clamp (A) to the specified torque (Sect.

  • Page 400: Removal Of The Cooling System Hoses And Unions

    section Engine N 3.2 Removal of the cooling system hoses and unions Operation Section reference Drain the cooling system Remove the side fairings Remove the battery support Loosen the clamps (14) securing the hose (2) connecting the radiator (10) to the pump and the radiator/thermostat hose (15) to the thermostat (16).
  • Page 401 section Engine N 3.2 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 402 section Engine N 3.2 Disconnect the wiring connector (A) of the temperature sensor (21) on the horizontal cylinder head union (1) from the main wiring loom. Unscrew the bolts (12) and remove the horizontal cylinder union (1). Recover the O-rings (19) located between the union and the horizontal cylinder head. Important Periodically check the connection hoses for signs of leaks.

  • Page 403: Refitting The Cooling System Hoses And Unions

    section Engine N 3.2 Refitting the cooling system hoses and unions Install a seal (19) in the seat on the horizontal cylinder head union (1) and one in seat of the union (20). Fix the union (1) to the horizontal cylinder head (12) and tighten the bolts to the specified torque (Sect. C 3, Frame torque settings).
  • Page 404 section Engine N 3.2 Locate the thermostat (16) - thermostat/cylinder head hose (18) – thermostat/cylinder head hose (22) assembly with the clamps (14) and (17) and tighten the clamps to the specified torque (Sect. C 3, Frame tightening torques). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 405 section Engine N 3.2 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 tightening torques). Operation Section reference Refit the battery support Refit the side fairings Fill the cooling system WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 406: Cooling System: Water Pump

    section Engine N 3.3 3.3 - Cooling system: water pump 1 Bolt 2 Washer 3 Circlip 4 Washer 5 Outer bearing 6 Inner bearing 7 Spacer 8 Seal seat 9 Mechanical seal 10 Water pump impeller 11 Locating dowel 12 Water pump cover assembly 13 Bolt 14 Plug 15 Seal...

  • Page 407: Removal Of The Water Pump

    section Engine N 3.3 Removal of the water pump Operation Section reference Remove the side fairings Drain the cooling system Remove the cooling circuit hoses from the N 3.2 water pump cover. Remove the left-hand side crankcase cover Notes For clarity, the figures show the engine removed from the frame. Undo and remove the five screws (13) securing the water pump cover (12) to the left-hand side crankcase cover (16).
  • Page 408 section Engine N 3.3 Recover the ceramic washer (A) and seal ring (B) located on the inner side. Undo and remove the screws (1) with washer (2). Working from the impeller side, use a suitable drift to press on the inner race of the bearing (5) until it can be extracted from the cover.
  • Page 409 section Engine N 3.3 Working from the inside of the cover, remove the seat (8) of the mechanical seal (9). Remove the inner spacer (7). Check the condition of the components of the mechanical seal: there should be no signs of deformation, cracking, or excessive wear.

  • Page 410: Refitting The Water Pump

    section Engine N 3.3 Refitting the water pump Clean the seat in the cover, any parts you intend to reuse, and the impeller shaft. Lubricate with engine oil and refit as follows. Use drift part no. 88713.0869 to install the new mechanical seal (9) on the impeller shaft. 88713.0869 Working from the inside of the cover, fit the inner spacer (7) with its square edge (A) facing outwards.
  • Page 411 section Engine N 3.3 Fit the two screws (1) with washer (2) and tighten them to the specified torque (Sect. C 3). Turn over the cover and use drift part no. 88713.0870 to install the seal seat (8), oriented as shown in the figure, fully home against spacer (7).
  • Page 412 section Engine N 3.3 Fit the seal ring (B) and the ceramic washer (A). Insert the impeller shaft (10) with the mechanical seal (9). Turn the cover over. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 413 section Engine N 3.3 Insert the impeller shaft (10) with the mechanical seal. Turn the cover over. Fit the spacer (4), positioned as shown in the cross-sectional view, and secure with the circlip (3). Rotate the impeller (5) and make sure it turns smoothly without sticking. Clean the mating surfaces thoroughly on the pump cover and on the left-hand side crankcase cover.
  • Page 414 section Engine N 3.3 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 left-hand side crankcase cover. Start the screws (13) in their threads. Tighten the screws (13) to the specified torque (Sect.
  • Page 415 section Engine N 4.1 4.1 - Cylinder head assemblies: checks and adjustments 1 Closing shim 2 Intake side camshaft 3 Opening shim 4 Exhaust side camshaft 5 Valve Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.

  • Page 416: Checking And Adjusting The Valve Clearances

    section Engine N 4.1 Checking and adjusting the valve clearances Operation Section reference Remove the side fairings Remove the radiator N 3.2 Remove the fuel tank/seat cowling assembly Remove the airbox Remove the timing belts N 4.2 Remove the rocker cover N 4.4 Notes For clarity, the figures show the engine removed from the frame.
  • Page 417 section Engine N 4.1 Checking the closing clearance Using a feeler gauge, check the clearance between the closing rocker arm shoe and the upper edge of the camshaft cam, taking care not to compress the rocker arm return spring. The clearance must be within the specified limits (Sect. C 1.1). If it is not, remove the closing shim, as described in the paragraph “Valve disassembly”...

  • Page 418: Checking Valve Lift

    section Engine N 4.1 Checking valve lift Put the engine in the condition described in “Checking and adjusting the valve clearances” above. Install the dial gauge stand (E) 88765.1518 on the intake side camshaft bearing studs, and secure it with the knobs (F). 88765.1518 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.
  • Page 419 section Engine N 4.1 Refit all parts by carrying out the operations described under “Checking and adjusting the valve clearances” above. Refit the components removed in the procedure. Operation Section reference Refit the timing belts N 4.2 Refit the rocker cover N 4.4 Refit the airbox Refit the fuel tank/seat cowling assembly E 3...
  • Page 420 section Engine N 4.1 Checking the engine timing Operation Section reference Remove the side fairings Remove the radiator N 3.2 Remove the fuel tank/seat cowling assembly Remove the airbox Remove the timing belts N 4.2 Remove the rocker cover N 4.4 Remove the water pump cover N 3.3 Put the engine in the condition described in “Checking and adjusting the valve clearances”...
  • Page 421 section Engine N 4.1 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. Refit the belts and tension them as described in Sect. N 4.2. Turn the degree wheel (L) counterclockwise until the dial gauge (H) on the exhaust side reads a lift of 1 mm.
  • Page 422 section Engine N 4.1 Remove all tools installed for the timing check and tension the belts to their prescribed operating tension, as described in Sect. D 5. If the values obtained are outside the specified ranges (Sect. C 1.1), loosen the timing pulley bolts (M) and correct the value by using the wrench supplied with service tool part no.

  • Page 423: Cylinder Head Assemblies: Timing

    section Engine N 4.2 4.2 - Cylinder head assemblies: timing 1 Vertical cylinder timing belt cover 13 Idler pulley assembly 2 Air filter 14 Timing belt 3 Horizontal cylinder timing belt cover 15 Nut 4 Bolt 16 Key 5 Filter cover 17 Spacer 6 Bolt 18 Camshaft pulley...

  • Page 424: Removal Of The Timing Belt Covers

    section Engine N 4.2 Notes For clarity, the figures show the engine removed from the frame. To work with the engine installed, first proceed as follows: Operation Section reference Remove the side fairings Disconnect the electrical system components on right-hand side of the engine Notes Remove also any parts which may impede the procedure in any way.

  • Page 425: Removal Of The Tensioner Pulley/Timing Belt

    section Engine N 4.2 Removal of the tensioner pulley/timing belt Loosen the nut (8) and remove 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 426: Removal Of The Tensioner And Idler Pulley Mounting Studs

    section Engine N 4.2 Removal of the tensioner and idler pulley mounting studs Using service tool no. 88713.1821, remove the mounting studs (12) from the cylinder heads. 88713.1821 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 427: Disassembly Of The Camshaft Pulleys

    section Engine N 4.2 Disassembly of the camshaft pulleys Undo and remove the bolts (22). Slide off the washer (23). Withdraw the camshaft pulley (11) from the spacer flange (24). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 428: Removal Of The Timing Belt Driveshaft Pulleys

    section Engine N 4.2 Removal of the timing belt driveshaft pulleys Using service tool no. 88713.1805 hold the driveshaft pulleys against rotation Important If this operation is carried out with the engine installed in the frame, hold the driveshaft pulleys against rotation using service tool part 88713.2011 on the left-hand crankcase cover.
  • Page 429 section Engine N 4.2 Remove the inner spacer (17) and second Woodruff key (16) on the timing belt driveshaft. At this point it is possible to remove the circlip (10) located on the timing belt driveshaft. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 430: Refitting The Timing Belt Driveshaft Pulleys

    section Engine N 4.2 Refitting the timing belt driveshaft pulleys 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. Fit the first Woodruff key (16) on the timing belt driveshaft.
  • Page 431 section Engine N 4.2 Refit the second Woodruff key (16) and the washer (19). 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 timing belt pulleys on reassembly.
  • Page 432 section Engine N 4.2 Refitting the idler and tensioner pulley mounting studs Apply the recommended threadlocker to the threads of the studs To fit the studs correctly on the cylinder heads, note the references of the parts given in the photographs. Insert the idler and tensioner pulley mounting studs (12) in the cylinder heads and tighten them using service tool no.

  • Page 433: Reassembly Of The Timing Pulleys

    section Engine N 4.2 Reassembly of the timing pulleys Fit the pulley (11) on the hub (24), aligning the timing mark (D) on the pulley with the timing mark on the (E) on the hub. Install the washer (23) up aginst the pulley, aligning the timing notch (F) with the timing marks on the pulley and the hub. Insert the three bolts (22) in the threaded holes (G) of the hub.

  • Page 434: Refitting The Camshaft Pulley/Idler Pulley

    section Engine N 4.2 Refitting the camshaft pulley/idler pulley Check that the keyway on the end of the camshaft is in good condition and without burrs. Fit a Woodruff key 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.
  • Page 435 section Engine N 4.2 Install service tool no. 88713.1806 on the pulley to hold it against rotation. Apply the recommended grease to the mating face of the nut (21). Fit the nut (21). Carry out the same operations on the other camshaft. Important Always fit new nuts on reassembly.
  • Page 436 section Engine N 4.2 Unscrew the bolts (22) holding the pulleys, turning them anti-clockwise through 90° ± 5°. Check that the pulleys have no endfloat and can rotate freely at all points along the full length of the slots. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 437: Refitting The Timing Belts

    section Engine N 4.2 Refitting the timing belts Turn the pulleys on the timing belt driveshaft until the timing mark on the outer roller is aligned with the mark on the clutch cover. In this condition, the horizontal cylinder piston will be at top dead center. Install service tool no.
  • Page 438 section Engine N 4.2 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) on the mounting studs on the two cylinder heads.

  • Page 439: Refitting The Timing Covers

    section Engine N 4.2 Once the belts are correctly tensioned, ensure that the nuts (8) securing the tensioner pulleys (9) and the bolts (22) are tightened to the specified torque (Sect. C 3). Remove the camshaft holding tool no. 88765.1524 and crankshaft holding tool no. 88713.2011. 88765.1524 Refitting the timing covers Locate the horizontal cylinder timing cover (3) and secure it in place with bolts (4).

  • Page 440: Cylinder Head Assemblies: Camshafts

    section Engine N 4.4 4.4 - Cylinder head assemblies: camshafts 27 1 11 2 22 23 1 Cylinder head 15 Horizontal cylinder intake camshaft 2 Stud bolt 16 Plug 3 Special screw 17 Oil seal 4 Seal 18 Vertical cylinder exhaust camshaft 5 Horizontal cylinder head rocker cover 19 Key 6 Vertical cylinder head rocker cover...

  • Page 441: Removal Of The Camshafts

    section Engine N 4.4 Removal of the camshafts Operation Section reference Remove the engine from the frame Remove the timing belt covers, the timing N 4.2 belts and timing belt pulleys Remove the engine lubrication system N 2.1 Remove the coils Unscrew and remove the screws (7) in the rocker covers.
  • Page 442 section Engine N 4.4 Undo 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). Remove the exhaust camshaft (14) and the intake camshaft (15), and slide off the seal rings (17) on their ends. Repeat the same procedure for the other cylinder head.

  • Page 443: Checking The Camshafts And Supports

    section Engine N 4.4 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 using two dial gauges. Service limit: 0.1 mm.

  • Page 444: Refitting The Camshafts

    section Engine N 4.4 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 stud bolts (2) to the specified torque (Sect. C 3, engine tightening torques). LOCK Check that the camshafts (marked “VA”...
  • Page 445 section Engine N 4.4 Lubricate with the specified lubricant (Molycote M55 Plus), the camshaft seats on both the cylinder head and the supports (22) and (23) (green zone). Fill the reservoirs (A) with lubricant (Molycote M55 Plus). 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.
  • Page 446 section Engine N 4.4 Install the camshafts (14) and (15) in the cylinder head, and rotate them to distribute the lubricant evenly. Check that the locating dowels (11) are present. Fit the supports (22) and (23) to the cylinder head, checking that the number stamped in zone (B) of the cylinder head is the same as the number stamped in zone C (C) of the supports.
  • Page 447 section Engine N 4.4 Tighten the bolts (3) to the specified torque (Sect. C 3, engine tightening torques). Pre-tighten one support at a time, working in the sequence 1-2-3-4-5-6-7-8. Then tighten the bolts to the specified torque (Sect. C 3, engine tightening torques). Tighten one support at a time, working in the sequence 1-2-3-4-5-6-7-8.
  • Page 448 section Engine N 4.4 When correctly installed, the oil seal should be flush with the bevel of the cylinder head bore. Rocker cover Apply sealant (Three Bond 1215 liquid gasket) at the four points of the rocker cover shown in red in the photo. Fit the gaskets (4) and (9) on the rocker cover, as shown in the figure.
  • Page 449 section Engine N 4.4 Rocker cover identification: the vertical head rocker cover (6) has a nib (A) on the left-hand side (exhaust side), whereas rocker cover (5) has a nib (B) on the right-hand side (exhaust side). Locate the cover (6) on the cylinder head, aligning the four fixing holes. Install the four washers (8) in the cover fixing holes, with the rubber sides facing the cover.
  • Page 450 section Engine N 4.4 Removal of the intake manifold and coolant union Operation Section reference Remove the side fairings Remove the radiator N 3.2 Remove the fuel tank/seat cowling assembly Remove the airbox Remove the manifolds (25) by undoing the bolts (21). Loosen the clamp (A) and remove the hose (B).

  • Page 451: Refitting The Intake Manifold And Coolant Union

    section Engine N 4.4 Refitting the intake manifold and coolant union Apply the recommended threadlocker to the union (12), fit it with seal (24) and tighten to the specified torque (Sect. C 3, Engine tightening torques). Refit the hose (B) and tighten the clamp (A) to the specified torque (Sect. C 3, Engine tightening torques). LOCK 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.

  • Page 452: Cylinder Head Assemblies: Valves-Rocker Arms

    section Engine N 4.5 4.5 - Cylinder head assemblies: valves–rocker arms 19 17 1 17 19 12 15 9 13 9 10 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...

  • Page 453: Removal Of The Cylinder Heads

    section Engine N 4.5 Removal of the cylinder heads Operation Section reference Remove the engine from the frame Remove the coolant hoses N 3.2 Remove the timing belt covers and the N 4.2 timing belts Remove the engine lubrication system N 2.1 Using service tool no.

  • Page 454: Removal Of The Valves

    section Engine N 4.5 Removal of the valves Operation Section reference Remove the cylinder head assembly from N 4.5 the engine Remove the timing belt pulleys N 4.2 Remove the camshafts N 4.4 Raise the rocker arm (3) and remove the opening shim (5) from the valves with a pair of pliers (A). Push down the closing rocker arms (16) and (4) and the closing shim (7).

  • Page 455: Removal Of The Valve Rocker Arms

    section Engine N 4.5 Removal of 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). Using an M5 bolt, withdraw the shafts (2) of the opening rocker arms (3) on the exhaust and intake sides. Remove the opening rocker arms (3).
  • Page 456 section Engine N 4.5 Using accessory (C) 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. Use the shaft to slide the end of the spring into its final position.
  • Page 457 section Engine N 4.5 Remove the closing rocker arms (4) and (16), the springs (18) and (19) with the spacers (17). Remove the seal rings (8) from the ends of the valve guides. Repeat the same procedure for the other cylinder head. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 458: Overhaul Of Cylinder Head Components

    section Engine N 4.5 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 459 section Engine N 4.5 Valve seat Visually inspect the valve seats: for cracking or pitting. 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 460 section Engine N 4.5 Heat the cylinder head gradually and evenly up to 150 °C and chill the new valve seats in dry ice. Drive the seats perfectly square into the head bores using the appropriate valve guide seat installer 88713.2846 and 88713.2847. Allow the cylinder head to cool down and grind the seats to the following dimensions: CA = Ø41.6±...
  • Page 461 section Engine N 4.5 Valve guides 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. The assembly clearance must be: highest measured value –...
  • Page 462 section Engine N 4.5 Checking the valve Check that the stem and the surface that contacts the valve seat 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 463 section Engine N 4.5 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. Checking the valve seal After grinding the seats it is important to check the seal between the valve face and the seat: if the seat contact area (S) on the valve is wider than the 45°...
  • Page 464 section Engine N 4.5 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 465 section Engine N 4.5 Reassembly of the cylinder head Notes The cylinder heads are identical. Only the definition of the intake and exhaust side determines whether they are to be installed on the vertical or horizontal cylinder. 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.
  • Page 466 section Engine N 4.5 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 M5 bolt, position the closing rocker shaft (1) towards the exhaust side of the cylinder head.
  • Page 467 section Engine N 4.5 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. Load the springs (18) and (19) on the closing rocker arms (16) and (4) respectively using service tool no. 88713.2069. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 468 section Engine N 4.5 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). Notes Always install the closing rocker arms on the exhaust side before those on the intake side. Warning Take care not to damage the shoe of the closing rocker arm with the intake spring during assembly.
  • Page 469 section Engine N 4.5 Insert the new half rings (6) and release the rocker arm to ensure that they seat inside the shim (7). To ensure the half-rings are seated in the shim, tap the end of the rocker arm (16) with a rubber mallet. 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);...
  • Page 470 section Engine N 4.5 Refitting the opening shims and opening rocker arms Using an M5 bolt, position the opening rocker arm shaft (2) (diameter 9 mm). 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.
  • Page 471 section Engine N 4.5 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 4.2) to check the valve opening clearances (Sect. N 4.1). Apply the recommended threadlocker to the plugs (12).
  • Page 472 section Engine N 4.5 Fitting the cylinder head assemblies Before fitting the cylinder head, check that gasket is in position on the mating surface between the head and cylinder (Sect. N 5). Notes When fitting the gasket, side (E) with the stamped code must be in contact with the cylinder head. Lower the cylinder head carefully over the studs.
  • Page 473 section Engine N 4.5 Tighten down the nuts (21) on the studs in the sequence 1-3-2-4 using service tool no. 88713.2676 combined with a torque wrench. Pre-tighten and tighten the cylinder head nuts (21) to the specified torque (Sect. C 3). 88713.2676 Operation Section reference...

  • Page 474: Cylinder/Piston Assemblies

    section Engine 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 Bush...

  • Page 475: Disassembly Of The Cylinder/Piston

    section Engine Disassembly of the cylinder/piston Loosen the clamps (7) and remove the hoses (8) and (9) from the cylinder barrels (10) and from the left-hand crankcase cover. Unscrew the unions (6). Notes This operation is described with the engine removed from the frame and the cylinder head removed (Sect. N 4.5). Remove the cylinder head gasket (11) from the cylinder barrel.
  • Page 476 section Engine Remove the locating dowels (12). Use tool no. 88765.1523 to bring the piston of the horizontal cylinder to TDC. 88765.1523 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 477 section Engine 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 478 section Engine Overhaul of the cylinder barrel/piston components Overhauling the cylinder Check that the walls are perfectly smooth. Measure the cylinder bore diameter at 50 mm from the top surface and determine the size class to which it belongs in accordance with the values specified in Sect. C 1.1. Measure the bore diameter again at three different heights A, B and C and at positions offset by 90°;...
  • Page 479 section Engine Overhauling the piston Clean the piston crown and piston ring grooves of 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 480 section Engine 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 481 section Engine Checking the piston ring-grooves clearance The maximum permissible wear limit is 0.15 mm for the top compression ring (1 ) and 0.10 mm for the others (2 and oil control ring). The markings punched on the piston rings must always be facing upwards. compression ring compression ring Oil control ring...
  • Page 482 section Engine 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 483 section Engine Refitting the cylinder/piston assembly If you are using new cylinders and pistons, match cylinders with pistons from the same class (see “Overhauling 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 484 section Engine 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. 88713.1920 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 485 section Engine 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 486 section Engine Fit the cylinder head gasket (11) over the studs. The side marked with the part number must be facing the head. Notes The shape prevents incorrect fitting of the gasket, provided that the coolant flow holes are aligned with those on the cylinder. Repeat the procedure for the other cylinder and refit the cylinder heads (Sect.

  • Page 487: Clutch Assembly: Clutch

    section Engine N 6.1 6.1 - Clutch assembly: clutch 5 20 16 15 1 Clutch spring 13 Clutch drum 2 Collar 14 Bearing 3 Clutch lifter 15 O-ring 4 Bolt 16 Spacer 5 Lock washer 17 O-ring 6 Cush drive rubber 18 Nut 7 Cush drive hub 19 Locating dowel...

  • Page 488: Description

    section Engine N 6.1 Description The clutch is disengaged by a slave cylinder consisting of a piston (1) housed inside a cylinder mounted to the left-hand crankcase cover. This piston (1) moves a pushrod (2), which runs through gearbox input shaft and operates the pressure plate (3) located on top of the clutch plate pack (4).
  • Page 489 section Engine N 6.1 Disassembly of the clutch Operation Section reference Remove the side fairings Notes For clarity, the figures show the engine removed from the frame. Undo the four retaining bolts (23) and the two retaining bolts (24) from the clutch cover (22). Remove the cover and the sound deadening gasket (21).
  • Page 490 section Engine N 6.1 Unscrew the retaining bolts (4) and remove the collars (2) and the clutch springs (1). Remove the pressure plate (12). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 491 section Engine N 6.1 Remove the clutch lifter (3) and its O-ring (17) using a suitable drift and a plastic headed mallet. Then remove the bearing (14) installed from inner side of the pressure plate (12) using a drift of suitable size. Notes Once disturbed, the bearing must be renewed.
  • Page 492 section Engine N 6.1 Restrain the clutch centre (10) using service tool 88713.2133 and remove the centre nut (18). 88713.2133 Remove the washer (5), bush (20) and thrust washer (9). Remove the clutch centre (10) complete with the cush drive rubbers from the shaft. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 493 section Engine N 6.1 When renewing the cush drive rubbers (6), use a drift to remove the hub (7) from the clutch centre (10) and overcome the resistance of the rubbers. Slide off the spacer (16), taking care not to damage its internal O-ring (15). Visually check the O-ring for wear and renew it if necessary.
  • Page 494 section Engine N 6.1 Inspection and overhaul of the clutch components Checking the clearance between the clutch drum and the friction plates Insert the friction plate (A) in the clutch drum (B) and measure tang-to-slot clearance (S) with a feeler gauge. The clearance “S”...
  • Page 495 section Engine N 6.1 Overhaul of the pressure plate Check the condition of the bearing: renew the bearing if the play is excessive. Check the contact surface of last plain steel plate. If extremely scored, polish it in the same manner as described previously for the cylinder head surface.

  • Page 496: Reassembly Of The Clutch

    section Engine N 6.1 Reassembly of the clutch Assemble the clutch drum to the primary drive gear. Apply threadlocker to the threads of the eight retaining bolts (11) and insert them into the gear. Important Use new bolts. Tighten the bolts (11) to the specified torque working in a crosswise pattern (Sect. C 3). Fit the spacer (16) to the gearbox input shaft along with the lubricated O-ring (15).
  • Page 497 section Engine N 6.1 Restrain the clutch centre with the service tool 88713.2133, grease the retaining nut and tighten it to the specified torque (Sect. C 3). 88713.2133 Fit the clutch plates (8) in the following order (see figure): - two plain plates (G) 1.5 mm thick; - one friction plate (H) 3 mm thick;...
  • Page 498 section Engine N 6.1 Insert the clutch lifter (3) in the bearing (14) of the pressure plate (12). Install the pressure plate (12) so that the mark on the end of one of the clutch spring posts is aligned with the marks on the corresponding pressure plate hole, indicated by the triangle.
  • Page 499 section Engine N 6.1 Locate the gasket (21) and the clutch cover (22) and then tighten the cover retaining bolts (24) and (23) to the specified torque (Sect. C 3). Operation Section reference Refit the side fairings WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 500: Clutch Assembly: Right-Hand Side Crankcase Cover

    section Engine N 6.2 6.2 - Clutch assembly: right-hand side crankcase cover 1 Locating dowel 2 O-ring 3 Plug 4 Oil level plug 5 Bolt 6 Ring 7 O-ring 8 Seal 9 Switch 10 Bush 11 Oil seal 12 Shim 13 Circlip 14 Right-hand side crankcase cover 15 Bolt...

  • Page 501: Removal Of The Right-Hand Side Crankcase Cover

    section Engine N 6.2 Removal of the right-hand side crankcase cover Operation Section reference Remove the side fairings Drain the engine oil Remove the clutch centre N 6.1 Notes For clarity, the figures show the engine removed from the frame. Undo and remove the six short bolts (5) and the long retaining bolts (15) and (19) from the crankcase cover (14).

  • Page 502: Disassembly Of The Right-Hand Side Crankcase Cover

    section Engine N 6.2 Disassembly of the right-hand side crankcase cover Remove the plug (3) and the O-ring (7), the engine oil pressure sensor (9) and the seal (8), the plug (16) and the seal (17) from the crankcase cover. Remove the circlip (13) and withdraw the shim (12) and the oil seal (11).

  • Page 503: Reassembly Of The Right-Hand Crankcase Cover

    section Engine N 6.2 To check the condition of the oil seal (6) installed in the rh crankcase cover between the clutch drum and primary drive gear, first remove the latter two components (Sect. N 6.1). Reassembly of the right-hand crankcase cover If the bush has been renewed, seat the new bush (10) in the crankcase cover using a suitable drift or a press.
  • Page 504 section Engine N 6.2 Fit the plug (3) and the seal (7). Fit the sensor (9) and the seal (8). Fit the plug (16) and the seal (17). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 505: Refitting The Right-Hand Side Crankcase Cover

    Apply a uniform continuous bead of DUCATI liquid gasket onto crankcase mating surfaces, working around all the holes. Lubricate the oil seal (6) with engine oil and fit the bush 88700.5665 onto the primary drive gear so as not to damage the seal while fitting the cover.
  • Page 506 section Engine N 6.2 Tighten the bolts (5), (15) and (19) to the specified torque (Sect. C 3) following the numbered sequence: Retaining bolts Type Qty. M6x25 hex socket bolts M6x65 hex socket bolts M6x70 hex socket bolts 88700.5665 Operation Section reference Refit the clutch drum, clutch centre and N 6.1...

  • Page 507: Clutch Assembly: Primary Drive Gears

    section Engine N 6.3 6.3 - Clutch assembly: primary drive gears 1 O-ring 2 Oil seal 3 Primary drive gears 4 Bearing 5 Circlip 6 Bearing 7 Spacer 8 Spacer 9 Spacer 10 Lock washer 11 Nut 12 Circlip Important Bold reference numbers in this section identify parts not shown in the figures alongside the text.

  • Page 508: Removal Of The Primary Drive Gears

    section Engine N 6.3 Removal of the primary drive gears Operation Section reference Remove the side fairings Remove the clutch drum, the clutch N 6.1 centre and the clutch plate pack Remove the right-hand side crankcase N 6.2 cover Notes For clarity, the figures show the engine removed from the frame.
  • Page 509 section Engine N 6.3 To renew the inner parts of the gear, use a suitable drift (A) and a support (B). After removing the oil seal (2), tap from the inside towards the exterior using part of the inner race of bearing (4) to be removed, after moving aside spacer (5) located between the two bearings.
  • Page 510 section Engine N 6.3 Fit the service tool no. 88713.2102 to the gear (D) and immobilise it by inserting a pin in one of the holes mounting the engine block to the frame. 88713.2102 Loosen the retaining nut (11) of the driving gear (D) using a socket wrench of suitable length. Remove the nut (11) and the lock washer (10).

  • Page 511: Refitting The Primary Drive Gears And Checking Backlash

    section Engine N 6.3 Refitting the primary drive gears and checking backlash Carefully degrease the splined end of the crankshaft and the corresponding internal splines of the primary gear. Fit the inner spacer (9) to the shaft with its flat side facing outwards. Fit gear (D) onto the crankshaft with oil pump drive sprocket facing the crankcase.
  • Page 512 section Engine N 6.3 If fitting a new primary drive gear pair (3), check the backlash. Temporarily fit the gear (C) complete with the bearings and the oil seal onto the gearbox input shaft and fix a dial gauge on the crankcase;...
  • Page 513 section Engine N 6.3 Refit the oil pump and check the backlash between the oil pump gear and primary drive gear on the crankshaft (Sect. N 2.3). Operation Section reference Refit the right-hand crankcase cover N 6.2 Refit the clutch drum, clutch centre and N 6.1 the clutch plate pack Refit the side fairings...

  • Page 514: Gearbox Assembly: Gearchange Mechanism

    section Engine N 7.1 7.1 - Gearbox assembly: gearchange mechanism 1 Return spring 15 Selector drum control fork 2 Washer 16 Gearchange lever pin 3 Special screw 17 Shaft with gearchange lever arm 4 Gear pawl assembly 18 Gearchange lever arm return spring 5 Interlock plunger holder 19 Bolt 6 Seal...
  • Page 515 section Engine N 7.1 Removal of the gearchange mechanism Operation Section reference Remove the alternator cover and flywheel/ alternator assembly Remove the right-hand crankcase cover N 6.2 complete with clutch drum and primary drive gear Undo and remove the bolts (18) and (20) securing the gearchange mechanism (25). Remove the gearchange mechanism complete with the shaft, spring, and stop plate.
  • Page 516 section Engine N 7.1 Important Visually inspect the gear selector claw (14) for wear, particularly around the area where it contacts the selector drum. If it is necessary to renew any components, disassemble the gearchange mechanism 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 517: Disassembly Of Gear Interlock Plunger And Pawl Assembly

    section Engine N 7.1 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 rh crankcase half bolt (3) and remove the pawl (4), washer (2) and spring (1). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 518: Refitting The Gear Interlock Plunger And Pawl Assembly

    section Engine N 7.1 Refitting the gear interlock plunger and pawl assembly Fit the pawl (4), washer (2) and spring (1) on the retaining bolt (3). Fit the assembled unit on the right-hand crankcase half, locating the end of spring (1) behind the crankcase rib. Tighten the bolt (3) to the specified torque (Sect.

  • Page 519: Refitting The Gearchange Mechanism

    section Engine N 7.1 Refitting the gearchange mechanism Locate the gearchange mechanism (25) with the shaft, spring, and stop plate, on the chain-side crankcase half. 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 520 section Engine N 7.1 Then tighten the retaining bolts (18) and (20) of the gear selector mechanism to the specified torque (Sect. C 3). With the gearbox in neutral, check that the lever travel is the same when shifting up and down. The same should apply when a gear is engaged.

  • Page 521: Gearbox Assembly: Gearbox Shafts

    section Engine N 7.2 7.2 - Gearbox assembly: gearbox shafts Gearbox input shaft Gearbox output shaft 1 Shim, thickness 1 18 1 speed driven gear 2 Gearbox input shaft 19 Shim, thickness 1 3 Shim, thickness 0.5 20 5 speed driven gear 4 Needle roller bearing 21 4 speed driven gear...

  • Page 522: Removal Of The Gearbox Assembly

    section Engine N 7.2 Removal of the gearbox assembly Operation Section reference Remove the engine from the frame Separate the crankcase halves N 9.2 Withdraw the selector fork shafts (30). Move the forks (28) and (29) to disengage them from the slots in the selector drum (34). Withdraw the selector drum (16) taking care not to lose shims (31) and (27) mounted on the shaft.
  • Page 523 section Engine N 7.2 Now you can renew the needle roller retaining ring (32) and the special needle rollers (33). Remove gear selector forks (29) and (28). Remove the gearbox input (2) and output (25) shafts complete with gears, taking care to recover the spacers on the ends of the shafts.

  • Page 524: Disassembly Of The Gearbox Shafts

    section Engine N 7.2 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. Disassembly of the gearbox output shaft Remove the chain-side shim (15) and the clutch-side shim (26) from the output shaft.
  • Page 525 section Engine N 7.2 Use two flat screwdrivers to remove the circlip (7) taking care not to damage the shaft surface. Remove the circlip (7) and the splined washer (6). 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).
  • Page 526 section Engine N 7.2 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). Disassembly of the gearbox input shaft Remove the chain-side shim (11) and the clutch-side shim (1) from the input shaft.
  • Page 527 section Engine N 7.2 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 528 section Engine N 7.2 Remove the circlip (7) and the splined washer (6). Remove the fifth speed driving gear (5) with the roller cage (4). Slide the shim (3) off the input shaft (2). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 529: Overhaul Of The Gearbox

    section Engine N 7.2 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. When refitting, make sure the circlips are correctly positioned.

  • Page 530: Inspection Of The Gear Selector Forks

    section Engine N 7.2 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 531: Inspection Of The Gear Selector Drum

    section Engine N 7.2 Inspection of the gear selector drum Use a gauge to measure the clearance between fork pin and the slot on the selector drum. If the service limit is exceeded, determine which part must be changed by comparing dimensions with those of new components (Sect.

  • Page 532: Reassembly Of The Gearbox Shafts

    section Engine N 7.2 Reassembly of the gearbox shafts Figure 1 shows all the parts to be reassembled on the gearbox input shaft (2), with the calculated shims (1) and (11) (Sect. N 9.2). Fig. 1 Figure 2 shows all the parts to be reassembled on the gearbox output shaft (25), with the calculated shims (15) and (26) (Sect.
  • Page 533 section Engine N 7.2 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 and 4 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 534 section Engine N 7.2 Fit the 3 speed gear (22). 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 speed gear (21).
  • Page 535 section Engine N 7.2 Fit another 3-pointed washer (6) and another circlip (7) onto the shaft. Seat the circlip using the drift used previously. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...

  • Page 536: Reassembly Of The Gearbox

    section Engine N 7.2 Reassembly of the gearbox To reassemble the gearbox components, follow the procedure in Sect. N 9.2 relating to reassembly of the engine crankcases. As a final practical test, ensure that with the gearbox in neutral the front coupling dogs (A) of sliding gears (B) are equidistant on both sides with respect to the corresponding coupling dogs on the fixed gears (C).

  • Page 537: Flywheel/Alternator

    section Engine 8 - Flywheel/alternator 32 31 1 Bolt 18 Washer 2 Cylinder coolant inlet union 19 Inner ring 3 Ignition inspection plug 20 Needle roller bearing 4 Oil seal 21 Electric starter driven gear 5 O-ring 22 Starter clutch 6 Cover 23 Flywheel-starter clutch assembly 7 Bolt...

  • Page 538: Removal Of The Left-Hand Side Crankcase Cover

    section Engine Removal of the left-hand side crankcase cover Operation Section reference Remove the front sprocket cover Drain the engine oil Remove the clutch pushrod F 10 Remove the pump-cylinder hoses Remove the water pump-radiator hose N 3.3 Notes This operation is described for an engine removed from the frame since all reassembly procedures are easier with the engine on the bench.
  • Page 539 section Engine Unscrew the left-hand crankcase cover bolts (1), (11), (12) and (13). Fix service tool 88713.1749 to the holes of the two bolts (7) you have just removed. Turn the tool shaft slowly to remove the cover (29) from the LH crankcase half. 88713.1749 On the cover in correspondence with the gearchange shaft, there is an oil seal (4) that may be damaged when removing the crankcase cover.

  • Page 540: Disassembly Of The Left-Hand Crankcase Cover

    section Engine Disassembly of the left-hand crankcase cover Undo the three stator retaining bolts (25) and the two cable guide bracket (31) retaining bolts (32) from inside the lh crankcase cover. Remove the stator (33) and the cable guide (31). The lh crankcase cover is fitted with a bearing (27), held in place by circlip (28), which locates on the end of the crankshaft.

  • Page 541: Removal Of The Flywheel/Alternator Assembly

    section Engine Removal of the flywheel/alternator assembly Use the service tool no. 88713.2874 fixed on the M10 sidestand fixing holes (D). Secure the tool to the flywheel with the bolt (E). Unscrew the alternator/flywheel retaining nut (15). Warning While unscrewing the nut, apply axial pressure to the wrench socket to avoid damage or injury in the event of the wrench suddenly slipping off the nut.
  • Page 542 section Engine Remove the inner ring (19), the needle roller bearing (20) and the washer (18). Important Check the bush (19), the needle roller bearing (20) and the inner washer (18) for wear. Renew if worn. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 543 section Engine 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. If there is any malfunction, remove the whole assembly.
  • Page 544 section Engine Insert two of the bolts (26) just removed from the flywheel rotor-side in their holes in order to remove the flange (14) and the starter clutch (22) from the flywheel (17). The starter clutch is a slight interference fit on the flange. To remove it, use a suitable drift. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 545 section Engine 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 546 section Engine 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 547 section Engine Important Assemble the components (flange and flywheel) so that edge (A) of the starter clutch (22) is enclosed between the flange and flywheel. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 548 section Engine Install the rotor (24) on the flywheel (17), aligning the flywheel locating hole (D) with the rotor locating hole (G). Notes The flywheel locating hole (D) of the flywheel is the hole that was previously aligned with the flange locating hole (C), i.e. the hole with the countersunk lead-in (E).
  • Page 549 section Engine Tighten the bolts (26) to the specified torque (Sect. C 3, Engine torque settings) in the indicated sequence. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 550 section Engine Lubricate the surface (L) of the driven gear (21) with engine oil. Install the driven gear in the starter clutch, ensuring it is properly seated. Notes To facilitate installation, rotate the driven gear in the direction of the green arrow. Hold the flywheel (17) with one hand and check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow.
  • Page 551 section Engine Refitting the flywheel/alternator assembly 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. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 552 section Engine Fit the Belleville washer (16) on the end of the crankshaft. Warning The Belleville washer is tapered: position it as shown in the photo. Apply the recommended threadlocker to the thread on the end of the crankshaft and the nut (15). Start the nut (15) on the crankshaft.

  • Page 553: Refitting The Left-Hand Crankcase Cover

    Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the cover. Fit the two locating dowels (30). Spread a continuous uniform bead of DUCATI liquid gasket on the cover mating surface, ensuring continuity around the holes for the retaining screws and bushes.
  • Page 554 section Engine Insert the retaining bolts in their holes following the indications given in the table. Ref. Qty. Description M6x25 mm bolts M6x20 mm bolts M6x30 mm bolts M6x25 mm drive-lock bolt Under the bolt (11), located in correspondence with the starter motor, fit the washer (10) and hose/wiring clip (9). Tighten the retaining bolts to the specified torque (Sect.
  • Page 555 section Engine Apply threadlocker to the bolts (7). Tighten the two retaining bolts (7) of the centre cap (6) over the end of the crankshaft to the specified torque (Sect. C 3). Reconnect the alternator wiring to the main wiring loom (A). Operation Section reference Refit the water pump-radiator hose...

  • Page 556: Crankcase Assembly: External Components

    section Engine N 9.1 9.1 - Crankcase assembly: external components 1 Oil breather valve 15 Key 2 O-ring 16 Bolt 3 Seal 17 Bolt 4 Neutral switch 18 Washer 5 Cylinder barrel/head stud 19 Starter idler gear 6 Nipple 20 Washer 7 By-pass spring 21 Gear shaft 8 Nipple...
  • Page 557 section Engine N 9.1 Removal of external components Operation Section reference Remove the engine from the frame Remove the lubrication system N 2.1 Remove the oil filter cartridge Remove the cylinder head assemblies and N 4.2 the timing parts Remove the cylinder barrel/piston assemblies Unscrew the bolt (17) and remove the oil breather valve (1) with the O-rings (2).
  • Page 558 section Engine N 9.1 Unscrew and remove the oil filter support nipple (6) and remove also by-pass spring (7). Remove the mesh filter (A) with its seal from the right-hand crankcase half (Sect. D 4). Remove the drain plug (10) with its seal (9). Remove the neutral switch (4) with its seal (3).
  • Page 559 section Engine N 9.1 Remove the cylinder head studs (5) with the aid of the appropriate tool. To remove the engine sensor (23), unscrew the bolt (25) and recover the shim (24) and the washer (26). Check the condition of O-rings (22) and renew them if necessary. If the engine sensor is to be renewed, it will be necessary to check the air gap as indicated in the paragraph “Checking the engine sensor air gap”.
  • Page 560 section Engine N 9.1 Refitting the external components Grease the engine sensor (23) in the part indicated. Fit the engine sensor (23) in its seat in the crankcase. Position the 0.6 mm thick shim (24). Insert the bolt (25) with washer (26) and tighten to the specified torque (Sect. C 3, Engine torque settings). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 561 section Engine N 9.1 Use a feeler gauge to check the clearance between the engine sensor (23) and the timing gear (13). The values must be between 0.6 and 0.8 mm. Notes If the gap is incorrect, loosen the screw (25) of the engine sensor and replace the shim (24) with one of suitable thickness (paragraph “Checking the engine sensor air gap”).
  • Page 562 section Engine N 9.1 Locate the by-pass spring (7) and screw in the nipple (6) that supports the oil filter cartridge, tightening to the specified torque (Sect. C 3). Fit the drain plug (10) with its seal (9) and tighten to the specified torque (Sect. C 3) applying the specified threadlocker. LOCK Refit the neutral switch (4) with seal (3).
  • Page 563 section Engine N 9.1 Install the studs (5) in the crankcase, applying thread locker and tightening to the specified torque value (Sect. C 3). Use the appropriate commercial tool for this operation. LOCK Operation Section reference Refit the cylinder barrel/piston assemblies N 5 Refit the cylinder head assemblies and the N 4.2 timing parts...

  • Page 564: Removal Of The Timing Gears

    section Engine N 9.1 Removal of the timing gears Operation Section reference Remove the left-hand crankcase cover and alternator assembly Slide out driving gear (A) of timing gear pair (13) and remove the Woodruff key (14). Relieve the staking on the lock washer (12) of the nut (11). Restrain the driven timing gear by inserting a pin (C) in one of the holes, and unscrew the nut (11).

  • Page 565: Refitting The Timing Gears

    section Engine N 9.1 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 566: Removal Of The Starter Motor Idler Gear

    section Engine N 9.1 Removal of the starter motor idler gear Operation Section reference Remove the left-hand crankcase cover and alternator assembly Unscrew the bolt (16) and remove the idler gear (19) with the washers (18) and (20) and the shaft (21). It is now possible to remove the starter motor as described in Sect.
  • Page 567 section Engine N 9.1 Refitting the starter motor idler gear Refit the idler gear assembly (19), bolt (16), washers (18) and (20) and shaft (21) as indicated. Notes Apply the prescribed threadlocker to the bolt (16) and tighten to the specified torque. LOCK Operation Section reference...
  • Page 568 section Engine N 9.1 Checking the engine sensor air gap If either the alternator or the engine sensor has been renewed, the sensor air gap must be checked as described below. Operation Section reference Remove the left-hand fairing Remove the plug (B) from inspection hole in the left-hand crankcase cover. Insert a feeler gauge (A) through the hole, positioning it between the end of sensor (23) and the teeth of timing belt driveshaft gear.

  • Page 569: Crankcase Assembly: Crankcase Halves

    section Engine N 9.2 9.2 - Crankcase assembly: crankcase halves 14 15 1 Bearing 18 Bearing 2 Bearing shell 19 Bearing 3 Crankcase half - front 20 Bolt 4 Bearing 21 Spacer 5 Circlip 22 Bush 6 Washer 23 Bearing 7 Bearing 24 Bolt (M6x35) 8 Oil seal...
  • Page 570 section Engine N 9.2 Separation of the crankcase halves Operation Section reference Remove the engine from the frame Remove the lubrication system N 2.1 Remove the cooling system N 3.2 Remove the cylinder head assemblies and N 4.2 the timing parts Remove the cylinder barrel/piston assemblies Remove the left-hand crankcase cover...
  • Page 571 section Engine N 9.2 Unscrew the two bolts (12) and (25) on the right-hand side near the vertical cylinder. Re-use the left-hand crankcase cover or a service cover with puller 88713.1749. Secure it to the crankcase half using some of the original screws and begin separating the crankcase halves by turning the central pin of the tool.
  • Page 572 section Engine N 9.2 Remove the gear shafts and gear selector drum from the crankcase halves as described in Sect. N 7.2. Drive out the crankshaft (L) using a plastic mallet, taking care not to lose the shims. Remove the timing belt driveshaft (30). Remove the bolts (34), remove the hoses (33) and recover the O-rings (32).
  • Page 573 section Engine N 9.2 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 bearings (1) and (18) and bushes (2) and (17) are in perfect condition. Note that main bearings must always be changed in pairs (refer to the procedure below in “Main bearings”).
  • Page 574 section Engine N 9.2 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). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 575 section Engine N 9.2 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 576 section Engine N 9.2 Check that the oilways are free of restrictions or clogging. Check the condition of locating dowels (22). In the event of signs of distortion or excessive assembly clearance with the corresponding seats, remove the locating dowels using appropriate tools. If it proves difficult to remove the dowels (22) from the crankcase, use a tap with a left-hand thread to force them out.

  • Page 577: Main Bearings

    section Engine N 9.2 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 578: Reassembly Of The Crankcase Halves

    section Engine N 9.2 Reassembly of the crankcase halves The crankcase halves must be in good condition and perfectly clean. The mating surfaces must be perfectly flat and free from burrs. Overhauling the right-hand side crankcase half The following parts must be present on the internal side of the crankcase half: the output shaft end bearing (23);...
  • Page 579 section Engine N 9.2 Refitting the left-hand side crankcase half The following parts must be present on the internal side of the crankcase half: the double cage ball bearing (9) supporting the fork control shaft with stop plate (10) and retaining bolts (11). The gearbox input shaft end bearing (7) with the inner spacer (6).
  • Page 580 section Engine N 9.2 Refit the gauze filter as described in Sect. D 4. Important To avoid damaging the filter, insert it by hand only. Do not use hammers or other metal tools. Above the gauze filter seat there is a plug (19) which closes off the lubrication oilway. If it is to be renewed, apply the prescribed threadlocker to its threads.

  • Page 581: Shimming The Shafts

    section Engine N 9.2 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”...
  • Page 582 section Engine N 9.2 Add a pre-load of 0.30 mm to prevent excessive crankshaft end float when the crankcase halves are at their normal operating temperature. This gives: SA=LA1+LA2+0.30-LA. To calculate the each single shim thickness note that: SA=SA1+SA2 where “SA1” and “SA2” represent the shims for the right-hand crankcase half 1 and the left-hand crankcase half 2. Considering the alignment of the shaft, this gives: SA1=LA1+0.15-LA/2;...
  • Page 583 section Engine N 9.2 Place a dial gauge (A) with a magnetic base on a support plate fixed to the crankcase. Bring the stylus into contact with the end of the crankshaft and set the dial gauge to zero in this position. Insert a lever (B) between the crankcase and the crank web and force the crankshaft towards the dial gauge.
  • Page 584 section Engine N 9.2 Shimming the gearbox shafts To establish the total shim thicknesses to be installed on the input shaft “SP” and the output shaft “SS”, proceed as follows: Measure the dimensions “LP” and “LS” on the input and output shafts (for the output shaft add shim thickness “R” of 2.3 mm; Measure the depth corresponding to the distance between the contact surface of the crankcase half and the contact surface of the inner race of the bearing for the input shaft (“CP1”...
  • Page 585 section Engine N 9.2 Shimming the gearbox selector drum A similar procedure is used to establish the total shim thickness “ST” for the gearbox selector drum; Given that: LT1 = right-hand side crankcase depth LT2 = left-hand side crankcase depth LT = gearbox selector drum shoulder.

  • Page 586: Reassembly Of The Crankcase Halves

    section Engine N 9.2 Reassembly of the crankcase halves Apply the recommended threadlocker to the bolts (34) and secure the hoses (33) with the O-rings (32), tightening the bolts (34) to the specified torque (Sect. C 3). LOCK Install the timing belt driveshaft (30) in the roller bearing (4) in the right-hand crankcase half. To avoid damaging the oil seal (14) on the timing belt driveshaft, protect the threaded end of the shaft with the special protective cap 88700.5749.
  • Page 587 section Engine N 9.2 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 right-hand crankcase half with the calculated shims. Notes A figure and a list of the component parts of the gearbox appear in Sect.
  • Page 588 section Engine N 9.2 Install the 5 gear selector fork (E) in the input shaft driven gear. Install the selector drum (F) in the crankcase with calculated shim thickness. Fit the pins (G) in the previously installed selector forks. Fit the shimmed crankshaft into the right-hand crankcase half, positioning the connecting rods (H) in correspondence with the relative cylinder barrel seats.
  • Page 589 Grease the O-ring (31) to hold it in position and install it. 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.
  • Page 590 section Engine N 9.2 Apply the recommended grease to the bolts and insert them in their holes (note that the bolts are different lengths). Start with the larger diameter bolts (M8), and in particular, the left-hand side bolt (25) and follow the order indicated. Q.ty Description M8x90 mm bolts...
  • Page 591 section Engine N 9.2 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 0.20 to 0.30 mm); check also that all the parts you have fitted are free to rotate or move correctly. Install the gauze filter cover with its gasket as described in Sect.

  • Page 592: Crankcase Assembly: Connecting Rods

    section Engine N 9.3 9.3 - Crankcase assembly: connecting rods 1 Special screw 2 Connecting rod assembly 3 Half bearing 4 Grub screw 5 Key 6 Crankshaft 7 Grub screw 8 Shim 9 Bushes Important Bold reference numbers in this section identify parts not shown in the figures alongside the text. Refer to the exploded view diagram.
  • Page 593 section Engine N 9.3 Removal of the connecting rods assembly Operation Section reference Remove the engine from the frame Remove the lubrication system N 2.1 Remove the cooling system Remove the cylinder head assemblies and N 4.2 the timing parts Remove the cylinder barrel/piston assemblies Remove the left-hand crankcase cover...

  • Page 594: Disassembly Of The Connecting Rods

    section Engine N 9.3 Disassembly of the connecting rods To disassemble the connecting rod, undo the bolts (1) and separate the connecting rod from the crankshaft. Important Take care not to mix up components of different connecting rods and maintain the original orientation. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.

  • Page 595: Overhaul Of The Connecting Rods

    section Engine N 9.3 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), renew the connecting rod. The small end bushing must be in good condition and firmly driven into its seat. Check for parallelism error measured at 100 mm from the connecting rod longitudinal axis: the value must be H - h less than 0.02 mm;...
  • Page 596 section Engine N 9.3 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. Now ream out the bushing until the inside diameter (D) is 20.035 to 20.045 mm.
  • Page 597 section Engine N 9.3 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. -0,25 With the aid of a micrometer, measure the ovality and taper of the big-end journals, taking the measurements in various different directions.
  • Page 598 section Engine N 9.3 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 599 section Engine N 9.3 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 screws to a torque of 50 Nm. Remove the connecting rod and compare the width of the Plastigage strip to the scale (B).

  • Page 600: Reassembly Of The Connecting Rods

    section Engine N 9.3 Reassembly of the connecting rods Before starting the work, check that the crankshaft main bearing journals and big-end journals are free of burrs or evident signs of machining: if necessary, clean the surfaces with very fine emery cloth and oil. Check that the grooves are in perfect condition with no signs of forcing.
  • Page 601 section Engine N 9.3 Fit the spacer of the tool 88713.2878 between the connecting rods and take up residual axial play with the fork feeler gauge part no. 88713.2878 which is available in the following thicknesses: 0.1 mm - 0.2 mm - 0.3 mm. Temporarily fit the gudgeon pin to align the connecting rods, and then tighten the bolts.
  • Page 602 section Engine N 9.3 Refitting the connecting rods. Install the connecting rod assembly (7) and (2) in the crankcase, carry out the shimming and crankcase reassembly procedure as described in Sect. N 9.2. Important Make sure that the connecting rods (2) 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 603 Electric system WWW.PlanDeGraissage.ORG...
  • Page 604 section Electric system 1 - Wiring diagram Key to wiring diagram Wiring colour codes Key to fusebox Routing of wiring on frame Plate 1 Plate 2 Plate 3 Plate 4 Plate 5 Plate 6 Plate 7 Plate 8 Plate 9 Plate 10 Plate 11 Plate 12...
  • Page 605 section Electric system 4 - Lights and indicating devices Changing light bulbs High beam headlights relay Headlight aim 5 - Indicating devices Checking the indicating system components Coolant temperature sensor Fan relay Checking operation of the fan relay Changing light bulbs 6 - Protection and safety devices Checking protection and safety device components Checking the fuses...
  • Page 606 section Electric system 1 - Wiring diagram Gr/Bk W/Bk O/Bk Bn/Bk W/Bk Bn/R Gr/R G/Bk Bk/Y R/Bk Bk/W Gr/G STOP ANT ANTENNA - ANTENNA + O/Bk FRIZIONE Bk/W Gr/R TRAG Bn/R B/Bk BODY 1 BODY 4 BODY 6 Bn/Bk BODY 7 BODY 11 Bk/B BODY 14...
  • Page 607 section Electric system 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 608 section Electric system Wiring colour codes B Blue Bk Black Bn Brown G Green Gr Grey Lb Light blue O Orange P Pink R Red V Violet W White Y Yellow Key to fusebox Pos. Item Val. Key-on 10 A Lights 15 A Device...
  • Page 609 section Electric system Routing of wiring on frame Routing of wiring has been optimised to ensure the minimum obstruction. Each section is designed to prevent interference with parts that might damage wires or cause operating failures when riding. The diagrams on the following pages show the origins (“0” points) for correct re-routing of cables and the locations of cable ties. Each figure includes references to the diagrams showing the cable routing or the item it must be connected to.
  • Page 610 section Electric system Plate 31 Sidestand wiring (*) Plate 32 Vertical cylinder injector wiring Plate 33 Exhaust valve motor wiring Plates 34-35 Data acquistion connector Plates 34-35 Tail light connector Plates 34-35 Number plate and rear turn signals conector * Parts marked with this symbol are defined in “Refitting the battery support” in Sect. M 3. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 611 section Electric system Plate 1 Plate 2 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 612 section Electric system Plate 3 Plate 4 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 613 section Electric system Plate 5 Plate 6 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 614 section Electric system Plate 7 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 615 section Electric system Plate 8 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 616 section Electric system Plate 9 Plate 10 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 617 section Electric system Plate 11 Plate 12 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 618 section Electric system Plate 13 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 619 section Electric system Plate 14 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 620 section Electric system Plate 15 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 621 section Electric system Plate 16 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 622 section Electric system Plate 17 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 623 section Electric system Plate 18 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 624 section Electric system Plate 19 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 625 section Electric system Plate 20 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 626 section Electric system Plate 21 Plate 22 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 627 section Electric system Plate 23 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 628 section Electric system Plate 24 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 629 section Electric system Plate 25 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 630 section Electric system Plate 26 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 631 section Electric system Plate 27 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 632 section Electric system Plate 28 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 633 section Electric system Plate 28 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 634 section Electric system Plate 29 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 635 section Electric system Plate 30 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 636 section Electric system Plate 31 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 637 section Electric system Plate 32 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 638 section Electric system Plate 33 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 639 section Electric system Plate 34 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 640 section Electric system Plate 35 WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 641 section Electric 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. D 5. With the “DDS”...
  • Page 642 section Electric system Recharging the battery Examine the label on the battery showing the check intervals in order to determine when to test the voltage. 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.
  • Page 643 section Electric system Topping up the electrolyte Remove the battery from the motorcycle. Warning Carefully read the relevant safety rules before working on the battery (Sect. A 3, General safety rules). The electrolyte in the battery is toxic and can cause burns if it comes into contact with the skin because it contains sulphuric acid. Wear protective clothing, a face-mask and goggles when adding electrolyte.
  • Page 644 section Electric system Warning Do not peel or perforate the sealed areas. 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 645 section Electric system Rest the cap strip on the filler holes without fixing it. Recharge the battery as described in the paragraph “Recharging the battery”. Notes If using an automatic charge reducing battery charger, make certain that the charger current (amps) is greater than or equal to the standard (STD) recharging system indicated on the battery.
  • Page 646 section Electric system Battery Battery safety rules Warning Carefully read 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 647 section Electric system Refitting the battery Refitting is the reverse of removal. Pay particular attention to the terminals, which should not show any sign of oxidization. Tighten the terminal bolts to the specified torque (Sect. C 3) and apply a water repellent spray. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 648 section Electric 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, DDS tester). The absolute value of voltage measured across the terminals of two of the three yellow cables (measured value will be the same whichever the combination) must be within the range indicated in the table below.
  • Page 649 section Electric system Removal of the alternator Remove the left-hand side fairing (Sect. E 2). Disconnect the alternator wires from the electrical system (refer to plate in chapter “Routing of wiring on frame” Sect. P 1). Remove the left-hand crankcase cover, the stator (A) and rotor (B) (Sect. N 8, Removal of the left-hand side crankcase cover). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 650 section Electric system Refitting the alternator Fit the rotor (B), the stator (A) and the left-hand crankcase cover. Reconnect the alternator wires to the electrical system (refer to plate in chapter “Routing of wiring on frame” Sect. P 1). Refit the left-hand side fairing (Sect. E 2). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 651 section Electric system Regulator/rectifier The regulator (2) is fixed to the battery support (3). The regulator/rectifier unit 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 652 section Electric system Refitting the regulator Fit the regulator to the battery support (3). Secure it with the screws (1) and tighten to the specified torque (Sect. C 3). Notes For the correct positioning of the regulator wiring, follow the indications given in the plates in the chapter “Routing of wiring on the frame”...
  • Page 653 section Electric 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) and remove the protective cap (A). A blown fuse can be identified by breakage of the inner filament (B).
  • Page 654 section Electric 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). The engine starting strategy is managed entirely by the engine ECU (34), which monitors the following inputs: - Engine Stop switch on right-hand handlebar switch (1) - Engine starter switch on right-hand handlebar switch (1)
  • Page 655 section Electric system Starter motor Power: 0.7 kw/12 V Direction of rotation: counterclockwise viewed from power take-off side. 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 656 section Electric system Unscrew the retaining bolts (3). Notes The starter motor retaining bolts are assembled with threadlocker Slide out the starter motor and its gasket (5). Refitting the starter motor Inspect the condition of the gasket (5) and renew if necessary. Place the gasket (5) and the starter motor on the crankcase and tighten the bolts (3) to the specified torque (Sect.
  • Page 657 section Electric 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). 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 gears (Sect.
  • Page 658 section Electric system Starter contactor The contactor is elastically mounted to the battery support. Disconnect the battery (Sect. P 2, Battery). Remove the protective caps (A). Unscrew the nuts (4), taking care to recover the spring washers (3). Remove the starter motor-contactor cable (2). Remove the contactor-battery cable (1). Disconnect starter motor connector (5) from the wiring (see tables in chapter “Routing of wiring on frame”, Sect.
  • Page 659 section Electric 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 660 section Electric system Tighten the nuts (4) to the specified torque (Sect. C 3, Engine torque settings). Refit the connector (5) to the wiring (see plates in “Routing of wiring on frame”, Sect. P 1). Refit the protective caps (A). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 661 section Electric system 4 - Lights and indicating devices Changing light bulbs Changing the headlight bulbs Before replacing a burnt out light bulb, ensure that the replacement bulb you intend to fit has the same voltage and power rating as specified for the lighting device in question (Sect. C 1.1, Lights/instrument panel). Warning The halogen light bulbs in the headlight become hot when switched on and remain hot for some time after they are switched off.
  • Page 662 section Electric system 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 663 section Electric system Changing the number plate light bulb To access the number plate light bulb, unscrew the two screws (4) securing the cover (5). Extract the bulb and renew it. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 664 section Electric system 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). 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 665 section Electric system Checking operation of the high beam lights relay Disconnect the relay (1) from the electrical system and apply 12 V (battery voltage) between contacts (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).
  • Page 666 section Electric system 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. Position the motorcycle 10 metres from a wall or a screen. On the wall or surface, draw a horizontal line at the same height from the ground as the centre of the headlight and a vertical line aligned with the longitudinal axis of the motorcycle.
  • Page 667 section Electric system 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). Test the device using either an analogue or digital multimeter (Sect.
  • Page 668 section Electric system 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 669 section Electric system Refit the left-hand handlebar switch and tighten the screws (1) to the specified torque (Sect. C 3, Frame torque settings). Checking the right-hand handlebar switch To remove the right-hand handlebar switch, undo the retaining screws (1) and disconnect the wiring connector from the electrical system.
  • Page 670 section Electric 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. ENGINE STOP button Using a multimeter, check for continuity between the Red/Black and Red/White wires (see Sect. P 9, Diagnostic instruments for information on the operation of the multimeter).
  • Page 671 section Electric system 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. A) between the terminals of the corresponding switch when the front or rear brake is applied (see Sect.
  • Page 672 section Electric system Neutral indicator light To check the neutral light switch (3) proceed as follows: 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.
  • Page 673 section Electric system Clutch switch For the clutch switch (5) proceed in the same manner as for the brake light switches (see beginning of this paragraph). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 674 section Electric system Coolant temperature sensor The coolant temperature sensor (6) sends an electrical signal to the engine ECU, which shares it with the instrument panel over the CAN line. To check that the sensor (6) is functioning correctly, connect the DDS tester to the diagnostics socket of the ECU and follow the instructions given under the heading “Guided diagnosis”...
  • Page 675 section Electric system 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). 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 676 section Electric system 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 677 section Electric system Changing the front turn signals The front turn signals (1) are integrated in the rear-view mirrors (Sect. E 1) and in the event of malfunction, the mirror/turn signal assembly must be renewed as a complete unit. WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 678 section Electric system Changing the rear turn signal bulbs Undo the screws (2) and remove the cover (3). Disconnect the wiring (A) of the turns signals (4) and (5). Unscrew the nuts (6) and remove the turn signals. When refitting, position the turn signals by inserting the wires (A) through the relative apertures in the number plate holder (7). Slide the nuts (6) along the wires (A) and screw them onto the turn signals to secure them to the number plate holder.
  • Page 679 section Electric system Rear view mirror adjustment Grasp the outer part of the mirror surface (A) and move it manually to the required position relative to the mirror support (B). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y. 2007 - edition 00...
  • Page 680 section Electric system 6 - Protection and safety devices Checking protection and safety device components Checking the ignition switch Disconnect the ignition switch (A) from the wiring loom by opening its connector (see “Routing of wiring on frame”, Sect. P 1) 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 681 section Electric system Checking the sidestand switch Remove the switch (1) from the sidestand and disconnect the main wiring loom connector from the switch (see “Routing of wiring on frame” Sect. P 1). Use an analogue or digital multimeter (Sect. P 9, Diagnostic instruments) to check operation of the switch (see table). Notes The same check can also be performed using the “DDS”...
  • Page 682 section Electric system Checking the fuses The main fusebox (1) is locatd on the left-hand side of the motorcycle and is accessed by removing the left-hand sied fairing (Sect. E 2). The fuses are accessed by removing the cover (2), which shows the ampere ratings and mounting locations. For ampere ratings, refer to the “Wiring diagram”, Sect.
  • Page 683 section Electric system 7 - Instruments Instrument panel Remove the 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).
  • Page 684 section Electric system Instrument panel system The instrument panel comprises a LCD digital display unit. The information on the display can be accessed uing a 2-position puhsbutton (1) and the headlight flasher button (2) on the lweft- hand handlebar switch. Underneath the digital display there are eight indicator lights (four per side) and a further four auxiliary lights used to signal reaching of the limiter threshold.
  • Page 685 section Electric system 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 about 3 litres of fuel left in the tank. 5) Turn signal lights (green).
  • Page 686 section Electric system 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 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 687 section Electric system Total distance travelled indicator (odometer) At Key-On the system automatically enters this function. The reading is saved permanently and cannot be reset. If it exceeds 99999 km (or 99999 miles), the reading “99999” remains displayed permanently. vs. UK vs.
  • Page 688 section Electric system Trip meter “TRIP B” While in this function, if you press button (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”...
  • Page 689 section Electric system “TRIP FUEL” indicator (distance travelled on reserve fuel) 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. The count stops automatically when the fuel level rises above reserve.
  • Page 690 section Electric system Air temperature indicator Shows the outside air temperature. Display limits: -39 °C to +124 °C. In rge event of a FAULT with the sensor (-40 °C,+125 °C or disconnected) the series of dashes “- - -” is displayed (not flashing) and the Engine Diagnostics warning light (9) comes on.
  • Page 691 section Electric system Coolant temperature indicator Displays the engine coolant temperature: if the reading is less than or equal to -40 °C (-104 °F), the display shows a series of flashing dashes (“---”) and the Engine Diagnostics warning light comes on (9); if the reading is between -39 °C (-102.2 °F) and +39 °C (+102.2 °F), the word “LO”...
  • Page 692 section Electric system Battery voltage indicator (BATT) To display this function, go into the menu and select the “BATT” page. The battery voltage reading is displayed as follows: if the reading is between 12.1 and 14.9 Volts, it remains lit steadily; if the reading is between 10.0 and 12.0 Volts or between 15.0 and 16.0 Volts, it flashes;...
  • Page 693 section Electric system Adjusting the engine idle speed (rpm) To display the function, go into the menu and call up the “RPM” page. As well as the top rev counter scale, the display also shows engine rpm numerically so that you can adjust the idle speed more precisely.
  • Page 694 section Electric system Lap time display To activate this function, go into the menu and set the “LAP” function to “On” by keeping button (1) in position B “▼” for 3 seconds. START and STOP the timer by pressing the high beam FLASH button (2) on the left-hand handlebar switch. When the LAP function is active, each time you press the FLASH button, the display will show the lap time for 10 seconds, before reverting to normal mode.
  • Page 695 section Electric system 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).
  • Page 696 section Electric system LAP Memory display Displays the data saved with the LAP function: lap time, MAX speed and MAX rpm. To display the saved times, go into the menu and select the “LAP MEM” page. From this page, if you hold button (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.
  • Page 697 section Electric system During the lap, if the engine reaches one of the two thresholds before the limiter or the limiter itself, the respective warning lights (10) come on during the display of the saved times. USB DAQ This function activates the USB Data Acquisition (DAQ) (Sect. P 10): the DAQ must be connected to the motorcycle wiring. To activate the DAQ, go into the menu and set the USB DAQ to “On”...
  • Page 698 section Electric system Erase USB This function enables you to delete the data saved on the USB DAQ: the DAQ must be connected to the motorcycle wiring. To delete the data, go into the menu and select the “Erase USB” page. If you hold the button (1) in position B “▼”...
  • Page 699 section Electric system Clock setting To set the clock, select the “TIME Set” page from the menu. From this page, if you press the button (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 button (1) in position B “▼” will switch the display to “PM”;...
  • Page 700 section Electric system Setting the special functions (vehicle model and units of measurement) 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 settings, press button (1) in position A “▲” and simultaneously turn the ignition keyswitch from OFF to ON.
  • Page 701 section Electric system Instrument panel diagnostics Important The instrument runs the system diagnostics correctly 60 seconds after the last Key-Off. Any anomalous behaviours of the motorcycle are displayed. If there are several errors, they are displayed in rolling mode every 3 seconds. The table below shows the errors that can be displayed.
  • Page 702 TILT 6.2 Lambda 2 sensor error Traction control unit error (the error can only occur if the bike has been fitted with the traction DTC 8.0 control kit available from Ducati performance) ECU 30.0 Engine ECU error PK.UP 34.0 Pick-up sensor error SPEE.
  • Page 703 section Electric system Intelligent headlamp switch-on This function allows programmed headlight switch-on even with the motorcycle off (Key-Off). Immediately after key-off, the instrument panel remains active for 60 seconds, thus allowing the headlamp to be switched on if the button (1) is pressed in position B “▼”. During these 60 seconds, each time the button (1) is pressed in position B “▼”, the instrument panel will activate the headlight for 30 seconds;...
  • Page 704 section Electric system 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 705 section Electric system 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 706 section Electric system 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;...
  • Page 707 section Electric system 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 708 section Electric system 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 709 section Electric system If the code has been entered correctly, the message CODE and the code itself will flash simultaneously for 4 seconds. The motorcycle diagnostics warning light (2) will go off. The instrument panel then automatically exits the menu, thus allowing “temporary”...
  • Page 710 section Electric system Removal of the immobilizer Set the ignition switch to OFF. Remove the right-hand side fairing (Sect. E 3, Removal of the 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). WWW.PlanDeGraissage.ORG 1098/1098S - M.Y.
  • Page 711 section Electric system Refitting the immobilizer Apply the recommended threadlocker to the inside of the cover (2) in two poinst 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 tightening torques). LOCK Removal of the transponder from the key Clamp the grip of the key (4) in a vice with protective jaw facings.
  • Page 712 section Electric system 9 - Diagnostic instruments For information on the “DDS” tester, refer to Sect. D 5, DDS 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 713 section Electric system Measurement of resistance values and electrical continuity Resistance measurements must be taken only when the electrical device or section of the circuit is not powered and isolated from the main electrical system (i.e. not connected to the main electrical system). These measurements can be utilised to check the resistance value across several sensors.
  • Page 714 section Electric system P 10 10 - USB Data Acquisition (DAQ) (for 1098S only) A USB DAQ (1) is supplied in kit form. To use it, position it under the seat with the cap (2) fitted and the connector (3) from the main wiring loom connected.

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