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Ducati HyperMotard 796 2010 Service Manual

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Summary of Contents for Ducati HyperMotard 796 2010

Page 2: Information About The Model
A - General 0A - General 0B - Information about the model 0C - Technical data 0D - Use and maintenance 0E - Fairings 0F - Controls - Devices 0G - Wheels - Suspension - Brakes 0H - Frame 0L - Fuel/Exhaust System 0M - Fuel injection - ignition system 0N - Engine 0P - Electrical system...
Page 3: Technical Data
A - General Section C 0C - Technical data 1.1 - Technical specifications General 3 Colours 4 Transmission 4 Timing system/valves 4 Exhaust system 5 Cylinder/Piston 5 Gearbox 5 Cooling system 5 Front wheel 6 Front suspension 6 Rear wheel 6 Rear suspension 6 Hydraulic brakes 7 Charging system/alternator 7...
Page 4 Adjusting the position of the gearchange and rear brake pedals 39 Adjusting the rear shock absorber 40 5 - Diagnostic instruments Description of the Ducati Diagnostic System instrument 43 Tester power supply 46 DDS tester 50 Checking and adjusting timing belt tension 51...
Page 5 A - General Guided diagnosis 77 Testing the battery charging system 80 Deactivating the “service” indication on the instrument panel 83 Icons table 87 Section E 0E - Fairings 1 - Headlight fairing - hand guards - rear-view mirrors Removal of the hand guards - rearview mirrors 4 Refitting the hand guards - rearview mirrors 5 Removal of the headlight fairing 7 Refitting the headlight fairing 9...
Page 6 A - General Removal of the clutch master cylinder assembly 8 Refitting the clutch master cylinder assembly 9 Removal of the clutch slave cylinder 11 Refitting the clutch slave cylinder 12 3 - Front brake control Removal of the front brake master cylinder 18 Refitting the front brake master cylinder 19 4 - Rear brake control Removal of the rear brake master cylinder 24...
Page 7 A - General 4 - Rear wheel Removal of the rear wheel 30 Overhauling the rear wheel 30 Refitting the rear wheel 32 5 - Rear swingarm Removal of the rear eccentric hub 34 Refitting the rear eccentric hub 36 Removal of the swingarm 38 Inspecting the swingarm pivot shaft 41 Overhauling the rear swingarm 42...
Page 8 A - General 1 - Handlebar Removal of the handlebar 4 Refitting the handlebar 6 2 - Steering Adjusting the steering head bearings 10 Steering angle adjustment 11 Removal of the steering head components 12 Refitting the steering head components 15 4 - Footrest brackets Removal of the footrest brackets 22 Refitting the footrest brackets 25...
Page 9 A - General Removal of the fuel tank flange 10 Refitting the fuel tank flange 11 Refitting the fuel tank 12 6 - Throttle body Removal of the throttle body 24 Refitting the throttle body 28 7 - Air intake Removal of the airbox 34 Removal of the oil breather valve 39 Refitting the oil breather valve 39...
Page 10 A - General Stepper motor 15 Lambda sensor 16 Throttle Position Sensor (TPS) 18 Rpm/timing sensor 18 Air temperature sensor 19 Air pressure sensor 20 Spark plug 22 Coil 23 Injection relay 24 CAN Line 25 Section N 0N - Engine 1 - Removal - refitting of the engine assembly Removal of the engine 6 Refitting the engine 9...
Page 11 A - General Disassembly and reassembly of the timing belt pulleys 37 Refitting the timing system assembly 38 Refitting the timing belt covers 46 4.3 - Cylinder head assemblies: camshafts Removal of the intake manifolds 48 Refitting the intake manifolds 49 Removal of the inner timing belt covers and camshaft end caps 50 Removal of the valve covers 52 Refitting the valve covers 53...
Page 12 A - General Removal of the primary drive gears 116 Refitting the primary drive gears and checking backlash 118 7.1 - Gearbox assembly: gearchange mechanism Removal of the gearchange mechanism 122 Disassembly of the gear interlock plunger and pawl assembly 125 Reassembly of the gear interlock plunger and pawl assembly 126 Refitting the gearchange mechanism 128 7.2 - Gearbox assembly: gearbox shafts...
Page 13: Electrical System
A - General 9.3 - Crankcase assembly: crankshaft/connecting rods assembly Removal of the crankshaft/connecting rods assembly 196 Disassembly of the crankshaft/connecting rods assembly 197 Overhaul of the connecting rods 197 Reassembly of the connecting rods 203 Refitting the crankshaft/connecting rod assembly 205 Section P 0P - Electrical system 1 - Wiring diagram...
Page 14 A - General Recharging the battery 45 Topping up the electrolyte 46 Battery 50 Alternator 52 Regulator/rectifier 55 3 - Electric starting system Electric starting system 58 Starter motor 59 Starter contactor 62 4 - Lights and indicating devices Removal of the instrument panel 65 Changing bulbs 66 Headlight aim 69 5 - Indicating devices...
Page 15: Table Of Contents
A - Impianto elettrico 0A - Impianto elettrico 1 - How to use this manual Layout of the manual 3 2 - Symbols - Abbreviations - References Product specifications 5 3 - Hazardous Products - Warnings General safety rules 7 General maintenance indications 8...
Page 16: How To Use This Manual
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 17 The layout of the manual is designed in such a way as to be applicable to all the different models manufactured by Ducati Motor Holding. To facilitate consultation of the manual, the table of contents is identical for all motorcycle models.
Page 18: Symbols - Abbreviations - References
Symbols - Abbreviations - References 2 - Symbols - Abbreviations - References To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which maximum care is required, as well as practical advice or information. Pay attention to the meaning of the symbols since they serve to avoid repeating technical concepts or safety warnings throughout the text.
Page 19 Symbols - Abbreviations - References GREASE B Molybdenum disulphide grease, high mechanical SHELL stress and high temperature resistant. Retinax HDX2 GREASE C Bearing/joint grease for parts subject to prolonged SHELL mechanical stress. Temperature range: -10 to 110 °C. Retinax LX2 GREASE D Protective grease, with anti-corrosive and SHELL...
Page 20 Medium-strength threadlocker. Loctite 401 LOCK 12 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel 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. Eliminates...
Page 21: Hazardous Products - Warnings
Hazardous Products - Warnings 3 - Hazardous Products - Warnings General safety rules Carbon monoxide When a maintenance operation must be performed with the engine running, make 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 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; your questions to the customer concerning symptoms of the fault should be aimed at clarifying the problem;...
Page 23: Identification Data
B - Impianto elettrico 0B - Impianto elettrico 1 - Identification data Hypermotard identification data 3...
Page 24 Identification data 1 - Identification data Hypermotard identification data 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).
Page 25 Please quote these numbers, which identify the motorcycle model, when ordering spare parts. Data stamped on the frame Europe version 1 Manufacturer: Ducati Motor Holding 2 Type, same on all Hypermotard models 3 Variant (01= EC homologation; 02= 25 kW homologation)
Page 26 Identification data Data stamped on the frame US version 1 Manufacturer: Ducati Motor Holding 2 Motorcycle type 3 Variant – Numeric or X (Check digit) 4 Model year (A = 2010) 5 Manufacturing facility 6 Progressive serial No. Data stamped on engine...
Page 27 Identification data Data stamped on engine US version 1 Engine type 2 Model year (A = 2010) 3 Progressive production No.
Page 28 1.1 - Technical specifications 3 1.1 - Technical specifications General 3 Colours 4 Transmission 4 Timing system/valves 4 Exhaust system 5 Cylinder/Piston 5 Gearbox 5 Cooling system 5 Front wheel 6 Front suspension 6 Rear wheel 6 Rear suspension 6 Hydraulic brakes 7 Charging system/alternator 7 Ignition system 7...
Page 29: Technical Specifications
Lubrication system Pump-forced Oil pump type Gear pump Cooling system Air-cooled Air filter One filtering element Crankshaft type One-piece Cylinder arrangement “L” at 90° Colours Description Code no Ducati Anniversary Red F_473.101 (PPG) Transparent 228.880 (PPG) Red frame with black wheels...
Page 30: Transmission
Technical specifications StreetFighter pearl white L2909004 (LECHLER) Basecoat L0050786 (LECHLER) Transparent 923I1281 (PALINI) Black frame with black wheels Matt black 291.501 (PPG) Black frame with black wheels Transmission Reference Technical specifications Clutch Wet multiplate Clutch control Hydraulic Gearbox 6 speed Primary drive 33/61 Transmission ratio...
Page 31: Cylinder/Piston
Technical specifications Exhaust system Catalytic converter with lambda Euro 3 sensor Cylinder/Piston Reference Standard value Service limit Max. bore ovality 0.03 mm Cylinder barrel Max. bore taper 0.03 mm Nominal diameter 88 mm Class A 88.000 to 88.010 mm Class B 88.010 to 88.020 mm Class C 88.020 to 88.030 mm...
Page 32: Rear Wheel
Technical specifications Reference Technical specifications Type Marzocchi hydraulic upside-down forks, non- adjustable, Ø 43 mm Travel along leg axis 165 mm Fork Not adjustable Oil charge per leg 450 cc (right fork) 470 cc (left fork) Rear wheel Reference Standard value Service limit Minimum tread depth In the most worn part...
Page 33: Charging System/Alternator
Technical specifications Braking surface material Steel Diameter 245 mm Braking surface 25 cm Brake caliper Make Brembo Type 34 - 2 piston Caliper cylinder diameter 34 mm Pad friction material FERIT I/D 450 FF Brake master cylinder Type PS11 Master cylinder diameter Charging system/alternator Reference Technical specifications...
Page 34 Technical specifications Instrument panel DDA and battery charging Spare 20 A Spare 20 A Spare 15 A...
Page 35: Dimensions
Dimensions 1.2 - Dimensions...
Page 36 Dimensions...
Page 37: Fuel, Lubricants And Other Fluids
Fuel, lubricants and other fluids 2 - Fuel, lubricants and other fluids Fluids and lubricants Type dm³ (litres) Unleaded fuel with 95 fuel octane rating (at 12.4 Fuel tank, including a reserve of 3.3 dm least) (litres) Lubrication circuit SHELL Advance Ultra 4 Front/rear brake and clutch circuits Special hydraulic system fluid - SHELL Advance –...
Page 38: Torque Settings
Torque settings 3 - Torque settings Frame torque settings Part Thread/pitch (mm) Nm ±10% Tolerance Notes Accessories and equipment Bolt securing hand guard to handlebar (rh+lh) M6x1 Bolt securing hand guard mounting clamp/stud to M5x0.8 handlebar (rh+lh) Bolt securing front turn signal to hand guard (rh+lh) AF2.9 0.33 Bolt securing hand guard to stud (rh+lh)
Page 39 Torque settings Fastener securing lower headlight fairing support M6x1 Electrical system Fastener securing voltage regulator and horn to frame M6x1 LOCK 2 Immobilizer antenna — — Assembled in line apply LOCK 11 or LOCK 12 between antenna and commutator cover Speed sensor fastener M6x1 Commutator fastener (rh+lh)
Page 40 Torque settings Throttle twistgrip fastener M6x1 Sequence 1-2-1 Clutch master cylinder fastener M6x1 Sequence 1-2-1 Rear suspension Fastener securing shock absorber/tie-rod to swing arm M10x1.25 GREASE B Fastener securing the shock absorber to suspension rocker M10x1.25 GREASE B Fastener securing tie-rod to suspension rocker arm M10x1.25 GREASE B Fastener securing suspension rocker arm to frame...
Page 41 Torque settings Silencer joint clamp fastener M8x1.25 Silencer joint bracket fastener M8x1.25 Fastener securing silencers bracket to subframe M8x1.25 Fastener securing number plate bracket to silencers M8x1.25 Under-silencer spray guard fastener M6x1 Fastener securing presilencer stay to bracket M6x1 Seat Fastener securing seat to tank M5x0.8 Fastener securing seat adjustment slide...
Page 42: Engine Torque Settings
Torque settings Notes For product specifications and symbols, see paragraph “Product specifications” (Sect. A 2). Engine torque settings Part Thread/pitch (mm) Min. Max. Notes Oil temperature sensor holder nut M30x1.5 LOCK 4 Camshaft timing belt pulley nut M15x1 GREASE A Oil temperature sensor M12x1.5 LOCK 4...
Page 43 Torque settings Starter motor rear bolt M6x1 Idler gear shaft retaining bolt M6x1 LOCK 2 or TB1324 Alternator rotor nut M24x1 LOCK 5 Primary drive gear nut M22x1 GREASE B Steel/aluminium crankshaft blanking cap M20x1 13.5 16.5 TB 1375B Connecting rod bolt M10x1 Apply GREASE B Tighten at 50 rpm...
Page 44: Service Tools
Service tools 4 - Service tools Parts catalogue Workshop service tools Specific tools for the engine Code No Description 88700.5644 Socket wrench for camshaft pulley nut 88713.3218 Timing belt roller tool 88713.2423 Torque wrench for tightening front sprocket nut 88713.2676 Wrench for tightening cylinder head nuts 88713.2103 Stand for cylinder head assembly...
Page 45 Service tools 98112.0002 Timing degree wheel 88713.0123 Timing check tool DDS (Ducati Diagnosis System) + cylinder vacuum measuring 97900.0215 88713.0137 Front sprocket holding wrench 88765.1581 Valve lift gauge 88713.2878 Spacer and fork feeler gauge 0.2/0.3 mm...
Page 46 Service tools 88713.2783 Tool for fitting spring and closing rocker 88713.2282 Pulley holding tool 88713.2011 Crankshaft holding tool 88700.5749 Crankcase assembly cap 88713.3334 Plate for gear selector fork positioning 88713.1749 Puller for drive pulley and cover...
Page 47 Service tools 88765.1297 TDC gauge 88713.2092 Primary drive gears puller 88713.1010 Exhaust gases pick-up connector 88713.2036 Alternator holding tool for tightening nut 88713.2442 Valve seal installer Ø 7 88713.2906 Oil filter cartridge wrench...
Page 48: Specific Tools For The Frame
Service tools 88713.2556 Clutch drum holding tool 88713.2591 Clutch screw 88713.3220 Engine repair bench Parts catalogue Workshop service tools Specific tools for the frame Code No Description 88713.2409 Swingarm ball bearing installer 88713.1058 Wrench for steering stem nut...
Page 49 Service tools 88713.1062 Tool for installing steering head bearings 88713.3203 MARZOCCHI fork disassembly rod 88713.1068 Tool for installation of swingarm roller bearings 88713.1071 Drift to drive rocker arm needle rollers 88713.1038 Wrench for adjustment of the eccentric hub 88713.1073 Rear wheel balancing tool...
Page 50 Service tools 88713.1344 Chain assembly tool 8000.70139 Front wheel axle wrench 88713.3204 Tool for overhaul of MARZOCCHI forks - oil seal installer 88713.1072 Drift to install half bearing in bottom yoke...
Page 51 Adjusting the position of the gearchange and rear brake pedals 39 Adjusting the rear shock absorber 40 5 - Diagnostic instruments Description of the Ducati Diagnostic System instrument 43 Tester power supply 46 DDS tester 50 Checking and adjusting timing belt tension 51...
Page 52 D - Impianto elettrico Fuel pressure test 71 Immobilizer override procedure 74 Guided diagnosis 77 Testing the battery charging system 80 Deactivating the “service” indication on the instrument panel 83 Icons table 87...
Page 53: Preliminary Checks
Throughout the running-in period, be careful to stick to the recommended maintenance schedule and periodic service intervals indicated in the warranty booklet. Failure to follow these instructions shall release Ducati Motor Holding S.p.A. from all liability for any engine damage or shorter engine life.
Page 54: Pre-Ride Checks
Preliminary checks 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 needed (Sect. C 2, Fuel, lubricants and other fluids).
Page 55: Starting - Engine Warmup
Starting - Engine warmup 2 - Starting - Engine warmup Starting the engine This motorcycle is equipped with an automatic starter (stepper motor). This allows automation of the engine warmup procedure. For information on the operation of the stepper motor, see Section M 3, Stepper motor.
Page 56 Starting - Engine warmup Important Do not run the engine at high speed when cold. Allow some time for the oil to warm up and reach all points that need lubricating. Warning The engine can be started with the sidestand down and the gearbox in neutral. When starting the engine with a gear engaged, pull in the clutch lever (in this case the sidestand must be in the raised position).
Page 57: Routine Maintenance Table
Routine maintenance table 3 - Routine maintenance table Programmed maintenance plan: operations to be carried out by the dealer km x1000 List of operations with frequency miles x1000 22.5 37.5 (distance or time interval*) Months Change the engine oil • •...
Page 58 Routine maintenance table * Service operation to be carried out in accordance with the specified distance or time intervals (km, miles or months), whichever occurs first.
Page 59: Maintenance Operations
Maintenance operations 4 - Maintenance operations Checking the engine oil level Check the engine oil level through 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 60 Maintenance operations Fit a new cartridge (4) using service tool 88713.2906: lubricate the seal with engine oil. Notes It is advisable to fill the filter cartridge (4) with engine oil before installing it: this enables the recommended oil level to be maintained without topping up. Screw the filter into place and tighten to the specified torque (Sect.
Page 61 Maintenance operations Unscrew the filter (7) and withdraw it from the crankcase. Clean the filter with petrol and compressed air. Take care not to damage the gauze. Replace the pick-up filter (7), fit the seal (5) to the plug (6) and tighten to the specified torque (Sect. C 3, Engine torque settings).
Page 62: Checking Valve Clearances
Maintenance operations Check for oil leaks. Check that the oil pressure light on the instrument panel switches off a few seconds after the engine starts. If not, switch off the engine and trace the fault. After a few minutes, check the oil level again and top up to the MAX level line, if necessary. Refit all parts removed.
Page 63 Maintenance operations 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: Adjusting clearance 0 to 0.05 mm Checking clearance 0 to 0.05 mm Exhaust: Adjusting clearance 0 to 0.05 mm...
Page 64: Changing And Cleaning The Air Filters
Maintenance operations If the measured clearances are outside the prescribed limits, replace the opening and/or closing shim, as described in the paragraph “Removal of the rocker arms, shims and valves” (Sect. N 4.4), with one of suitable height to obtain the specified clearance.
Page 65 Maintenance operations Remove the filter cartridge (3). The filter cartridge can be cleaned with a jet of compressed air or renewed as necessary. Important A clogged air filter will reduce air intake and engine power, increase fuel consumption and cause a build up of deposits on the spark plugs.
Page 66: Changing The Brake Fluid
Maintenance operations Install the cartridge (3) in its housing (A) in the airbox cover and replace all the removed parts; tighten the bolts (1) to the specified torque (Sect. C 3, Frame torque settings): in the sequence 1-2-3-4-5-6. Important If the motorcycle is used in very damp or dusty conditions, the air filter cartridge must be changed more frequently. Changing the brake fluid Warning Brake fluid will damage painted surfaces if spilled on them.
Page 67 Maintenance operations Attach a length of transparent plastic tubing to the bleed valve (2) and insert the other end of the tubing in a container placed on the floor. Loosen the bleed valve (2) to allow fluid to escape. Warning While filling the circuit, keep the fluid level above the MIN mark at all times to prevent the formation of air bubbles in the circuit.
Page 68 Maintenance operations Operate the brake pedal two or three times to pressurize the circuit. Hold the pedal pressed down. Attach a length of transparent plastic tubing to the bleed valve (2) and insert the other end of the tubing in a container placed on the floor.
Page 69: Draining The Brake Circuits
Maintenance operations Draining the brake circuits 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. Undo the screws (1) and remove the cover and membrane from the front brake fluid reservoir (A).
Page 70: Filling The Brake Circuits
Maintenance operations Unscrew the bleed valve by a 1/4 turn. Operate the brake lever (or pedal) until all the fluid has drained out. Repeat this operation for each brake caliper. Filling the brake circuits Warning Brake fluid will damage painted surfaces if spilled on them. In addition, it is very harmful in contact with the skin or with the eyes;...
Page 71 Maintenance operations Important During the following operation, the fluid level must remain topped up at all times. The end of the transparent plastic tubing must remain immersed in the discharged fluid at all times. Operate the brake lever (or pedal) several times to allow the fluid to reach all points of the circuit and expel any air. Connect the bleed tool to the caliper bleed valve (4) or (5).
Page 72: Changing The Clutch Fluid
Maintenance operations Open the bleed valve (4) or (5) by a 1/4 turn and operate the brake lever (or pedal) several times until the fluid starts to emerge from the bleed valve. Pull the lever or depress the pedal fully and loosen the bleed valve by at least a 1/4 turn. Wait a few seconds, then release the lever or pedal gradually while simultaneously closing the bleed valve.
Page 73: Draining The Clutch Hydraulic Circuit
Maintenance operations Attach a length of transparent plastic tubing to the bleed valve (2) and insert the other end of the tubing in a container placed on the floor. Loosen the bleed valve (2) to allow fluid to escape. Warning While filling the circuit, keep the fluid level above the MIN mark at all times to prevent the formation of air bubbles in the circuit.
Page 74 Maintenance operations Unscrew the bleed valve by a 1/4 turn. Undo the bolts (1) and remove the cover and membrane from the reservoir (A). Operate the clutch lever until all the fluid has been expelled. To help drain the circuit fully, unscrew the three retaining bolts (3) and remove the clutch slave cylinder from the engine.
Page 75: Filling The Clutch Circuit
Maintenance operations Refit the clutch slave cylinder and tighten the retaining bolts (3) to the specified torque (Sect. C 3, Frame torque settings). Tighten the bleed valve to the specified torque (Sect. C 3, Frame torque settings). Replace the dust cap. Filling the clutch circuit Warning Clutch fluid will damage painted surfaces if spilled on them.
Page 76: Adjusting The Steering Head Bearings
Maintenance operations Open the bleed valve (2) 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 open 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 77: Adjusting The Clutch Lever And Front Brake Lever
Maintenance operations Loosen the clamp bolt (5) that holds the steering tube to the top yoke. Using service tool no. 88713.1058, turn the nut (6) to the specified torque (Sect. C 3, Frame torque settings). Tighten all previously loosened bolts to the specified torque (Sect. C 3, Frame torque settings).
Page 78: Adjusting The Chain Tension
Maintenance operations Adjusting the chain tension Slowly move the motorcycle to determine the position at which the chain is most taut. Place the motorcycle on its sidestand and measure the freeplay on the bottom run of the chain in correspondence with the front end of the lower chain guard.
Page 79 Maintenance operations Apply an extension bar to the wrench supplied and insert the tooth of the wrench in the eccentric hub. Rotate the eccentric hub to obtain the correct chain tension. Rotate the hub clockwise to tighten the chain or anti- clockwise to slacken it (as viewed from chain side of the bike).
Page 80: Checking Brake Pad Wear And Changing Brake Pads
Maintenance operations Warning For the safety of the rider and passenger, it is essential that the eccentric hub bolts are correctly tightened. After adjusting the chain tension, reposition the chain guard (2) making sure that its outer edges are equidistant from the chain.
Page 81 Maintenance operations Important If either of the pads is worn, both pads must be renewed as a set. Change the brake pads as follows. Remove the cotter pin (2) from the pad retaining pins. Withdraw the pad retaining pins (3) from the outside. Remove the clip (4) from between the two caliper halves.
Page 82 Maintenance operations Remove the inner membrane from the reservoir. Top up to the MAX level with the specified brake fluid. Refit all previously removed components. Checking rear brake pad wear Remove the bolts (1) and remove the front brake calipers from the forks. Check that the wear indicator groove (A) in the friction material of the pads (4) is visible.
Page 83: Adjusting The Throttle Cables
Maintenance operations 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 master cylinder reservoir is between the MIN and MAX marks. If not, unscrew the reservoir cover (4) and top up with the recommended brake fluid.
Page 84: Adjusting The Position Of The Gearchange And Rear Brake Pedals
Maintenance operations Adjust travel of the cold start control cable by turning the control lever on the handlebar to its maximum position and checking that plate (4) is located against the travel limit stop. The condition of the outer throttle cables should be checked at regular intervals. The outer cables should show no signs of kinking or cracking.
Page 85: Adjusting The Rear Shock Absorber
Maintenance operations Tighten the lock nut (2) against the rod (1). Rear brake pedal Loosen the locknut (5). Turn the pedal travel adjustment bolt (6) until the pedal is in the desired position: the standard position is shown in the above drawing. Tighten the locknut (5) to the specified torque (Sect.
Page 86 Maintenance operations Adjuster nuts (2) and (3), located at the top end of the shock absorber, serve to adjust the preload of the outer spring. To adjust the spring preload, unscrew the upper adjuster nut (3) using a pin wrench. Screw the adjuster nut (3) in or out to respectively increase or reduce the pre-load.
Page 87 Maintenance operations necessary to adjust the rebound damping accordingly.
Page 88: Diagnostic Instruments
Diagnostic instruments 5 - Diagnostic instruments 1 97900.0215 DDS (Ducati Diagnosis System) + manifold vacuum measuring kit 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...
Page 89: Description Of The Ducati Diagnostic System Instrument
Description of the Ducati Diagnostic System instrument The Ducati Diagnostic System (DDS) is used for diagnosis of the injection-ignition system via a serial connection. The system is also equipped with functions to test various devices on the motorcycle. The DDS tester can be used to measure current and voltage on any electrical device, to perform tests on individual components and to measure pressure and temperature values.
Page 90: Tester Power Supply
Diagnostic instruments - one RS232 serial port for connection of peripheral devices (COM1) (F); - a second RS232 serial port for connection of peripheral devices (COM2) (G); - two generic USB ports (USB1 and USB2) (H). The bottom connection panel has 3 connection sockets with the following functions: - one USB port (L);...
Page 91 Diagnostic instruments - from the mains power supply: by connecting the mains adapter (14) to the power connection socket (M); - from the motorcycle: by connecting the specific cables (see paragraph “Connection to motorcycle”); from the tester's internal battery: the battery (P) is housed in the top part of the tester. To operate the tester (1) using the internal battery and to recharge the battery, refer to the “User Manual”...
Page 92 Diagnostic instruments When using the tester, take care never to allow the power supply to fall below the minimum voltage: this situation could occur during engine starting and idling on motorcycles in which the battery is not in perfect working order. If the tester detects a power supply voltage of less than 9 Volts, the current procedures will be aborted;...
Page 93 Diagnostic instruments connect the power and diagnostic cable (2) to the diagnostic connection socket (N) on the tester; then connect the motorcycle power socket (S) to the connection socket (R) of the power and diagnostic cable (2).
Page 94: Dds Tester
Diagnostic instruments 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 95 Diagnostic instruments Remove the battery P 2, Removal of the battery Remove the starter contactor P 3, Starter contactor Remove the fuel tank L 2, Removal of the fuel tank Remove the timing belt covers N 4.2, Removal of the timing belt covers Remove the spark plugs.
Page 96 Diagnostic instruments the DDS tester (1). Connect the belt tension sensor (15) to the connector (T) of the power and diagnostics cable (Measurement Module) (3). Fix the mounting bracket of the belt tension sensor (15) using the timing belt cover bolt (23). Aim the central green LED of the sensor (15) at the mid-point of the belt run, with the reader parallel to the belt and at a distance of about 1-1.5 cm from it.
Page 97 Diagnostic instruments The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. Flick the belt lightly with your finger and read the frequency value (Hz) on the DDS tester. Notes Do not flick the belt several times repeatedly, as the minimum time necessary for the DDS tester to take a reading is 1 second.
Page 98: Self-Learning Throttle Position Sensor (Tps)
Diagnostic instruments Correct tension values are as shown in Sect. C 1.1, Timing system/valves and must be checked with the engine cold: apply the installation values when fitting a new belt, and the reset values when belt tension reaches 70 Hz. Warning The timing belts can become slack during normal operation.
Page 99 Diagnostic instruments Enter the general functions menu by pressing the icon “Menu 1” (A). Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm. Press the icon “Select system”...
Page 100 Diagnostic instruments The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. Notes Make all connections with the motorcycle ignition key in the OFF position. Press the “Settings” icon to display the special parameters. Select the option “Reset TPS”...
Page 101 Diagnostic instruments On completion of the operation, the message “Was the operation was completed successfully?” will appear; press “Confirm” (C). If any problems were encountered during the operation, the tester will display the relative error messages: each message must be confirmed, (by pressing the “Confirm” icon (C)), or rejected (by pressing the “Exit” icon (D)). Once the reset has been performed, the ECU will be associated with the motorcycle's throttle body.
Page 102: Adjusting The Idle Speed
Diagnostic instruments Adjusting the idle speed Notes Check that the motorcycle is fitted with a genuine Ducati ECU, intake system and exhaust system; if not, fit genuine components. Procedure Connect the inserts of the exhaust gas analyser code 88713.1010 to the outlets on the exhaust pipes using the fittings (19).
Page 103 Connect the Measurement Module cable (3) to the Measurement Module connector on the DDS tester as described in the 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 104 Diagnostic instruments Open both bypass screws (20) by one turn from the fully closed position. 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).
Page 105 Diagnostic instruments The onscreen indicator light (E) will turn red when the function is active. Start the engine. The values may be displayed in two different ways: in numerical form or in graphic form; to select the desired display type, press the “Value display” icon (F). The values can be reset by pressing the “Reset” icon (G). To adjust the balance (within the tolerance range of 260 mbar to 270 mbar), turn the bypass screws (20) until the two lines on the graph coincide, if in graphic mode, or until identical numerical values are displayed, if in numerical mode.
Page 106: Checking The Engine Oil Pressure
Diagnostic instruments Checking the engine oil pressure To measure the pressure of the lubrication circuit, use the engine oil pressure test point (19) as described below. Disconnect the wiring connector (A) and remove the pressure switch (19), taking care to recover the seal. Insert the fitting (9) into the connection on the hose (12), interposing the two copper sealing washers (20).
Page 107 Diagnostic instruments 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 108 Diagnostic instruments On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Pressure Test” icon (D) followed by the “Start” icon (E). The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C.
Page 109 Diagnostic instruments Start the engine. The values may be displayed in three different ways: in one numeric form and in two graphic forms; to select the desired display type, press the “Value display” icon. 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 value measured will displayed next to the letter (A) on the screen.
Page 110: Cylinder Compression Test
Diagnostic instruments Disconnect the DDS tester. Cylinder compression test Notes The on-screen icons used during this procedure are explained in a table at the end of this section. Engine performance is directly correlated to the pressure that can be measured in the combustion chambers of the two cylinders.
Page 111 Diagnostic instruments the DDS tester (1). 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 112: Fuel Pressure Test
Diagnostic instruments The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. Turn over the engine with the starter motor until the pressure stops rising. Check the pressure in each cylinder: standard value: 11 to 12 bar;...
Page 113 Diagnostic instruments Notes The on-screen icons used during this procedure are explained in a table at the end of this section. To test the fuel pressure, use the fuel pressure test pipe (17). Remove the fuel tank outlet pipe (D) on the left side of the flange along with the fitting (E). Fit the fuel pressure test pipe (17), connecting one end (F) to the flange and the other (G) to the fitting (E): in this way, the fuel pressure can be measured at the test outlet (H).
Page 114 Diagnostic instruments Connect the pressure sensor (5) to socket (A) or (C) of the cable (3). On the DDS tester (1), select the “Measurement module” function by pressing the corresponding icon; then press the “Pressure Test” icon (L) followed by the “Start” icon (M). 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 115: Immobilizer Override Procedure
Diagnostic instruments 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 value measured will displayed next to the letter (A) on the screen. The maximum pressure must be 3 bar (nominal).
Page 116 Diagnostic instruments Enter the general functions menu by pressing the icon “Menu 1” (A). Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm. Press the icon “Select system”...
Page 117 Diagnostic instruments The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. Notes Make all connections with the motorcycle ignition key in the OFF position. Press the “Actuators” icon (C) to display the actuators and other components connected to the ECU. Select the “Immobilizer Override”...
Page 118: Guided Diagnosis
Diagnostic instruments A screen will appear in which you can enter the 5 digit secret code. Use the red arrows (E) and (F) to enter each digit: after entering each digit, press the “Confirm” icon (B). One the entire code has been entered, press the “Confirm” icon (B) again. On completion of the operation, the message “Was the operation completed successfully?”...
Page 119 Diagnostic instruments Enter the general functions menu by pressing the icon “Menu 1” (A). 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.
Page 120 Diagnostic instruments Press the icon “Select system” to display a list of the bike’s systems that can be analysed. Select “Engine electronics” and press the “Confirm” icon (B). Press the “Guided diagnosis” icon (C) to access the corresponding function. 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”...
Page 121: Testing The Battery Charging System
Diagnostic instruments diagnosis procedure; press the “Guided Diagnosis” icon (C). The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. 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 the battery, power the injection/ignition system and all the electrical equipment on the motorcycle.
Page 122 Diagnostic instruments Connect the ammeter clamp to the connector (E) of the power and diagnostics cable (Measurement Module) (3). Warning The ammeter clamp must not be connected to wires through which electrical current is flowing. Apply the ammeter clamp to the battery positive terminal lead with the arrow on the clamp pointing towards the battery positive terminal (+).
Page 123 Diagnostic instruments The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter: A, B or C. If the measured current is a positive quantity, this means that alternator is powering all the electrical loads and charging battery at the same time.
Page 124: Deactivating The "Service" Indication On The Instrument Panel
Diagnostic instruments Refit the seat (Sect. E 3, Refitting the seat). Deactivating the “service” indication on the instrument panel The instrument panel multifunction display features a wrench symbol that signals the need for servicing in accordance with the programmed maintenance routine. After the scheduled service has been carried out, the indication must be switched off as follows.
Page 125 Diagnostic instruments Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and confirm, then select the version and confirm by pressing the “Select vehicle system” icon. A list of the motorcycle’s systems that can be analysed will appear on the display. Select “Engine electronics”.
Page 126 Diagnostic instruments The DDS tester will interrogate the electronic control unit and display the parameters analysed with their relative values. Press the “Settings” icon to display the special parameters. Select the option “Service light OFF” and then press the “Apply” icon. On completion of the operation, the message “Was the operation was completed successfully?”...
Page 127: Icons Table
Diagnostic instruments Notes Once the “service” indication has been reset with the DDS tester, set the ignition switch to OFF and wait for at least 30 seconds before switching it ON again. Refit the seat (Sect. E 3, Refitting the seat).
Page 128 Diagnostic instruments Actuators Guided diagnosis Select system Errors Ammeter clamp...
Page 129: Impianto Elettrico
E - Impianto elettrico 0E - Impianto elettrico 1 - Headlight fairing - hand guards - rear-view mirrors Removal of the hand guards - rearview mirrors 4 Refitting the hand guards - rearview mirrors 5 Removal of the headlight fairing 7 Refitting the headlight fairing 9 2 - Fairings Removal of the side fairings 11...
Page 130: Headlight Fairing - Hand Guards - Rear-View Mirrors
Headlight fairing - hand guards - rear-view mirrors 1 - Headlight fairing - hand guards - rear-view mirrors 1 Headlight fairing 2 Spacer 3 Clip 4 Bolt 5 Washer 6 Lower support 7 RH mirror 8 LH mirror 9 RH hand guard 10 LH hand guard 11 Bolt 12 Bolt...
Page 131: Removal Of The Hand Guards - Rearview Mirrors
Headlight fairing - hand guards - rear-view mirrors 25 Cover 26 Bolt Parts catalogue HANDLEBARS AND CONTROLS Headlight fairing Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 132: Refitting The Hand Guards - Rearview Mirrors
Headlight fairing - hand guards - rear-view mirrors To disassemble the hand guard-mirror-turn signal assembly, refer to the exploded view at the beginning of this section. Refitting the hand guards - rearview mirrors If the hand guard-mirror-turn signal assembly has been disassembled, proceed with reassembly, fitting the right turn signal (23) to the hand guard (9), routing the wiring (A) behind clip (B) and fitting bolts (12).
Page 133: Removal Of The Headlight Fairing
Headlight fairing - hand guards - rear-view mirrors Locate the hand guard-mirror assemblies (9) and (10) on the handlebar and tighten the bolts (11). Refit the clamp (13) on the handlebar and tighten the bolts (16) to the specified torque (Sect. C 3, Frame torque settings).
Page 134 Headlight fairing - hand guards - rear-view mirrors Unscrew and remove the bolts (4) securing the bottom of headlight fairing (1) to the headlight support and recover the washers (5). Unscrew and remove the bolts (19) securing the headlight fairing (1) to the lower headlight bracket and recover the washers (5).
Page 135 Headlight fairing - hand guards - rear-view mirrors Reassembly of the headlight fairing Make sure that the clips (3) are fitted to the headlight fairing (1). Insert the bolts (17) complete with the washers (18) in the mudguard (6). Fit the mudguard (6) to the headlight shell (1) and tighten the bolts (17) to the specified torque (Sect. C 3, Frame torque settings).
Page 136: Refitting The Headlight Fairing
Headlight fairing - hand guards - rear-view mirrors Refitting the headlight fairing Locate the headlight fairing (1) on the headlight support; fit the bolts (4) and (19) with their respective washers (5). Tighten the bolts (4) and (19) to the specified torque (Sect. C 3, Frame torque settings).
Page 137: Fairings
Fairings 2 - Fairings 1 RH side fairing 2 LH side fairing 3 RH panel 4 LH panel 5 Bolt 6 Washer 7 Quick-release fastener 8 Bolt 9 Washer 10 Quick-release fastener Parts catalogue Fairing Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 138 Fairings Operation Section reference Remove the seat E 3, Removal of the seat Unscrew the bolt (5) securing RH side fairing (1) to the frame and recover the washer (6). Unscrew the bolts (8) securing RH side fairing (1) to the fuel tank and recover the washers (9). Remove the RH side fairing assembly (1) from the motorcycle.
Page 139 Fairings Repeat the above steps to disassemble the LH side fairing (2). Notes Removal of the LH panel (4) gives access to the document compartment. Reassembly of the fairing To reassemble the fairing, carry out the steps of the disassembly procedure in reverse order; in particular, prepare the quick-release fasteners (7) by putting them in the “open”...
Page 140: Refitting The Side Fairings
Fairings Refitting the side fairings Notes If parts that have been removed are not refitted correctly, they may become loose suddenly while riding and cause you to lose control of your motorcycle. Fit the bolts (8) securing RH side fairing (1) to the fuel tank, interposing the washers (9).
Page 141 Fairings Fit the bolt (5) securing RH side fairing (1) to the frame, interposing the washer (6). Tighten all the fairing bolts to the specified torque (Sect. C 3, Frame torque settings). Repeat the above steps to refit the LH side fairing (2). Operation Section reference Refit the seat...
Page 142: Seat - Side Panels
Seat - side panels 3 - Seat - side panels 1 Seat 2 RH side panel 3 LH side panel 4 RH heat shield 5 LH heat shield 6 Washer 7 Bolt 8 Rubber 9 Washer 10 Bolt 11 Rubber mounting 12 Spacer 13 Spacer 14 Bolt...
Page 143: Removal Of The Seat
Seat - side panels found in the exploded view diagram. Removal of the seat To remove the seat (1), unscrew the bolt (10), slightly raise the rear of the seat and pull backwards. Refitting the seat To fit the seat (1), fully engage the slots (A) on the pins (B) of the fuel tank. Secure the seat with the bolt (10).
Page 144: Removal Of The Rear Side Panels
Seat - side panels Removal of the rear side panels Remove the pillion seat, as described in the paragraph “Removal of the seat”. Unscrew the bolts (7) securing the side panels (2) and (3) to the silencer, and recover the washers (6) and (9) and spacer (13).
Page 145: Refitting The Rear Side Panels
Seat - side panels Unscrew the bolts (14) securing the side panels (2) and (3) to the subframe, and recover the washers (15). Refitting the rear side panels Refit the side panels following the steps of the removal procedure in reverse order. In particular, check that the rubber dampers (8) are installed on the side panels;...
Page 146 Seat - side panels Refit the pillion seat, as described in the paragraph “Refitting the seat”.
Page 147: Front Mudguard
Front mudguard 4 - Front mudguard 1 Right heel plate 2 Left heel plate 3 Bolt 4 Washer 5 Mudguard 6 Bolt 7 Washer 8 Stay Parts catalogue FAIRING Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 148: Refitting The Front Mudguard
Front mudguard Release the front brake hose (A) from the mudguard (5). Unscrew the bolts (6) securing the mudguard to the fork and recover the washers (7). Remove the mudguard. Unscrew the stays (8) and remove them from the fork legs. Refitting the front mudguard...
Page 149 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. Apply the recommended threadlocker to the threads of the stays (8). Screw the supports (8) onto the fork legs.
Page 150 Front mudguard...
Page 151: Hydraulic Clutch Control
1 - Throttle twistgrip 3 1 - Throttle twistgrip Adjusting the throttle cable 4 Removal of the throttle twistgrip 4 Refitting the throttle twistgrip 5 2 - Hydraulic clutch control Removal of the clutch master cylinder assembly 8 Refitting the clutch master cylinder assembly 9 Removal of the clutch slave cylinder 11 Refitting the clutch slave cylinder 12 3 - Front brake control...
Page 152: Throttle Twistgrip
Throttle twistgrip 1 - Throttle twistgrip 1 Throttle twistgrip 2 Cable adjuster on throttle body 3 Throttle cable 4 Bolt 5 Left grip 6 Cover 7 Cable adjuster on handlebar Parts catalogue HANDLEBAR AND CONTROLS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 153: Refitting The Throttle Twistgrip
Throttle twistgrip Operation Section reference Remove the RH hand guard-mirror E 1, Removal of the hand guards - assembly rearview mirrors Loosen locknut (A) and fully unscrew the adjuster (2) from the throttle body pulley (B). Rotate the throttle body pulley (B) so that the cable end fitting (C) can be disengaged from the pulley. Remove the bolts (4) and the cover (6) and disconnect the throttle cable from the twistgrip, freeing the cable end from the race and fully unscrewing the adjuster (7).
Page 154 Throttle twistgrip Refer to the photos on the following pages for correct routing of the throttle cable. Operation Section reference Refit the RH hand guard-mirror E 1, Refitting the hand guards - assembly rearview mirrors Throttle cable positioning...
Page 155 Throttle twistgrip...
Page 156: Hydraulic Clutch Control
Hydraulic clutch control 2 - Hydraulic clutch control 1 Clutch master cylinder 2 Inspection plug (replacement part) 3 Lever pivot pin 4 Lever with grub screw 5 Fluid reservoir cover 6 Clutch hose 7 Mounting clamp 8 Sealing washer 9 Rubber mounting 10 Banjo bolt 11 Bleed valve 12 Dust cap...
Page 157: Removal Of The Clutch Master Cylinder Assembly
Hydraulic clutch control Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the clutch master cylinder assembly Warning The clutch master cylinder manufacturer advises against servicing of the clutch master cylinder (1) due to the safety- critical nature of this component.
Page 158 Hydraulic clutch control Locate the hose (6) on the slave cylinder (14), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder (14). Warning An incorrectly positioned hose can cause clutch faults and interfere with moving parts. Locate the two sealing washers (8) and tighten the banjo bolt (10) to the specified torque (Sect.
Page 159: Removal Of The Clutch Slave Cylinder
Hydraulic clutch control For the positioning of the clutch hose (6) and retaining clips, see the illustration at the end of this section. Operation Section reference Fill the clutch circuit D 4, Filling the clutch circuit Refit the LH hand guard-mirror E 1, Refitting the hand guards - assembly...
Page 160: Refitting The Clutch Slave Cylinder
Hydraulic clutch control At this point the clutch pushrod (16) may also be withdrawn. Check the state of wear of the two O-rings (17) and renew them if necessary. Notes If the two O-rings (17) are renewed, it will also be necessary to renew the O-ring (13) of the clutch slave cylinder (14).
Page 161 Hydraulic clutch control Locate the slave cylinder unit (14) in the crankcase and tighten the bolts (15) to the specified torque (Sect. C 3, Frame torque settings). Locate the hose (6) on the slave cylinder (14), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder (14).
Page 162 Hydraulic clutch control Operation Section reference Fill the clutch circuit D 4, Filling the clutch circuit Positioning of the clutch hose...
Page 163 Hydraulic clutch control...
Page 164 Hydraulic clutch control...
Page 165 Hydraulic clutch control...
Page 166: Front Brake Control
Front brake control 3 - Front brake control 1 Front brake master cylinder 2 Brake lever pedal 3 Rubber mounting 4 Fluid reservoir cover 5 Microswitch 6 Lever pivot pin 7 Inspection plug (replacement part) 8 Mounting clamp 9 Calipers-master cylinder hose Parts catalogue FRONT BRAKE Important...
Page 167: Refitting The Front Brake Master Cylinder
Front brake control Warning The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical nature of this component. Incorrect overhaul of this component could 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 168 Front brake control brake system. Operation Section reference Reconnect the brake hose to the G 3, Refitting the front brake system master cylinder Fill the brake circuit D 4, Filling the clutch circuit Refit the RH hand guard-mirror E 1, Refitting the hand guards - assembly rearview mirrors...
Page 169 Front brake control...
Page 170 Front brake control...
Page 171 Front brake control...
Page 172: Rear Brake Control
Rear brake control 4 - Rear brake control 1 Rear brake master cylinder 2 Clamp 3 Reservoir - master cylinder hose 4 Fluid reservoir 5 Filler cap 6 Sealing washer 7 Banjo bolt 8 Pushrod 9 Nut 10 Clevis 11 Pin 12 Bolt 13 Rear brake hose 14 Brake pedal...
Page 173: Removal Of The Rear Brake Master Cylinder
Rear brake control 25 Dust boot 26 Switch 27 Bolt 28 Washer Parts catalogue REAR BRAKE Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the rear brake master cylinder Warning The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical...
Page 174 Rear brake control Remove the bolt (23) securing the reservoir (4). Remove the complete master cylinder and the reservoir (4) with the hose (3). If necessary, remove the footrest bracket as described in Section H 4, Removal of the footrest brackets.
Page 175: Refitting The Rear Brake Master Cylinder
Rear brake control If the bush (18) in the footrest bracket is to be renewed, install the new bush using a press so that it is recessed 2 mm relative to the outer surface of the footrest bracket (B). Refitting the rear brake master cylinder Warning After working on the rear brake control, check the operation of the brake pedal following the instructions given in Section D 4,...
Page 176 Rear brake control If removed, refit the right-hand footrest bracket as described in Section H 4, Refitting the footrest brackets. Locate the rear brake master cylinder (1) on the motorcycle and fit the retaining bolts (12), applying the recommended threadlocker. Tighten the bolts (12) to the specified torque (Sect.
Page 177 Rear brake control Lubricate the other end of the rod (8) with the recommended grease and insert it in the master cylinder (1). Reconnect the hose (13), locating the sealing washers (6) on both sides of the hose end fitting, and secure it with the banjo bolt (7).
Page 178 Rear brake control...
Page 179 Rear brake control...
Page 180 Rear brake control...
Page 181: Gearchange Control
Gearchange control 5 - Gearchange control 1 Gearchange pedal pivot bolt 2 Gearchange pedal 3 Bolt 4 Pedal rubber 5 O-ring 6 Bush 7 Washer 8 Gearchange lever tie-rod 9 Nut 10 Bolt 11 Bolt 12 Lever 13 Pivot Parts catalogue L.H.
Page 182: Removal Of The Gearchange Control
Gearchange control Removal of the gearchange control Unscrew and remove the pivot bolt (1) securing the gearchange pedal (2). Unscrew and remove the clamp bolt (10) securing the gearchange lever to the gear selector shaft. Withdraw the lever (12) complete with the gearchange control assembly. Notes Mark the position of lever (12) relative to the gear selector shaft.
Page 183: Refitting The Gearchange Control
Gearchange control To adjust the position of the gear pedal, follow the instructions provided in Sect. D 4, Adjusting the position of the gearchange and rear brake pedals. Refitting the gearchange control To refit the gearchange control, reverse the operations of the removal procedure. In particular, grease the O-rings (5), apply threadlocker to the bolt (10), pivot bolt (1) and then tighten them to the specified torque (Sect.
Page 184 G - Impianto elettrico 0G - Impianto elettrico 1 - Front wheel Removal of the front wheel 4 Overhauling the front wheel 6 Refitting the front wheel 9 2 - Front fork Removal of the front forks 12 Overhauling the front forks 13 Refitting the front forks 21 3 - Hydraulic front brake Maintenance operations 23...
Page 185 G - Impianto elettrico Removal of the rear shock absorber 57 Overhauling the rear shock absorber 58 Removal of the rear suspension rocker arm 60 Overhauling the rear suspension rocker arm 61 Refitting the rear suspension 63 8 - Final drive Inspecting the final drive 67 Removal of the front sprocket 68 Refitting the front sprocket 69...
Page 186: Front Wheel
Front wheel 1 - Front wheel 1 Nut 2 Valve 3 Right spacer 4 Seal 5 Bearing 6 Front wheel 7 Inner spacer 8 Washer 9 Left spacer 10 Front wheel axle 11 Bolt Parts catalogue FRONT FORKS FRONT AND REAR WHEELS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 187: Removal Of The Front Wheel
Front wheel 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 fluid to leak out from the actuating pistons.
Page 188: Overhauling The Front Wheel
Front wheel Working from the left-hand side, use a plastic mallet to drive the axle (10) out from the opposite side and remove it. Remove the wheel and recover the spacers (3) and (9). Overhauling the front wheel Wheel bearings Before checking the dimensions, check the wear on wheel bearings (5).
Page 189 Front wheel Position a drift (A) against the inner race of the bearing (5). Tap the drift with a hammer to drive out the bearing. Apply the drift at different points to keep the bearing square during removal. Importante Once removed, the used bearings and seals must not be refitted. Before fitting new bearings, check that the housing is clean and free from scoring and damage.
Page 190 Front wheel Notes Wheels must be rebalanced after repair, maintenance and overhaul operations. Front wheel axle Check the wheel axle for straightness. Roll the axle on a reference surface and measure maximum distortion using a feeler gauge (see Sect. C 1.1, Front wheel).
Page 191 Front wheel Refitting the front wheel When all the necessary inspections have been completed, refit the wheel as follows. Lubricate and fit the spacers (3) and (9) to the seal rings on the sides of the wheel hub. Install the complete wheel between the fork legs. Lubricate the shank and thread of the wheel axle (10).
Page 192 Front wheel Refit the front brake calipers complete with hoses securing them with the bolts (A). Warning Do not operate the brake lever when the calipers are removed. This could cause fluid to leak out from the actuating pistons. Check that the brake discs turn freely inside the calipers. Before tightening the axle clamp bolts (11), lower the bike to the ground and push up and down on the handlebars to load the suspension so the fork legs will become properly seated onto the wheel axle.
Page 193 Front wheel...
Page 194: Front Fork
Front fork 2 - Front fork 1 Bolt 2 Bolt 3 Top yoke 4 Bottom yoke 5 Right fork leg assembly 6 Left fork leg assembly 7 Right inner tube assembly 8 Spring kit 9 Dust seal 10 Circlip 11 Seal 12 Collar 13 Top bush 14 Spacer...
Page 195 Front fork FRONT FORKS handlebar and controls Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Notes Not all parts shown are available separately as spares: however they are indicated for clearer explanation of the procedure.
Page 196 Front fork Disassembly of the front fork Restrain the lock nut (A) with a hex wrench. Using a second wrench, unscrew and remove the cap (16) with its O-ring seal from the damper. Withdraw the complete spring kit (8), recovering, in order, the spring (B), the preload tube (C) and the bush. Drain the oil from inside the leg by pumping with the outer tube (15) and the damper (F).
Page 197 Front fork Warning This movement generates pressure so that the oil will be rapidly expelled from the fork. Aim the jet of oil into a previously prepared container and avoid contact with fork oil. Clamp the inner tube (7) in a vice with soft-faced jaws. Withdraw the damper assembly (F).
Page 198 Front fork Remove the circlip (10). Important Take care not to damage the inner tube (7) and the seat of circlip (10) in the outer tube (15). Slide the outer tube (15) off the inner tube (7). From the outer tube, remove: - oil seal (11);...
Page 199 Front fork Inspection of the front fork Place the spring on a flat surface and measure the free length (L). Service limit: - 270 mm. Renew the spring if the length is not within the specified limit. Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes. They must be free from scoring, steps, or dents.
Page 200 Front fork Check the collar (12) for distortion in the area indicated. Renew if distorted. Reassembly of the front fork Clamp the inner tube in a vice. Protect the end of the inner tube (7) with tape. Important Before installation, smear the sliding edges of oil seal (11) with fork oil or oil seal grease. Install the oil seal (11) with the marked surface facing the dust seal (9).
Page 201 Front fork Install the following components in the outer tube (15) using the oil seal installer no. 88713.3204: - bush (13); - preload tube (14); - bush (13).
Page 202 Front fork Notes Before assembling the inner and outer fork tube (15), lubricate the sliding surfaces of the bushes (13) with fork oil. Assemble the inner tube (7) with the outer tube (15). Push the collar (12) and the oil seal (11) using the oil seal installer no. 88713.3204. Fit the circlip (10) and the dust seal (9).
Page 203 Front fork SHELL ADVANCE FORK 7.5 or DONAX TA Standard capacity: 450 cc (right fork). 470 cc (left fork). The quantity of oil affects fork response during the final part of the compression stroke. High oil level increases compression loading, low oil level will decrease it. Before reassembly, remove any oil from the spring kit (8).
Page 204 Front fork Warning The difference in height between the two fork legs must be no greater than 0.1 mm. Locate the fork legs (5) and (6) in the bottom yoke (4). Locate the fork legs (5) and (6) in the top yoke (3). Grease the threads and the undersides of the heads of bolts (1) and (2).
Page 205 Hydraulic front brake 3 - Hydraulic front brake 1 Pad retaining pin and clip 2 Bolt 3 Right brake caliper 4 Sealing washer 5 Bleed valve 6 Banjo bolt 7 Dust cap 8 Calipers–master cylinder hose 9 Pair of brake pads 10 Left brake caliper 11 Spring 12 Hose guide...
Page 206 Hydraulic front brake Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. 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.
Page 207 Hydraulic front brake Removal of the brake discs Operation Section reference Remove the front wheel G 1, Removal of the front wheel The front discs are comprised of a rotor. Undo the bolts (14) securing the brake discs to the wheel and remove the discs (13) from both sides of the wheel. Refitting the brake discs Before refitting the brake disc to the wheel, clean all contact surfaces thoroughly and apply threadlocker to the threads of retaining bolts (14).
Page 208: Overhauling The Front Brake Components
Hydraulic front brake Tighten the bolts to the specified torque (Sect. C 3, Frame torque settings). Operation Section reference Refit the front wheel G 1, Refitting the front wheel Overhauling the front brake components Important Critical safety components. The brake caliper manufacturer advises against any servicing of the internal components of calipers.
Page 209 Hydraulic front brake Fit the sealing washers (4) to either side of the connection fitting when connecting the brake hose to the brake caliper. Reconnect the hose (8) to the front brake calipers (10) and (3) and tighten the bolts (6) to their specified torque (Sect.
Page 210 Hydraulic front brake If removed, insert the clips (12) in the front brake hose grommets (B), positioning them so that the tabs (C) lie flush with the tops of the grommets, without however altering their position relative to the brake hoses. Notes Apply the recommended lubricant to facilitate insertion of the clips.
Page 211 Hydraulic front brake Fill the brake circuit D 4, Filling the brake circuits...
Page 212: Rear Wheel
Rear wheel 4 - Rear wheel 1 Circlip 2 Nut 3 Washer 4 Bush 5 Valve 6 Wheel Parts catalogue FRONT AND REAR WHEELS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 213 Rear wheel Using a suitable socket, loosen the wheel nut (2). Fully unscrew the wheel nut (2), then slide of the washer (3) and the bush (4). Remove the rear wheel (6) from the motorcycle. Overhauling the rear wheel Inspect the condition of the rear wheel. As the rear wheel has no bearings, it should be supported on the service tool part no.
Page 214 Rear wheel Refitting the rear wheel Clean the mating surfaces. Fit the rear wheel (6) on the axle (C), inserting the pins (A) in the corresponding holes (B) in the wheel. Install the tapered spacer (4) on the axle, with the tapered side facing the wheel, as shown in the figure. Fit the washer (3).
Page 215 Rear wheel...
Page 216 Rear swingarm 5 - Rear swingarm 1 Rear swingarm 2 Bearing 3 Spacer 4 Seal 5 Bush 6 Roller bearing 7 RH spacer 8 LH spacer 9 Swingarm pivot shaft 10 Special nut 11 Pin 12 Bolt 13 Plug 14 Upper drive chain slider 15 Bolt 16 Lower drive chain slider 17 Upper chain guard...
Page 217 Rear swingarm 25 O-ring 26 Caliper mounting bracket 27 Bolt 28 Hub assembly 29 Pin 30 Bolt 31 Nut 32 Splashguard 33 Bracket 34 Bush Parts catalogue REAR WHEEL AXLE SWINGARM Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 218 Rear swingarm Remove the splashguard (32) by unscrewing the bolts (21) securing it to the bracket (33). Remove the circlip (23) on the wheel side of the eccentric hub. Remove the washer (24), the caliper mounting bracket (26) with the O-rings (25) and the other washer (24). Withdraw the eccentric hub (28) from the chain side of the swingarm.
Page 219 Rear swingarm Important The rear hub is a component particularly critical to the dynamic safety of the motorcycle. For this reason, any overhaul of the internal components of the hub is strictly forbidden. The hub is available as complete assembly, part no.
Page 220 Rear swingarm If the caliper bracket locating pin (11) was removed, apply the recommended threadlocker on reassembly. Fit the washer (24) on the hub (28). Fit the caliper mounting bracket (with the 2 O-rings) on the hub, inserting the locating pin (11) on the swingarm in the slot on the bracket (26) as shown.
Page 221: Removal Of The Rear Wheel
Rear swingarm Operation Section reference Refit the rear brake caliper G 6, Refitting the rear brake system Refit the rear sprocket G 8, Removal of the rear sprocket Adjust the drive chain tension D 4, Adjusting the chain tension Refit the rear wheel G 4, Refitting the rear wheel Tension the drive chain as indicated in the paragraph...
Page 222 Rear swingarm Disconnect the speed sensor wiring connector (A) from the main wiring loom. Unscrew the nut (10) and drive out the pivot bolt (9) using a suitable drift.
Page 223 Rear swingarm Withdraw the swingarm (1) from its seat sufficiently to recover the bush (5). Where the right-hand side of the swingarm is attached to the frame, there are two internal spacers (8) and (7). Disconnect the wiring connector (A) from speed sensor. Remove the bolt (B) securing the rear brake fluid reservoir.
Page 224: Inspecting The Swingarm Pivot Shaft
Rear swingarm Inspecting the swingarm pivot shaft Before refitting the swingarm pivot shaft, check it carefully for distortion. Roll the shaft on a reference surface and measure maximum distortion using a feeler gauge (see Sect. C 1.1, Rear wheel). Renew the pivot shaft when distortion exceeds the specified limit or if cracked or otherwise damaged. Overhauling the rear swingarm Inside the swingarm (1), at the point at which it pivots on the frame, there are a pair of ball bearing races (2) on the right-hand side and a pair of roller bearings (6) with seals (4) on the left-hand side.
Page 225 Rear swingarm To change the bearings, proceed as follows. Remove the spacers (8) and (7) from the right-hand side of the swingarm and remove the bush (5) from the left- hand side. Remove the bearings (2), the seals (4) and the roller bearings (6) using a suitable punch and a press. Support the swingarm and take care not to damage the bearing bores.
Page 226 Rear swingarm Once removed, the bearings (2), seal rings (4) and roller bearings (6) must not be reinstalled. Heat the entire swingarm up to 150 °C and support it. Insert the new roller bearings (6) in the service tool no. 88713.1068 and install them from the outside into the bore on the left–hand side of the swingarm.
Page 227 Rear swingarm (A) - drift for internal bearings; (A) - drift for external bearings; (C) - guide pin. Fit a new bearing (2) with the internal spacer (3) onto the drift (A) and position it on the interior of the right-hand side support of the swingarm.
Page 228: Refitting The Swingarm
Rear swingarm Before refitting the swingarm (1), grease the ball bearings (2), roller bearings (6) and seals (4) with the recommended grease. Refitting the swingarm If the swingarm has been disassembled, reassemble it referring to the exploded view at the beginning of this chapter. Locate the swingarm assembly (1), making sure that spacers (7) and (8) are present on the RH side and that the bush (5) is present on the LH side.
Page 229 Rear swingarm Lubricate the swingarm pivot shaft (9) with the recommended grease and insert it fully into the frame. Lubricate the nut (10) with the recommended grease and screw it on the opposite end of the pivot shaft. Tighten the nut (10) to the specified torque (Sect. C 3, Frame torque settings).
Page 230 Rear swingarm Operation Section reference Refit the shock absorber and tie-rod G 7, Refitting the rear suspension to the swingarm Refit the rear wheel G 4, Refitting the rear wheel Refit the rear brake caliper G 6, Refitting the rear brake system Refit the final drive assembly G 8, Final drive...
Page 231: Hydraulic Rear Brake
Hydraulic rear brake 6 - Hydraulic rear brake 1 Banjo bolt 2 Sealing washer 3 Pair of brake pads 4 Rear brake hose 5 Bolt 6 Rear brake caliper 7 Dust cap 8 Bleed valve 9 Clip 10 Rear brake disc 11 Locating dowel 12 Bolt 13 Bolt...
Page 232: Removal Of The Rear Brake System
Hydraulic rear brake Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the rear brake system Before removing the parts in question, you must first carry out the following operations: Operation Section reference Remove the banjo bolt securing the...
Page 233: Removal Of The Rear Brake Disc
Hydraulic rear brake Remove the hose (4). Unscrew the two bolts (5) securing the rear brake caliper to the caliper mounting bracket and remove the caliper (6). Notes “Checking brake pad wear and changing brake pads” (Sect. D 4) for instructions on how to change the brake pads.
Page 234 Hydraulic rear brake Remove the rear wheel G 4, Removal of the rear wheel Slacken off the drive chain D 4, Adjusting the chain tension Remove the rear sprocket G 8, Removal of the rear sprocket Remove the rear brake caliper G 6, Removal of the rear brake system Unscrew and remove the four bolts (13) securing the brake disc to the stub axle and remove the rear brake disc (10).
Page 235: Refitting The Rear Brake Disc
Hydraulic rear brake Refitting the rear brake disc Proceed with refitting of the rear brake disc (10). Install the brake disc (10), positioning it so that the countersinks (S) for the bolt heads are facing upwards. Apply the recommended threadlocker and tighten the bolts (13) to the specified torque (Sect. C 3, Frame torque settings) in the sequence 1-2-3-4.
Page 236: Refitting The Rear Brake System
Hydraulic rear brake Operation Section reference Refit the rear brake caliper G 6, Refitting the rear brake system Refit the rear sprocket G 8, Refitting the rear sprocket Adjust the drive chain tension D 4, Adjusting the chain tension Refit the rear wheel G 4, Refitting the rear wheel Refitting the rear brake system...
Page 237 Hydraulic rear brake After positioning the end fittings correctly, tighten the banjo bolts (1) to the specified torque (Sect. C 3, Frame torque settings). Notes For the sake of clarity the following photos show the swingarm removed from the motorcycle, however all the operations described can also be carried out with the swingarm installed on the frame.
Page 238 Hydraulic rear brake Operation Section reference Tighten the bolt securing the rear F 4, Refitting the rear brake master brake master cylinder hose cylinder Refit the catalyser L 8, Refitting the exhaust system...
Page 239: Rear Suspension
Rear suspension 7 - Rear suspension 1 Shock absorber 2 Tie rod 3 Plug 4 Bush 5 Bolt 6 Ball joint 7 Bolt 8 Rocker arm 9 Roller bearing 10 Seal 11 Spacer 12 Bolt 13 Spacer 14 Nut 15 Bolt 16 Special nut Parts catalogue REAR SUSPENSION...
Page 240: Removal Of The Rear Shock Absorber
Rear suspension Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Rear suspension system The rear suspension uses a fully adjustable progressive hydraulic monoshock (1). The system consists of an upper rocker arm (8) and a non-adjustable tie-rod (19), which is fixed to the single-sided swingarm.
Page 241: Overhauling The Rear Shock Absorber
Rear suspension 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. Disassembly of the rear shock absorber Slacken off the locknut (A) and the spring adjuster nut (B) with a pin wrench or special tool. Remove the retaining ring (C) and the spring.
Page 242: Removal Of The Rear Suspension Rocker Arm
Rear suspension Removal of the rear suspension rocker arm Disconnect the top of the rear shock absorber from the rocker arm as described in “Removal of the rear shock absorber” in this chapter. Separate the linkage assembly (2) from the rocker arm (8) by undoing the bolt (7) and recover the bushings (6) at the sides of the ball joint (4).
Page 243: Overhauling The Rear Suspension Rocker Arm
Rear suspension Overhauling the rear suspension rocker arm Disassembly of the rear suspension rocker arm The rocker arm's movement is obtained by needle roller bearings (9) rotating on an inner spacer (13). Two seals (10) keep the lubricant inside the roller cages. Remove the inner spacer (13) and remove the seals and the roller bearings using a drift with outside diameter Ø...
Page 244 Rear suspension Reassembly of the rear suspension rocker arm Insert a new roller cage (9) on the service tool no. 88713.1071 and lubricate the rocker arm bore with the recommended grease. Support the rocker arm and drive the needle roller bearing into the rocker arm bore until the tool seats against rocker arm.
Page 245: Refitting The Rear Suspension
Rear suspension Important Make sure to drive the bearings perfectly square into the bore without jamming. Use a press, if necessary. Fit a new seal (10) onto the drift with its metal side outermost. Seat it against the previously installed bearing (9). Repeat the above procedure for the other roller bearing (9) and the other seal (10).
Page 246 Rear suspension Insert the upper end of the tie-rod in the rocker arm and tighten the bolt (7) to its specified torque (Sect. C 3, Frame torque settings). Insert the lower end of the shock absorber (1) and the tie-rod (2) in the swingarm. Grease the sliding surface of the threaded bush (16) and insert it in the bore on the swingarm.
Page 247 Rear suspension Operation Section reference Refit the presilencer L 8, Refitting the exhaust system...
Page 248: Final Drive
Final drive 8 - Final drive 1 Circlip 2 Nut with left-hand thread 3 Washer 4 Nut 5 Rear sprocket flange 6 Washer 7 Bush 8 Bush 9 Cush drive bush 10 Rear sprocket 11 Seal 12 Collar 13 Chain 14 Front sprocket 15 Bolt 16 Front sprocket retaining plate...
Page 249: Inspecting The Final Drive
Final drive Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Inspecting the final drive To check wear of the final drive, carry out a visual inspection of the front sprocket (14) and the rear sprocket (10). If the teeth are found to worn as shown in the figure (dotted line), the sprocket must be renewed.
Page 250 Final drive Slacken the chain (Sect. D 4, Adjusting the chain tension). Engage a low gear and unscrew the two screws (15) on the sprocket retaining plate (16). Remove the retaining plate (16) from the gearbox output shaft. Slide the front sprocket (14) with the chain (9) off the gearbox output shaft and take the chain (13) off the sprocket. Refitting the front sprocket Check that the splines of the gearbox output shaft and the sprocket are in perfect condition.
Page 251 Final drive Tighten the screws (15) to the specified torque (Sect. C 3, Frame torque settings). Important Adjust the chain tension as described in Section D 4, Adjusting the chain tension. Fit the sprocket cover (18) and tighten the bolts (17) to the specified torque (Sect. C 3, Frame torque settings).
Page 252 Final drive Install the bush of service tool no. 88713.2060 on the output shaft. Lubricate the new oil seal (11) and press it into position. Using the drift of the tool, drive the oil seal home so that seats against the crankcase bearing. Refit the front sprocket as described in the previous paragraph.
Page 253 Final drive Fully unscrew the nut (2) and remove the washer (3) and the flange (5) complete with the rear sprocket. Recover the collar (12). Using a mallet, tap the sprocket flange (5) with the cush drive bushes (9) off the sprocket (10).
Page 254 Final drive Check the cush drive bushes (9) for signs of wear and, if necessary, remove from the sprocket flange and renew them. Refitting the rear sprocket Refitting is the reverse of removal; ensure that all mating surfaces and the undersides of the retaining nuts (4) of the cush drive bushes (9) are lubricated with the recommended grease.
Page 255: Lubricating The Chain
Final drive Install the safety clip (1), positioning it on the nut (2) as shown in the figure. Operation Section reference Refit the rear wheel G 4, Refitting the rear wheel Adjust the chain tension D 4, Adjusting the chain tension Washing the chain Chains with O-rings must be washed in oil, diesel fuel or paraffin (kerosene).
Page 256 H - Impianto elettrico 0H - Impianto elettrico 1 - Handlebar Removal of the handlebar 4 Refitting the handlebar 6 2 - Steering Adjusting the steering head bearings 10 Steering angle adjustment 11 Removal of the steering head components 12 Refitting the steering head components 15 4 - Footrest brackets Removal of the footrest brackets 22...
Page 257: Handlebar
Handlebar 1 - Handlebar 1 Upper clamp 2 Bolt 3 Bolt 4 Handlebar 5 Grips 6 Spacer 7 Washer 8 Lower clamp 9 Nut 10 Washer Parts catalogue HANDLEBAR AND CONTROLS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 258 Handlebar Operation Section reference Remove the LH and RH hand guards E 1, Removal of the hand guards - rearview mirrors Remove the throttle twistgrip F 1, Removal of the throttle twistgrip Remove the right-hand and left- P 5, Checking the indicating devices hand handlebar switches Remove the front brake lever F 3,...
Page 259: Refitting The Handlebar
Handlebar Refitting the handlebar Refit the grips (5) to the handlebar (4). If the spacers (6) were removed from the top yoke, lubricate with silicone spray. Seat the spacers (6) in the bores (A) in the top yoke, orienting them as shown in the figure. Important To drive in the spacers (6), use a drift that bears only on the outer ring (B) while applying a counterforce on zone (C) on the underside of the top yoke.
Page 260 Handlebar Locate the lower clamps (8) on the top yoke. Fit the bolts (2) in the clamps (8), screw on the nuts (9) complete with washers (7) and (10). Tighten the bolts (2) to the specified torque (Sect. C 3, Frame torque settings) while counterholding the nuts (9).
Page 261 Handlebar Position and orientate the handlebar so that the punch marks (A) are equidistant from the lower clamps and aligned with the faces of the clamps. Apply the recommended grease to the threads and undersides of the heads of the bolts (3). Refit the upper clamp (1) and insert the bolts (3).
Page 262 Handlebar Operation Section reference Refit the front brake lever F 3, Refitting the front brake master cylinder Refit the right-hand and left-hand P 5, Checking the indicating devices handlebar switches Refit the throttle twistgrip F 1, Refitting the throttle twistgrip Refit the clutch lever F 2, Refitting the clutch master cylinder...
Page 263: Steering
Steering 2 - Steering 1 Bolt 2 Top yoke 3 Nut 4 Seal 5 Bearing 6 Bearing 7 Seal 8 Washer 9 Bottom yoke 10 Adjuster screw 11 Nut 12 Headlight support 13 Bolt 14 Spacer 15 Rubber 16 Nut 17 Instrument panel 18 Bush 19 Rubber mounting...
Page 264: Adjusting The Steering Head Bearings
Steering HANDLEBAR AND CONTROLS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Adjusting the steering head bearings Notes See Section D 4, Adjusting the steering head bearings for adjustment of steering head bearing play.
Page 265: Removal Of The Steering Head Components
Steering yoke, 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 (10) on the opposite side to bring it into contact with the stop on the steering head. Apply threadlocker to the thread of nut (11).
Page 266 Steering Notes All parts fitted to the top and bottom yokes, including the wiring and control cables, can remain on the motorcycle provided they do not hinder the following operations. It is possible to remove the instrument panel (17) by unscrewing the nuts (16). Remove the headlight support (12), unscrewing the bolts (13) securing it to the top yoke (2).
Page 267 Steering With the service tool no. 88713.1058 loosen the nut (3) and unscrew it from the steering stem. Slide the oil seal (4), the inner race (A) and the ball race (B) of the upper bearing (5) off the steering stem. Remove the bottom yoke (9) complete with the steering stem from the frame tube.
Page 268 Steering Important Once disturbed, the oil seals (4) and (7) and the bearings (4) and (6) must not be refitted. Using a suitable drift, remove the outer bearing races (C) from the steering head. Proceed with extreme care to avoid damaging the seats.
Page 269 Steering Insert the washer (8), oil seal (7) (with the rim facing upwards) and inner race (A) of bottom bearing (6) onto the steering stem after heating it for about 10 minutes to 120 °C. Fit tool no. 88713.1072 into the steering stem. Keep the inner race (A) pressed against the dust seal (7) by hand for at least 15 seconds.
Page 270 Steering Grease the ball race (B) and fit it to outer race (C) of the top bearing. Fit the inner race (A) of the upper bearing (5) to the steering head, with the larger diameter side of the race facing upwards.
Page 271 Steering Fit the top yoke (2) on the steering stem nut (3), aligning the fork leg bores with the corresponding bores on the bottom yoke. Relocate the fork legs as described in Section G 2, Refitting the front forks. Grease the bolt (1). Tighten the bolt (1) on the top yoke to the specified torque (Sect.
Page 272 Steering with the shorter thread should be facing the instrument panel. Fit the bush (18) to the centre rubber, screwing it on by hand. Locate the instrument panel (12) on the support and tighten the nuts (16). Apply the recommended grease to the threads and undersides of the heads of the bolts (G). Refit the clamp (H) and insert the bolts (G).
Page 273 Steering Operation Section reference Refit the headlight fairing E 1, Refitting the headlight fairing Connect the instrument panel to the P 1, Routing of wiring on frame main wiring loom Refit the fork legs G 2, Refitting the front forks...
Page 274: Footrest Brackets
Footrest brackets 4 - Footrest brackets 1 Rubber mounting 2 Washer 3 Bolt 4 Pin 5 Ring 6 Spring 7 Right front footrest 8 Right footrest bracket 9 Ball 10 Plate 11 Rubber mounting 12 Spring 13 Bolt 14 Footrest rubber 15 Plate 16 Bolt 17 Washer...
Page 275: Removal Of The Footrest Brackets
Footrest brackets Parts catalogue R.H. FOOTRESTS L.H. FOOTRESTS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the footrest brackets The following removal operations apply to both left and right footrest brackets.
Page 276 Footrest brackets Unscrew the bolts (13), bolt (19) securing the brackets to the engine block. Recover the washers (2) and (17). Unscrew the two bolts (3) securing the bracket to the frame. To detach the rear footrests (22) and (23) from the footrest brackets (8) and (18), remove the circlip (5) and pin (4) to release the footrests, plates (10), balls (9) and springs (12).
Page 277: Refitting The Footrest Brackets
Footrest brackets To disassemble the front footrests (20) and (7), separate them from the brackets (18) and (8). Remove the clip (5) and withdraw the pivot pin (4) to release the footrests and the spring (6). Unscrew the bolts (16) an separate the rubbers (14) from the footrests; recover the plates (15) and the bushes (21). Notes The footrests may also be removed with the footrest brackets installed on the motorcycle.
Page 278 Footrest brackets For the rear footrests (22) and (23), insert the springs (12) in the brackets as shown in the figure. Locate the balls (9) on the spring. Position the plates (10) on the footrest brackets as shown in the figure. Notes The side of the plate with the countersinking to the holes (L) must face the footrest bracket.
Page 279 Footrest brackets Check the condition of rubber mountings (1) and (11) in the footrest brackets (8) and (18). If new rubber mountings (1) are fitted, position them as shown in the figure. Locate the right footrest bracket (8) in correspondence with the fixing points on the engine crankcase using washers (2).
Page 280 Footrest brackets Locate the right footrest bracket (18) in correspondence with the fixing points on the engine crankcase using washers (2) and (17). Apply the recommended rubber assembly lubricant to bolts (13) and (19). Insert the bolts (13) and (19). Apply the recommended grease to the bolt (3).
Page 281 Footrest brackets Fix the gearchange control to the engine crankcase, applying threadlocker to the bolt (E) and tightening it to the specified torque (Sect. C 3, Frame torque settings). Grease the end of pushrod (C) and insert it in rear brake master cylinder (A). Apply the recommended threadlocker to the bolts (B).
Page 282: Sidestands
Sidestands 5 - Sidestands 1 Sidestand 2 Bolt 3 Bracket 4 Bolt 5 Switch 6 Spring 7 Plate 8 Pivot bolt 9 Nut Parts catalogue STANDS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 283 Sidestands Operation Section reference Remove the left-hand footrest H 4, Removal of the footrest brackets bracket assembly Disconnect the wiring connector of sidestand switch (5) from the main wiring loom (refer to Sect. P 1, Routing of wiring on frame). Unscrew the bolt (2) securing the sidestand bracket (3) to the engine and remove the complete sidestand assembly, recovering the washers (11).
Page 284: Refitting The Sidestand
Sidestands Inspecting the sidestand Fit the sidestand leg to the bracket and check that there is no excessive play. Ensure that the ends of the sidestand are not bent with respect to the shank. A stand which shows signs of cracking must be renewed immediately. For details of how to test the switch (5), see Section P 6, Checking protection and safety device components.
Page 285 Sidestands Refit the left-hand footrest bracket (Sect. H 4, Refitting the footrest brackets). Connect the sidestand switch wiring connector (5) to the main wiring loom. For correct routing of the sidestand switch wiring, refer to the diagrams in Section P 1, Routing of wiring on frame.
Page 286: Frame Inspection
Frame inspection 6 - Frame inspection 1 Frame 2 Rear subframe 3 Bolt 4 Bracket 5 Pin 6 Clamp 7 Spacer 8 Nut 9 Rubber 10 Bolt 11 Rubber mounting 12 Rubber 13 Bolt 14 Rubber 15 Circlip 16 Rubber mounting 17 Washer 18 Bolt Parts catalogue...
Page 287: Disassembly Of Structural Components And The Frame
Frame inspection Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Disassembly of structural components and the frame Before carrying out dimensional checks on the frame, you must remove all the superstructures fitted, referring to the removal procedures outlined in the sections of this manual.
Page 288: Reassembly Of Structural Components And The Frame
Frame inspection 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 289 Frame inspection Check that the clips (6) are installed on the frame. Refitting the rear subframe Locate the rear subframe (2) on the mountings on the frame (1). Insert the pins (5) from the outside and secure on inside with the nuts (8).
Page 290 Frame inspection Fit the rubber spacers (7) to the pins (5) and secure then with the circlips (15). Tighten the bolts (3) to the specified torque (Sect. C 3, Frame torque settings). Reconnect the wiring connections (Sect. P 1, Routing of wiring on frame) and refit the silencer (Sect.
Page 291: Tail Light And Number Plate Holder
Tail light and number plate holder 7 - Tail light and number plate holder 1 Tail light 2 Rubber mounting 3 Washer 4 Bolt 5 Bolt 6 Spacer 7 Rubber 8 Nut 9 Washer 10 Bolt 11 Tail light support 12 Plate 13 Bolt 14 Washer...
Page 292 Tail light and number plate holder 25 Nut 26 Number plate holder 27 Bolt 28 Number plate light 29 Spacer 30 Rubber mounting 31 Plate 32 Quick-release fastener 33 O-ring 34 Reflector 35 Nut 36 Bolt 37 Bolt 38 Bolt 39 Plate 40 Left turn signal 41 Bolt...
Page 293 Tail light and number plate holder Unscrew the bolt (5) and the nut (8) o release the headlight (1) with the heat shield (42) from the support (11). Refitting the tail light If removed, fit the silicone vibration dampers (2) on the bosses (A) on the tail light (1). Fit the washers (4) on the bolts (3), insert the bolts in the bosses, and tighten to the specified torque (Sect.
Page 294 Tail light and number plate holder PLocate the heat shield (42) on the the tail light (1), using the rubber bush (7) to connect the two parts. Fit the tail light (1) on the rear grab handle (11), locating the vibration dampers (2) in the slots in the grab handle indicated by the arrows.
Page 295 Tail light and number plate holder Fix the tail light (1) with the heat shield (42) to the grab handle (11), as described below. Insert a bush (6) in the rubber bush (7). Insert a bolt (5) in the bush (6), interposing a washer (43) between the tail light and the grab handle. Fit a washer (9) on the bolt (5).
Page 296 Tail light and number plate holder Connect the tail wiring (A), fix the tail light support (11) to the frame with bolts (10) and tighten the bolts to the specified torque (Sect. C 3, Frame torque settings). Fix the cover (15) with the bolt (16) and washer (17) and tighten to the specified torque (Sect. C 3, Frame torque settings).
Page 297 Tail light and number plate holder Operation Section reference Refit the seat E 3, Refitting the seat Removal of the number plate holder Unscrew the bolts (19) securing the number plate holder bracket (18) to the silencers, recovering washers (20). Reconnect the turn signal and number plate light wiring connectors to the main wiring loom (Sect.
Page 298 Tail light and number plate holder Refitting the number plate holder For reassembly of the number plate holder, refer to the exploded view at the beginning of this section, in particular: tighten the bolts (27) and bolt (23), while counterholding nut (25), to the specified torque (Sect. C 3, Frame torque settings);...
Page 299 Tail light and number plate holder If the reflectors were removed, fit the O-rings (33) on the reflector (34). Fit the reflector on the bracket (31), with the word TOP towards the top. Secure the reflector oth quick-rlease fasteners (32), orienting them as show in the figure. Notes The O-rings (33) are only present on the EUROPA version.
Page 300 Tail light and number plate holder Removal of the rear turn signals To remove the rear turn signals (40) and (44), unscrew the bolts (41) and withdraw the wiring from supports (21) and (22). Refitting the rear turn signals Refitting is the reverse of removal; tighten the bolts (41) to the specified torque (Sect. C 3, Frame torque settings).
Page 301 Tail light and number plate holder...
Page 302: Throttle Body
L - Impianto elettrico 0L - Impianto elettrico 2 - Fuel tank Removal of the fuel tank 4 Removal of the fuel tank filler cap 8 Refitting the fuel tank filler cap 8 Removal of the fuel tank flange 10 Refitting the fuel tank flange 11 Refitting the fuel tank 12 6 - Throttle body...
Page 303 Evaporative emissions canister 10 - Evaporative emissions canister 1 Sealing washer 2 Union 3 Evaporative emissions canister 4 Union 5 Hose 6 Clamp 7 Hose 8 Hose 9 Hose 10 Clamp 11 Clamp 12 Clamp 13 Support 14 Bracket 15 Canister plate 16 Rubber 17 Spacer 18 Bolt...
Page 304 Evaporative emissions canister Evaporative emissions canister Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Evaporative emissions canister system (USA versions only) USA models are equipped with an additional system with an evaporative emissions canister that prevents fuel fumes from being discharged into the atmosphere.
Page 305 Evaporative emissions canister Loosen the clamps (6) securing the hoses connecting the canister (3) to the intake manifolds of the horizontal and vertical cylinders and the breather valve (23). Disconnect the hoses (8) and (9) connecting the canister (3) to the cylinders and the connection hose (22) to the breather valve (23).
Page 306 Evaporative emissions canister Refitting the evaporative emissions canister Refitting is the reverse of removal. Operation Section reference Refit the LH side fairing E 2, Refitting the side fairings Refit the seat E 3, Refitting the seat Positioning the hoses, clamps and evaporative emissions canister...
Page 307 Evaporative emissions canister...
Page 308 Fuel tank 2 - Fuel tank 1 Fuel tank 2 Breather hose 3 Breather valve 4 Filler cap 5 Bolt 6 Fuel tank cover 7 Bolt 8 Filler 9 O-ring 10 Bolt 11 Flange assembly 12 Washer 13 Quick-release fitting 14 Filter 15 Collar 16 Collar...
Page 309 Fuel tank 25 Plate 26 Bolt 27 Plate 28 Bolt 29 Key 30 O-ring 31 Bolt 32 Plate 33 O-ring 34 Plate 35 Bolt Parts catalogue FUEL TANK FUEL SYSTEM Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 310 Fuel tank Remove the bracket (G) by unscrewing the bolts (H). Disconnect the turn signal and number plate light wiring connectors (A) (Sect. P 1, Routing of wiring on frame). Withdraw the regulator fures assembly (B) from the support (C) and the self-diagnosis connector (E) from the strap (F) on the fuel tank.
Page 311 Fuel tank Warning Before removing the flange cover (20), check that the fuel tank (1) is empty. Unscrew the nuts (21), remove the flange cover (20) and disconnect the quick-release fittings (13) from the flange. Unscrew the bolts (M) securing the fuel hoses (N) to the fuel tank. Warning Unscrew the special bolt (L) while counterholding with a size 5 Allen key the threaded insert located on the top of the tank.
Page 312 Fuel tank Remove the fuel tank (1) from the motorcycle. Removal of the fuel tank filler cap Remove the hose (2) from the breather valve (3). Release the breather valve (3) by turnig it anti-clockwiseand remove it from the fuel filler (8). Remove the fuel filler flange (8) by unscrewing the bolts (10) and recover the O-ring (9).
Page 313 Fuel tank Refitting the fuel tank filler cap Fit a new O-ring (9). Refit the fuel filler flange assembly (8) in its housing in the tank and tighten the bolts (10) to their specified torque (Sect. C 3, Frame torque settings) in the sequence 1-2-3-4-5-6-7.
Page 314 Fuel tank Fit the hose (2). Removal of the fuel tank flange Unscrew the bolts (19) and (22) securing the fuel tank flange (11). Remove the flange (11) from the fuel tank. Recover the O-ring (30). Using the appropriate tool, undo the clips (15) next to the fuel filter (14). Remove the old filter from the connecting hoses and fit a new filter.
Page 315 Fuel tank Notes The flange is supplied as a spare part complete with the fuel pump and pressure regulator: the entire flange assembly must be replaced in the event of malfunction. Refitting the fuel tank flange Grease the O-ring (30) and locate the flange and refit by reversing the steps of the removal procedure. Tighten the bolts (19) and (22) to the specified torque (Sect.
Page 316 Fuel tank Refitting the fuel tank If the fuel tank has been disassembled into its component parts, reposition all the parts as shown in the figure. In particular: tighten the bolts (26), (28) and (A) to the specified torque (Sect. C 3, Frame torque settings).
Page 317 Fuel tank...
Page 318 Fuel tank If the battery retaining plate (34) was removed, refit positioning it as shown; insert the bolts (35) and tighten them to the specified torque (Sect. C 3, Frame torque settings). Fit the battery retaining plate (32), positioning it as shown; insert the bolts (24) and tighten them to the specified torque (Sect.
Page 319 Fuel tank Locate the fuel hoses (N) on the tank and tighten the bolts (M). Connect the quick-release fasteners (13) o the flange, refit the flange cover (20) and tighten the nuts (21) to the specifie torque (Sect. C 3, Frame torque settings).
Page 320 Fuel tank Disconnect the turn signal and number plate light wiring connectors (A) (Sect. P 1, Routing of wiring on frame). Reposition the regulator fures assembly (B) on the support (C) and the self-diagnosis connector (E) by closing the strap (F) on the fuel tank. Warning Screw in the special bolt (L) while counterholding with a size 5 Allen key the threaded insert located on the top of the tank.
Page 321 Fuel tank Refit the bracket (G), apply the recommended threadlocker and tighten the bolts (H) to the specified torque (Sect. C 3, Frame torque settings). Fit the cover (6) by first inserting the tab (M) in the recess (N) on the tank and then locating the cover on the tank. Fix the tank cover (6) with bolts (5) and (7) and washers (12).
Page 322 Fuel tank Operation Section reference Refit the contactor P 3, Starter contactor Refit the battery P 2, Battery Refit the seat and side panels E 3, Refitting the seat/Refitting the rear side panels Positioning of the fuel tank breather and drain hoses...
Page 323 Fuel tank...
Page 324 Fuel tank Positioning of the fuel hoses...
Page 325 Fuel tank...
Page 326 Throttle body 6 - Throttle body 1 Fuel system assembly 2 Throttle position sensor 3 Clamp 4 Washer 5 Bolt 6 Bolt 7 Clamp 8 Injector 9 Hose 10 Hose 11 Throttle body assembly 12 Hose 13 Stepper motor 14 Bolt 15 Fuel feed hose 16 Fuel return hose 17 Sensor support...
Page 327 Throttle body Parts catalogue INTAKE MANIFOLDS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the throttle body Operation Section reference Remove the seat E 3, Removal of the seat...
Page 328 Throttle body Disconnect the connector (D) connecting the main wiring loom to the stepper motor (13). Disconnect the wiring connector (E) connecting the main wiring harness to the air temperature sensor (19). Detach the air pressure sensor (25) from the throttle body and disconnect the wiring connector (F) from the main wiring harness.
Page 329 Throttle body Notes This operation can be performed also with the throttle body installed on the motorcycle. The throttle position sensor (2) is installed on the right-hand side of the throttle body, in the position of the vertical cylinder (MASTER) throttle. Undo the two bolts (5) to remove the throttle position sensor from the throttle body. Removal of the fuel injectors Undo the injector retaining clamps (7) with the fuel feed hose (15), fuel return hose (16) and injector connection hose (9).
Page 330 Throttle body Refitting the stepper motor Connect the hoses (G) to the throttle body. Locate the motor (13) with its support on the throttle body, fitting the bolts (14). Tighten the bolts (14). Refitting the throttle body If the hoses (12) were removed, reconnect them to the throttle body with the clamps (3), positioning the hoses and clamps as shown in the figure.
Page 331 Throttle body Notes The end of the hose with the smaller diameter is to be connected to the throttle body. Ensure the hoses are fully seated and cirrectly oriented on the throttle body. Tighten the clamps to the specified torque (Sect. C 3, Frame torque settings).
Page 332 Throttle body Tighten the clamps (3) to the specified torque (Sect. C 3, Frame torque settings), making sure that they do not protrude beyond the locating edges of the manifolds. Connect the wiring connector (F) of the air pressure sensor to the main wiring harness and locate the air pressure sensor (25) on the throttle body.
Page 333 Throttle body Connect the wiring connector (B) to connect the main wiring loom to the throttle position sensor (2). Connect the wiring connector (D) to connect the main wiring loom to the stepper motor (13). Important In the case of throttle body renewal, carry out the operation “Self-learning throttle position sensor (TPS)”...
Page 334 Throttle body Positioning of the stepper motor...
Page 335 Throttle body...
Page 336 Air intake 7 - Air intake 1 Hose 2 Airbox 3 Airbox cover 4 Bolt 5 Air filter element 6 Breather hose 7 Hose clip 8 Pin 9 Rubber 10 Spacer 11 Bolt 12 Pressure test fitting 13 Breather valve 14 O-ring 15 Soundproofing panel 16 Bolt...
Page 337 Air intake found in the exploded view diagram. Removal of the airbox Operation Section reference Remove the seat and the side panels E 3, Removal of the seat/Removal of the rear side panels Remove the battery P 2, Removal of the battery Remove the starter contactor P 3, Starter contactor...
Page 338 Air intake Loosen the front bolt (11) and recover the spacer (10) and the rubber mounting (9). Detach the two pins (8) from the rubber mountings (9). Loosen the clamps (L) of the intake manifolds (G).
Page 339 Air intake Remove the hose (H) from pressure test fitting (12). Lift the airbox (2) complete with the coils and leads. Disassembly of the airbox Unscrew the bolts (16) recovering the washers (17) and raise the soundproofing panel (15) from the airbox. Disconnect the drain hose (1) from the airbox (2).
Page 340 Air intake Unscrew the studs (8). To remove the coils (D) and (E) refer to Section M 3, Coil. Reassembly of the airbox To refit the coils (D) and (E) on the airbox, refer to Section M 3, Coil. Apply threadlocker to the two studs (8), screw them into the airbox (2) and tighten them to the specified torque (Sect.
Page 341 Air intake Removal of the oil breather valve Unscrew the bolt (V) and remove the oil breather valve (13) from the crankcase half. Check the condition of O-rings (14) and renew them if necessary. Refitting the oil breather valve Lubricate the O-rings (14) with the recommended grease. Tighten the bolt (V) of the valve (13) to the specified torque (Sect.
Page 342 Air intake Fit the stepper motor hose (H) on the pressure test point (12). Check that clamps (L) are correctly positioned on intake manifolds (G), with the fixing bolts oriented towards the exterior of the motorcycle. Connect the intake manifolds (G) to the airbox and tighten the clamps (L) to the specified torque (Sect. C 3, Frame torque settings).
Page 343 Air intake Reposition rubber mounting (9) and the spacer (10) and tighten the bolt (11) to the specified torque (Sect. C 3, Frame torque settings). Reconnect the main wiring loom connectors (F) to the coils. Reconnect the HT leads (C) of horizontal cylinder coil (D) and the vertical cylinder coil (E) to the respective spark plugs.
Page 344 Air intake Position the oil cooler (B) on the horizontal cylinder head, tightening the bolts (A) to the specified torque (Sect. C 3, Frame torque settings). Operation Section reference Refit the fuel tank L 2, Refitting the fuel tank Refit the starter contactor P 3, Starter contactor Refit the battery...
Page 345 Air intake...
Page 346 Air intake Positioning of the blow-by hose...
Page 347 Exhaust system 8 - Exhaust system 1 Support 2 Vertical cylinder head exhaust pipe 3 Nut 4 Exhaust gasket 5 Sealing washer, thickness 1 6 Plug 7 Clamp 8 Bolt 9 Spring (short) 10 Balance pipe 11 Presilencer exhaust pipe 12 Rubber mounting 13 Left-hand silencer 14 Bolt...
Page 348 Exhaust system 25 Bolt 26 Washer 27 Strap 28 Sealing washer 29 Quick-release fastener 30 Bracket 31 Bolt 32 Rubber 33 Strap 34 Splashguard 35 Rubber 36 Spacer Parts catalogue EXHAUST SYSTEM Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 349 Exhaust system Remove the splashguard (34), unscrewing the bolts (31) and recovering washers (26), (16) and bushes (36). To separate the silencers (13) and (19) unscrew the bolts (34) and remove the bracket (30). Unscrew the bolts (8) and remove the bracket (18). Undo the clamp (33) and separate the two silencers.
Page 350 Exhaust system Disconnect the lambda sensors (20) from the main wiring harness (Sect. P 1, Routing of wiring on frame). For the “Lambda sensor” refer to Section M 3. Remove the spring (9) and remove the pipe (11) from the presilencer (10). Unscrew the clamp (27) to separate the presilencer (10) from the vertical cylinder exhaust pipe (2): recover the gasket (28).
Page 351 Exhaust system Unscrew the bolts (25) and the nuts (21) securing the presilencer (10) to the frame. Recover the bracket (24) and the support (1). Unscrew the nuts (3) and remove the exhaust manifold (2) from the vertical cylinder head and the balance pipe (10) from the horizontal cylinder head, recovering the gaskets (4).
Page 352 Exhaust system Position the balance pipe (10) and vertical head exhaust pipe (2) with the gaskets (4) on their respective cylinder heads and tighten the nuts (3) to the specified torque (Sect. C 3, Frame torque settings). Position the presilencer (10) from the underside of the motorcycle; insert the presilencer pipe in the swingarm. Fit the bolts (25), the spacers (22), the support (1) and the nuts (21) to fix the presilencer (10) to the bracket (24).
Page 353 Exhaust system notches (A) in the end of the pipe. Position the clamp (27) so that it is flush with the end of the pipe, or at least so that the notches (A) are not completely uncovered. Tighten the clamp (27) to the specified torque (Sect. C 3, Frame torque settings).
Page 354 Exhaust system Frame torque settings). Secure the silencer bracket (39) with bolts (34) tightened to the specified torque (Sect. C 3, Frame torque settings). Fit the washers (16) on the bushes (36). Insert the rear end of the splashguard in the vibration damper (12), routing the wiring through the apertures in the spashguard.
Page 355 Exhaust system Reconnect the rear turn signal and number plate light wiring (Sect. P 1, Routing of wiring on frame). Operation Section reference Refit the right-hand footrest H 4, Refitting the footrest brackets Refit the number plate holder H 7, Refitting the number plate holder Refit the rear grab handle H 7,...
Page 356: Description Of The System
M - Impianto elettrico 0M - Impianto elettrico 1 - Description of the system General information on the fuel injection-ignition system 3 Fuel circuit 6 Air circuit 7 Operating phases 9 2 - Fuel injection-ignition system 3 - System components Electronic control unit (ECU) 11 Removal of the electronic control unit 12 Refitting the ECU 12...
Page 357 Description of the system 1 - Description of the system General information on the fuel injection-ignition system The integrated electronic control system, with ignition and injection both controlled by the same control unit, ensures optimal engine performance and output, thus reducing fuel consumption and harmful exhaust emissions.
Page 358 Description of the system Siemens M3C fuel injection-ignition system The Marelli injection-ignition system is the Alfa/N type, in which the engine speed and throttle position are used as the main parameters for measuring the quantity of intake air. If the quantity of air is known, the quantity of fuel can be dosed accordingly to obtain the required ratio.
Page 359 Description of the system 2 Injection relay 3 Fuel pump 4 Lambda sensor (horizontal cylinder) 5 Engine temperature sensor 6 Air temperature sensor 7 Horizontal cylinder coil 8 Pressure sensor 9 Engine speed sensor 10 Vertical cylinder coil 11 Sparkplug 12 Throttle position sensor 13 Injectors 14 Stepper motor...
Page 360 Description of the system Fuel circuit Fuel from the tank is pumped into the delivery line (OUT) and then to the injectors, by means of a pump located on a flange installed at the bottom of the fuel tank. The flange also incorporates the pressure regulator that controls the fuel feed pressure and keeps it constant at a higher value than the negative pressure generated by the engine.
Page 361 Description of the system Air circuit The air circuit is composed of two intake manifolds (A), the throttle body (B) and an airbox (C) located over the throttle body. This motorcycle is equipped with a stepper motor (14) that determines the supplementary air flow downstream of the butterfly valves during the engine starting phase (see “Operating phases”...
Page 362 Description of the system The engine control system (ignition and injection) relies on several sensors which adjust the mixture according to the air pressure and temperature and the engine load. An air temperature sensor (6) located on the intake manifold of the vertical cylinder and an air pressure sensor (5) located between the “V”...
Page 363 Description of the system There is a throttle position sensor (12) fitted on the spindle of the rear cylinder throttle. This device sends the ECU a signal that is an indirect indication of the quantity of air aspirated by the engine (indirect measurement of engine load).
Page 364 Description of the system Starting When the ignition switch is turned to ON, the control unit activates the fuel pump for a few moments to pressurise the fuel supply circuit. The throttle position and engine temperature signals are processed. When the engine is turned over by the starter motor, the unit receives the engine RPM and timing signals that allow it to proceed with injection and ignition.
Page 365 Fuel injection-ignition system 2 - Fuel injection-ignition system Key to fuel injection-ignition system diagram 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 “Wiring diagram”, Section P 1: 4 Fusebox 5 Data acquisition/Diagnostics 6 Starter motor...
Page 366: System Components
System components 3 - System components Electronic control unit (ECU) The engine ECU (1) is an electronic digital microprocessor-based unit. It controls both the injectors and the coils, thus controlling fuel injection and ignition in accordance with the engine operating conditions detected by the following sensors: Absolute pressure sensor (measures the barometric pressure and the engine load in Speed Density mode) - Air temperature sensor (measures intake air temperature)
Page 367 System components Remove the ECU from the motorcycle. Refitting the ECU Fix the ECU to the frame with bolts (2) and reconnect the wiring connector (1). Tighten the bolts (2) to the specified torque (Sect. C 3, Frame torque settings). Connector (1) is a 48 PIN connector.
Page 368 System components Operation Section reference Refit the right-hand fairing E 2, Refitting the side fairings Refit the seat E 3, Refitting the seat Fuel injectors The injectors (1) deliver the correct quantity of fuel required for optimal engine operation. The control unit controls injector opening by feeding current to the coil of an electromagnet which...
Page 369 System components creates a magnetic field thereby attracting an armature and generating fuel spray. If we take the physical characteristics of the fuel to be constant (viscosity, density), as well as the injector delivery and pressure head (controlled by the fuel pressure regulator), the amount of fuel injected depends on the duration for which the injector is open.
Page 370 System components The stepper motor simultaneously controls two by-pass ports having an air flow capacity of around 6 kg/h. The by-pass ports with adjuster screws are present because it is necessary to balance the air flow to the two cylinders. In order to compensate for the quantity of supplementary air supplied by the stepper motor and consequently deliver the correct amount of fuel, the ECU converts the stepper motor steps into angular degrees of the throttle: this system means that opening the stepper motor is equivalent to...
Page 371 System components The outer surface of the sensor element in zirconium dioxide is in direct contact with the exhaust gas, while the inner surface is in contact with the atmosphere. Both surfaces are coated with a thin layer of platinum. Oxygen in ionic form travels through the ceramic layer and charges the platinum layer electrostatically so that the platinum acts as an electrode: the electrical signal generated is carried on the sensor output cable.
Page 372 System components Throttle Position Sensor (TPS) The TPS is powered by the ECU to which it sends a signal indicating the throttle position. This information is an indirect measure of the engine load and is used by the ECU as one of the main parameters for defining the fuel flow rate and spark advance.
Page 373 System components and the 2 gaps (each equivalent to 2 teeth) positioned 180° apart. The signal coming from the pickup on the camshaft gear is used by the ECU to determine the engine speed and as a timing reference point. Notes To check these components for faults, use the DDS tester and follow the instructions given in the paragraph...
Page 374 System components Refitting the air temperature/pressure sensor Refitting is the reverse of removal: tighten the retaining screws (2) of the sensor to the specified torque (Sect. C 3, Frame torque settings. On completion of the refitting operation, reconnect the wiring connector (1) to the sensor. Air pressure sensor This sensor is powered by the ECU and it supplies information concerning the absolute air pressure in an area of the motorcycle that is not subject to turbulence.
Page 375 System components Refitting the air pressure sensor Refitting is the reverse of removal. On completion of the refitting operation, reconnect the wiring connector (3) to the sensor. Refit the airbox (Sect. L 7, Refitting the airbox).
Page 376 System components Spark plug Clean the area around the spark plug bores with a compressed air jet before removing the spark plugs themselves. Remove the spark plug connectors (1) from the spark plugs in both heads and remove the four spark plugs, making sure that no debris falls into the combustion chamber.
Page 377 System components Important Do not use spark plugs with inadequate thermal rating or incorrect thread length. The spark plug must be securely installed. If a spark plug is loose, it can overheat and damage the engine. Make: NGK. Type: DCPR8E. Alternative Make: CHAMPION.
Page 378 System components Notes To check the coils for faults use the “DDS” tester (Sect. D 5, Guided diagnosis). Injection relay The relay (1) is located next to the ECU. To access the relay, remove the seat (Sect. E 3, Removal of the seat) and remove the right-hand fairing (Sect.
Page 379 System components CAN Line This model utilises a CAN line (Controller Area Network) which has made it possible to greatly simplify the lay-out of the electrical system and consequently reduce its overall weight. The CAN line is connected to two nodes: the instrument panel and the engine ECU (I.A.W.
Page 380: Cylinder Head Assemblies: Checks And Adjustments
N - Impianto elettrico 0N - Impianto elettrico 1 - Removal - refitting of the engine assembly Removal of the engine 6 Refitting the engine 9 2.1 - Lubrication system: oil pump Removal of the oil pump 12 Disassembly of the oil pump 13 Reassembly of the oil pump 14 Refitting the oil pump 15 2.2 - Lubrication system: oil cooler...
Page 381: Cylinder/Piston Assemblies
N - Impianto elettrico Checking the oil seals 56 Refitting the camshafts 57 Refitting the camshaft end caps 60 4.4 - Cylinder head assemblies: valves - rocker arms Removal of the cylinder head assembly 63 Overhaul of cylinder head components 67 Refitting the cylinder head assembly 75 Refitting the cylinder heads 81 5 - Cylinder/piston assemblies...
Page 382: Flywheel-Alternator
N - Impianto elettrico Overhaul of the gearbox 141 Inspection of the gear selector forks 142 Inspection of the gear selector drum 143 Reassembly of the gearbox shafts 144 Reassembly of the gearbox 148 8 - Flywheel-alternator Removal of the alternator-side crankcase cover 150 Disassembly of the alternator-side crankcase cover 151 Removal of the flywheel-alternator assembly 152 Checking the flywheel/alternator assembly 154...
Page 383: Removal - Refitting Of The Engine Assembly
Removal - refitting of the engine assembly 1 - Removal - refitting of the engine assembly 1 Plug 2 Bolt 3 Nut 4 Special nut 5 Swingarm pivot shaft Parts catalogue FRAME SWINGARM Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 384 Removal - refitting of the engine assembly Operation Section reference Remove the seat E 3, Removal of the seat Remove the side fairings E 2, Removal of the side fairings Remove the battery P 2, Removal of the battery Remove the starter contactor P 3, Starter contactor Remove the fuel tank...
Page 385 Removal - refitting of the engine assembly Restrain the swingarm pivot shaft (5) on the right-hand side of the motorcycle while unscrewing the nut (4) on the left-hand side: Using drift 88713.1074, fully extract the swingarm pivot shaft. This frees the swingarm from the engine and therefore it can be left attached to the frame.
Page 386 Removal - refitting of the engine assembly Remove the two upper bolts (2). Withdraw the complete engine assembly from the frame by lowering it and pushing it forwards. Refitting the engine Refitting is the reverse of removal. In particular, lubricate the nuts (3), nut (4) and the swingarm pivot shaft (5). Tighten the nuts (3) and the nut (4) to the specified torque (Sect.
Page 387 Removal - refitting of the engine assembly Operation Section reference Reconnect the wiring connectors P 1, Routing of wiring on frame on the engine block Refit the front sprocket G 8, Refitting the front sprocket Adjust the drive chain tension D 4, Adjusting the chain tension Refit the clutch slave cylinder...
Page 388: Lubrication System: Oil Pump
Lubrication system: oil pump 2.1 - Lubrication system: oil pump 1 Complete oil pump assembly 2 O-ring 3 Circlip 4 O-ring 5 Pump body 6 Circlip 7 Reducer bush 8 Spring washer 9 Bolt 10 Bolt 11 Spring washer 12 Pump drive gear 13 Bush 14 By-pass plug 15 Locating bush...
Page 389 Lubrication system: oil pump Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the oil pump Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge...
Page 390 Lubrication system: oil pump Warning Make sure that vice jaws are faced with soft material. Remove the plug (14) and extract the spring (16) and by-pass valve (17). Check the condition of the above components. Check the condition of the above components. Remove the circlip (6), slide out the bush (13) and the circlip (3).
Page 391 Lubrication system: oil pump Install in the pump the by-pass valve (17) and the spring (16); screw in the plug (14) and tighten to the specified torque (Sect. C 3, Engine torque settings) after applying a medium strength threadlocker. Fit the cover (2) to the pump body (5) complete with the gears. Refitting the oil pump If removed, apply the recommended threadocker to the bush (7) and screw it into the crankcase half by the specified amount.
Page 392 Lubrication system: oil pump Position the oil pump (1) on the crankcase and tighten the bolts (9) and (10) to the specified torque (Sect. C 3, Engine torque settings). Check the gear backlash with the driving gear by fixing a dial gauge, equipped with the appropriate stylus, to the crankcase half.
Page 393: Lubrication System: Oil Cooler
Lubrication system: oil cooler 2.2 - Lubrication system: oil cooler 1 Oil cooler 2 Rubber mounting 3 Spacer 4 Bolt 5 Oil return hose 6 Oil supply hose 7 Connection fitting 8 Aluminium gasket Parts catalogue OIL COOLER Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 394 Lubrication system: oil cooler Drain the oil from the lubrication D 4, Changing the engine oil and system filter cartridge Loosen the nuts on the unions (A) and detach the oil cooler supply (6) and return (5) hoses from the connection fittings (7).
Page 395 Lubrication system: oil cooler To remove the hoses (5) and (6), free them from the guides (C). Notes The oil cooler can be removed complete with its hoses. Oil cooler inspection Visually inspect the cooler. Renew the cooler at any sign of damage or leaks. Refitting the oil cooler Fit the rubber mountings (2) on the horizontal cylinder head and tighten to the specified torque (Sect.
Page 396 Lubrication system: oil cooler Notes Lubricate the threads of the fittingss (5) and (6) and O-rings (D) with engine oil. Fit the hoses (5) and (6) on the fittings (7) without inserting the O-rings. Screw the nuts (G) fully on to the connection fittings by hand. Warning To avoid pinching the O-rings, do not push the hose into the connection fitting.
Page 397 Lubrication system: oil cooler Tighten the nuts (G) to the specified torque (Sect. C 3, Frame torque settings) while counterholding the flats on the connection fittings (7). Position the oil cooler (1) in correspondence with the rubber mountings (2) fitted previously and secure it with the collars (3) and bolts (4).
Page 398 Lubrication system: oil cooler Locate the hoses (5) and (6) in the guides (C). Operation Section reference Fill the system with engine oil D 4, Changing the engine oil and filter cartridge...
Page 399 Lubrication system: oil breather 2.3 - Lubrication system: oil breather 1 O-ring 2 Oil breather valve 3 Clamp 4 Hose Parts catalogue AIR INTAKE - OIL BREATHER Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 400 Lubrication system: oil breather Extract the hose (4) from the airbox (A). Unscrew the bolt (B) and remove the oil breather valve (2) from the engine. Check the condition of O-rings (1) and renew them if necessary. Refitting the oil breather system Refitting is the reverse of removal.
Page 401 Lubrication system: oil breather Notes To facilitate subsequent removal and refitting operations, we recommend that the hose clamps are installed in their original positions. Operation Section reference Refit the side fairings E 2, Refitting the side fairings Refit the seat E 3, Refitting the seat...
Page 402 Cylinder head assemblies: checks and adjustments 4.1 - Cylinder head assemblies: checks and adjustments 1 Valve closing shim 2 Camshaft 3 Valve opening shim 4 Valve Parts catalogue Cylinder head: timing system Vertical cylinder head Horizontal cylinder head Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 403 Cylinder head assemblies: checks and adjustments Remove the side fairings E 2, Removal of the side fairings Remove the battery P 2, Removal of the battery Remove the starter contactor P 3, Starter contactor Remove the fuel tank L 2, Removal of the fuel tank Remove the oil cooler N 2.2,...
Page 404 Cylinder head assemblies: checks and adjustments The clearance values must be within the specified limits (Sect. C 1.1, Timing system/valves). If they are not, remove the opening shim (3), as described in the paragraph “Removal of the cylinder head assembly”, Sect. N 4.4, and replace it with a shim of appropriate thickness to obtain the specified clearance. Notes Opening rocker arm shims measuring 1.8 to 3.45 are available as replacement parts: each shim is marked with its size.
Page 405 Cylinder head assemblies: checks and adjustments Checking valve lift Fit the gauge (C) 88765.1581 in correspondence with the fixing hole of the previously removed cylinder head valve cover, as shown in the photo. Reset the valve opening clearance when the camshaft is in its rest position by fitting a feeler gauge between the upper rocker arm and opening shim.
Page 406 Cylinder head assemblies: checks and adjustments Notes This operation is best done using one dial gauge for the exhaust valve and another one for the intake valve. Make sure the dial gauge fork is centred relative to the valve axis and located against the closing shim. Set the dial gauge to zero when the valve is fully closed.
Page 407 Cylinder head assemblies: checks and adjustments Turn the degree wheel (G) counterclockwise until the dial gauge (C) on the exhaust side shows a lift of 1 mm. Check that the angular displacement reading on the degree wheel (G) is as specified (Sect. C 1.1, Timing system/valves).
Page 408 Cylinder head assemblies: checks and adjustments Refit the starter contactor P 3, Starter contactor Refit the battery P 2, Refitting the battery Refit the side fairings E 2, Refitting the side fairings Refit the seat E 3, Refitting the seat...
Page 409 Cylinder head assemblies: timing belt covers/timing system 4.2 - Cylinder head assemblies: timing belt covers/timing system 1 Vertical cylinder timing belt cover 2 Horizontal cylinder timing belt cover 3 Bolt 4 Bolt 5 Spacer 6 Elastic stop ring 7 Washer 8 Outer timing belt driveshaft pulley 9 Horizontal cylinder timing belt 10 Intermediate spacer...
Page 410 Cylinder head assemblies: timing belt covers/timing system 25 Circlip 26 Key 27 Bolt Parts catalogue timing system Cylinder head: timing system Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 411 Cylinder head assemblies: timing belt covers/timing system Repeat the above operations to remove the vertical cylinder timing belt (23). To remove the camshaft pulleys, install the tool 88713.3152 on the pulley to be removed to prevent its rotation, and using service socket no. 88700.5644 inserted in a torque wrench or ratchet arm, loosen the pulley retaining nut (13). Remove the nut (13), washer (14) and pulley (16).
Page 412 Cylinder head assemblies: timing belt covers/timing system Use the wrench of tool no. 88700.5644 to lock rotation of the timing belt driveshaft pulley on the crankcase and, using the socket combined with the tool, loosen the nut (6). Remove the nut (6), the washer (7) and the outer pulley (8). Remove the first Woodruff key (24) located on the timing belt driveshaft.
Page 413 Cylinder head assemblies: timing belt covers/timing system Disassembly and reassembly of the timing belt pulleys To disassemble the pulleys, loosen and remove the three screws (12), slide of the washer and (15) and remove the pulley (16) from the flange (17). To reassemble, fit the pulley (16) on the hub (17), aligning the timing mark (G) on the pulley with the timing mark on the (H) on the hub.
Page 414 Cylinder head assemblies: timing belt covers/timing system Refitting the timing system assembly Refitting the camshaft timing pulleys Check that the keyway on the end of camshaft is in good condition and without burrs. Fit one key (C) into the camshaft keyway. Important During reassembly, take care that the timing mark “B”...
Page 415 Cylinder head assemblies: timing belt covers/timing system Fit the assembled pulley (16) onto the camshaft, so that is firmly seated. Warning Make sure that the Woodruff key is not dislodged. Fit the tool no. 88713.3152 onto the pulleys to prevent rotation. Apply a smear of grease to the thread and underside of the nut (13), and fit the washer (14) and the nut.
Page 416 Cylinder head assemblies: timing belt covers/timing system Refitting the timing belt driveshaft pulleys Install the circlip (25) on the pulley side of the timing belt driveshaft. Drive it into its seat using the protective cap 88700.5749 and the relative drift. Fit the spacer (5) with the slot facing the crankcase.
Page 417 Cylinder head assemblies: timing belt covers/timing system Important To prevent the nuts working loose and consequent serious engine damage, always use new self-locking nuts on all the timing belt pulleys on reassembly. Notes Apply a thin coating of grease to the thread and underside of the nut (6). Use the wrench of tool 88700.5644 to restrain the pulleys against rotation and, using the bush of the tool in a torque wrench, tighten the self-locking nut to the specified torque (Sect.
Page 418 Cylinder head assemblies: timing belt covers/timing system Important Turn the timing belt driveshaft pulley with the spark plugs removed from the engine. Remove the inspection cover (C) from alternator-side crankcase cover by unscrewing the two bolts (D). Install the service tool 88713.2011 in the alternator-side crankcase cover to hold the crankshaft against rotation and secure it with the relative pin.
Page 419 Cylinder head assemblies: timing belt covers/timing system Restrain the camshafts of both cylinder heads by screwing tool no. 88713.2282 into the camshaft end caps (E). Turn the pulleys by hand until the end of the tool engages the slot in the camshaft. Fit the horizontal (9) and vertical (23) timing belts using your hands only and without altering the alignment of the pulleys.
Page 420 Cylinder head assemblies: timing belt covers/timing system Check the timing belt tension and adjust if necessary as described in the paragraph “Measuring timing belt tension” (Sect. D 5). Warning Check the tension values on sections of belts (M) and (N) shown in the figure. When the correct belt tensioning value is reached, ensure that bolts (20), (27) and (12) are tightened to the specified torque (Sect.
Page 421 Cylinder head assemblies: timing belt covers/timing system Warning Whenever you renew any components of the timing system, it is good practice to also check the timing (Sect. N 4.1, Cylinder head assemblies: checks and adjustments). Remove the service tools no. 88713.2282 from the camshaft end caps (E) and refit the screws (F) with the washers, tightening them to the specified torque (Sect.
Page 422 Cylinder head assemblies: timing belt covers/timing system Refitting the timing belt covers Position the vertical timing belt cover (1) on the engine. Fit the cover retaining screws (4) and tighten to the specified torque (Sect. C 3, Engine torque settings). Locate the horizontal timing belt cover (2) on the engine.
Page 423 Cylinder head assemblies: camshafts 4.3 - Cylinder head assemblies: camshafts 1 Bolt 2 Vertical cylinder head inner timing belt cover 3 Seal 4 Bolt 5 Washer 6 Horizontal cylinder head inner timing belt cover 7 Bolt 8 Valve cover 9 O-ring 10 Vertical cylinder head 11 Horizontal cylinder head 12 Stud bolt...
Page 424 Cylinder head assemblies: camshafts 25 Valve cover Parts catalogue CYLINDER HEAD: TIMING SYSTEM Vertical cylinder head HORIZONTAL CYLINDER HEAD INTAKE MANIFOLDS Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 425 Cylinder head assemblies: camshafts Refitting the intake manifolds Apply the recommended threadlocker to the studs (12) and (13), install them in the cylinder heads and tighten them to the specified torque (Sect. C 3, Engine torque settings). Locate the intake manifolds (17) and secure with the nuts (14). Tighten the nuts (14) to the specified torque (Sect.
Page 426 Cylinder head assemblies: camshafts Operation Section reference Refit the throttle body L 6, Refitting the throttle body Reconnect the throttle cables to the F 1, Refitting the throttle twistgrip throttle body Refit the airbox L 7, Refitting the airbox Refit the fuel tank L 2, Refitting the fuel tank Refit the starter contactor...
Page 427 Cylinder head assemblies: camshafts Repeat the operation for the horizontal cylinder head (11). Notes When removing the covers, take care not lose the Woodruff keys (15) located on camshafts (16) and (22). Unscrew the bolts (21) of the end cap (20) of the camshaft (16). Remove the camshaft end cap (20) from the cylinder head and recover the O-ring (19).
Page 428 Cylinder head assemblies: camshafts Removal of the valve covers Operation Section reference Remove the seat E 3, Removal of the seat Remove the side fairings E 2, Removal of the side fairings Remove the battery P 2, Removal of the battery Remove the starter contactor P 3, Starter contactor...
Page 429 Cylinder head assemblies: camshafts Refitting the valve covers Always fit new O-rings (9) when refitting the valve covers. Fix the valve covers (8) and (25) with the relative O-rings (9) to the cylinder head. Tighten the bolts (7) to the specified torque (Sect. C 3, Engine torque settings).
Page 430 Cylinder head assemblies: camshafts Operation Section reference Refit the oil cooler N 2.2, Refitting the oil cooler Refit the fuel tank L 2, Refitting the fuel tank Refit the starter contactor P 3, Starter contactor Refit the battery P 2, Refitting the battery Refit the side fairings E 2,...
Page 431 Cylinder head assemblies: camshafts Withdraw the camshaft (16) from its housing. Remove the oil seal (3) from the cylinder head. Inspecting the camshafts 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.
Page 432 Cylinder head assemblies: camshafts Each camshaft is stamped with an identification letter: O: horizontal; V: vertical. Checking the oil seals Fit new oil seals at each engine overhaul. Insert the new oil seals squarely in their bores. Use suitable drifts. Lubricate the lip of oil seals after assembly.
Page 433 Cylinder head assemblies: camshafts Important If the rockers arms are already installed in the cylinder head (Sect. N 4.4, Refitting the rocker arms, shims and valves), insert the camshaft (16), carefully rotating it as you go, so that the camshaft lobes do not foul the rocker arms.
Page 434 Cylinder head assemblies: camshafts If previously removed, relocate the spring (A) of the opening rocker arm (B). Check the condition of the Woodruff key (15) and its groove, and install it. Operation Section reference Refit the inner timing belt covers N 4.3, Refitting the camshaft end caps and camshaft end caps...
Page 435 Cylinder head assemblies: camshafts Lubricate the new O-rings (19) with the recommended grease and fit on the end cap (20). Fit the end cap (20) on the left-hand side of the cylinder head. Secure the end cap (20) with the bolts (21). Tighten the bolts (21) to the specified torque (Sect.
Page 436 Cylinder head assemblies: camshafts Operation Section reference Refit the camshaft timing pulleys to N 4.2, Refitting the timing system the cylinder heads assembly Refit the timing belt covers N 4.2, Refitting the timing belt covers Refit the fuel tank L 2, Refitting the fuel tank Refit the starter contactor P 3,...
Page 437: Cylinder Head Assemblies: Valves - Rocker Arms
Cylinder head assemblies: valves - rocker arms 4.4 - Cylinder head assemblies: valves - rocker arms 1 Clip 2 Shim 3 Opening rocker arm 4 Rocker arm shaft 5 O-ring 6 Valve opening shim 7 Half rings 8 Valve closing shim 9 Spring 10 Valve rubber 11 Exhaust valve guide...
Page 438 Cylinder head assemblies: valves - rocker arms Vertical cylinder head HORIZONTAL CYLINDER HEAD Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the cylinder head assembly Operation Section reference...
Page 439 Cylinder head assemblies: valves - rocker arms Operation Section reference Remove the valve covers N 4.3, Removal of the valve covers Remove the camshafts N 4.3, Removal of the camshafts Remove the camshaft end caps N 4.3, Removal of the inner timing belt covers and camshaft end caps Remove the clip (1) securing the opening rocker (3).
Page 440 Cylinder head assemblies: valves - rocker arms Slide the valve closing shim (8) off the valve (17). Withdraw the valve (17) from the underside of the cylinder head. Repeat the above operations for the exhaust side. Attach the end of the spring (9) of the closing rocker arm (18) to the tool 88713.2783. Remove the closing rocker arm shaft (4) using service tool 88713.2837.
Page 441 Cylinder head assemblies: valves - rocker arms Overhaul of cylinder head components Overhaul of the cylinder heads Remove any carbon deposits from the combustion chamber and its ducts. Check for cracking and inspect the sealing surfaces for scoring, ridges or other damage.
Page 442 Cylinder head assemblies: valves - rocker arms The cylinder barrel mating surface must be perfectly flat. If this is not the case, spread diamond dressing compound (6 to 12 micron thickness) on a reference surface and slide the cylinder head on the surface as shown in the figure until a flat finish is obtained.
Page 443 Cylinder head assemblies: valves - rocker arms Check that valve head band (at 45° to valve head top face) is concentric to the valve stem as follows: place the valve on a V block, set a dial gauge at right angles to the head and rotate the valve. Service limit: 0.03 mm.
Page 444 Cylinder head assemblies: valves - rocker arms Important When you change the valve seats, change the valve guides as well. Renewal of the valve seat Remove the worn seats by grinding out the rings. Take great care not to damage the valve seat housing in the cylinder head.
Page 445 Cylinder head assemblies: valves - rocker arms Allow to cool and then lap the valve seats, smooth the connections between the ducts and the new seats and grind the valves. Valve–seat contact surfaces Use Prussian blue or a mixture of minium and oil to check that the contact surface (W) between valve and seat is 1.0 to 1.5 mm.
Page 446 Cylinder head assemblies: valves - rocker arms Valve-valve guide clearance Assembly clearance: - 0.03 to 0.06 mm. Maximum permissible wear limit: - 0.08 mm. Renewal of the valve guides To renew the valve guides (11) and (13), proceed as follows. Heat up the cylinder head gradually and evenly up to 200 °C.
Page 447 Cylinder head assemblies: valves - rocker arms Rocker shaft–rocker bore clearance The assembly clearance must be 0.03 to 0.06 mm. Maximum permissible wear limit: - 0.08 mm. The rocker arm shafts should be a light force fit in the cylinder head. In the event of excessive clearance, fit 0.02 mm oversize shafts (available from Parts Service).
Page 448 Cylinder head assemblies: valves - rocker arms Refitting the cylinder head assembly To refit the cylinder head reverse the steps of the removal procedure; pay particular attention to those operations mentioned specifically. It is very important that all the components are carefully cleaned. If removed, fit new valve guide seal rings (10), lubricate with engine oil and insert from the spring side with tool part no.
Page 449 Cylinder head assemblies: valves - rocker arms Important When assembling the rocker arm shafts (4) make sure that threaded hole is on the external side of the cylinder head. Detach the spring (9) and remove the tool 88713.2783. Proceed in the same way for the exhaust side.
Page 450 Cylinder head assemblies: valves - rocker arms Install the valve (17) and valves (16), first lubricating them with engine oil. Provisionally install the camshaft (C). Using two screwdrivers, hold the closing rocker (18) in the “valve open” position.
Page 451 Cylinder head assemblies: valves - rocker arms Fit the closing shim (8) on the valve stem (17) with the larger diameter side facing the rocker arm. Position the two half rings (7) on the valve stem. Remove the screwdriver and position the closing rocker arm (18) in the rest position. Reposition the screwdriver, and compress the spring as much as possible while holding the valve, the shim and the half rings in the “valve closed”...
Page 452 Cylinder head assemblies: valves - rocker arms that the clearance between the rocker and the closing shim is within the specified tolerance limits (Sect. N 4.1, Checking the closing clearance (Sc) of the intake/exhaust valves). If not, adjust the valve clearance (Sect. N 4.1, Checking and adjusting valve clearances).
Page 453 Cylinder head assemblies: valves - rocker arms Fit the side clip (1) on the shaft (4) of the opening rocker arm (3) between the two spacers (2). Operation Section reference Refit the camshaft end caps N 4.3, Refitting the camshaft end caps Refit the camshafts N 4.3,...
Page 454 Cylinder head assemblies: valves - rocker arms bushes (B) are installed (Sect. N 5, Cylinder/piston assemblies). Fit the cylinder head onto the studs and lower it down onto the cylinder barrel. Fit the special washers (12) over the stud bolts with the square edged face towards the cylinder head and the flat face towards the inside.
Page 455 Cylinder head assemblies: valves - rocker arms...
Page 456 Cylinder/piston assemblies 5 - Cylinder/piston assemblies 1 Pin 2 Circlip 3 Gudgeon pin 4 Vertical cylinder 5 Piston rings 6 Cylinder-crankcase gasket 7 Pin 8 Horizontal cylinder 9 Piston 10 Locating bush 11 Cylinder head gasket 12 Cylinder temperature sensor Parts catalogue Cylinders - Pistons Important...
Page 457 Cylinder/piston assemblies Operation Section reference Remove the engine from the frame N 1, Removal of the engine Remove the timing belt covers N 4.2, Removal of the timing belt covers Remove the timing belts and the N 4.2, Removal of the timing system timing belt pulleys assembly Remove the cylinder heads from...
Page 458 Cylinder/piston assemblies Since insertion of piston in the barrel is a difficult operation to perform at the time of reassembly, remove the piston together with the barrel as an assembly as described below. Close the opening in the engine crankcase with a rag or soft paper to prevent foreign material or solid combustion residue from falling in.
Page 459 Cylinder/piston assemblies To remove the vertical cylinder-piston assembly, proceed as described above for the horizontal cylinder. Remove the cylinder-crankcase gaskets (6) from the cylinder barrel. Important Mark the pistons to show from which cylinder they were removed: V= Vertical - H= Horizontal. Overhaul of the cylinder barrel/piston components Overhauling the cylinder Check that the walls of the cylinder bore are perfectly smooth.
Page 460 Cylinder/piston assemblies Overhauling the piston Clean the piston crown and piston ring grooves, removing any carbon deposits. Inspect the piston and check its dimensions carefully: there must be no signs of scuffing, scoring, cracks, or other damage. Check the piston diameter. The pistons must always be renewed as a pair.
Page 461 Cylinder/piston assemblies Piston-cylinder clearance The pistons are marked with a letter (punched into the piston crown) that indicates the size class to which they belong. Always match cylinders with pistons from the same size class. For the values, refer to Section C 1.1, Cylinder/Piston. Overhauling the gudgeon pins Gudgeon pins must be perfectly smooth without signs of scoring, steps, or blueing due to overheating.
Page 462 Cylinder/piston assemblies The maximum permissible wear limit is 0.15 mm for the top compression ring (1 st ) and 0.10 mm for the others (2 nd and oil control ring). Notes The piston rings must always be installed with markings facing upwards. Gudgeon pin-piston clearance Measure the diameter of the gudgeon pin bore in the piston.
Page 463 Cylinder/piston assemblies Maximum wear limit: - 0.025 mm. Notes If you fit a new gudgeon pin, you must also change the connecting rod small end bush. Piston ring-to-bore clearance It is essential that the measurement be performed with the piston ring (A) positioned perfectly square in the cylinder. For this reason, the piston (9) should be inserted in the cylinder without piston rings fitted and then place the piston ring to be checked on top of the piston.
Page 464 Cylinder/piston assemblies Measure the piston ring gap: Top and second piston ring (nominal): 0.20 to 0.40 mm. Wear limit: 0.80 mm. Oil control ring (nominal): 0.30 to 0.60 mm. Wear limit: 1.0 mm. Refitting the cylinder/piston assembly If a new cylinder/piston assembly is to be fitted, make sure that the piston and cylinder are of the same size class. The letter indicating the cylinder size class is stamped on the cylinder-head mating face;...
Page 465 Cylinder/piston assemblies If the pistons have been separated from their cylinders, before reassembling these components, position the piston ring gaps at 120° from one another (the markings must always face the piston crown). Use a universal tool to carefully insert the piston into the cylinder (first lubricate the inside of the cylinder with engine oil).
Page 466 Cylinder/piston assemblies Using service tool no. 88700.5644, bring the small end of the connecting rod up to near TDC. Fit the piston–cylinder assembly on the crankcase studs.
Page 467 Cylinder/piston assemblies Push the connecting rod small end into the piston close to the gudgeon pin (3) bore. Lubricate and insert the gudgeon pin. The gudgeon pin must slide smoothly in the connecting rod small end bush and in the piston (9). Stuff the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the circlip (2) using service tool 88713.2270.
Page 468 Cylinder/piston assemblies Repeat the procedure for the other cylinder. Operation Section reference Refit the cylinder heads N 4.4, Refitting the cylinder heads Refit the timing belt pulleys and the N 4.2, Refitting the timing system timing belts assembly Refit the timing belt covers N 4.2, Refitting the timing belt covers Refit the engine to the frame...
Page 469: Clutch Assembly: Aptc Wet Clutch
Clutch assembly: APTC wet clutch 6.1 - Clutch assembly: APTC wet clutch 1 Bolt 2 Collar 3 Clutch lifter 4 Clutch spring 5 Pressure plate 6 Bearing 7 Clutch plates 8 Nut 9 Lock washer 10 Clutch centre 11 Shim 12 Spring 13 Hub Parts catalogue...
Page 470 Clutch assembly: APTC wet clutch Description of the APTC clutch assembly The APTC system with servo-assisted torque and anti-wheel slip on braking. The advantages of this system are: prevents the unwelcome effects of excessive engine braking during hard downshifting, thus making for smoother, cleaner cornering (no rear wheel slip);...
Page 471 Clutch assembly: APTC wet clutch Removal of the APTC clutch Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Disconnect the oil pressure sensor P 5, Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Remove the clutch-side crankcase N 6.2,...
Page 472 Clutch assembly: APTC wet clutch Remove the washer (9). Withdraw the clutch hub–plates-centre assembly (B) from the clutch drum (A), marking the components so as to be able to install them in the same position. Remove the spacer (11) from the clutch drum (A).
Page 473 Clutch assembly: APTC wet clutch Disassembly of the clutch hub-plates-centre assembly Unscrew the three tools 88713.2591. Withdraw the hub (13) and the plates (7) from the clutch centre (10). Recover the three springs (12). Remove the clutch plates (7) from the hub (13). Important When removing the plates, keep them in the same order as they were originally installed, tying them together if necessary.
Page 474 Clutch assembly: APTC wet clutch Overhaul of the clutch plates The clutch plates must not show any signs of blackening, grooves or deformation. Measure the thickness of the friction plates. It should not be less than 3.2 mm. Important The total thickness of the clutch plate pack must not be less than 50.2 mm. Place the plate on a flat surface and check the amount of deformation with a feeler gauge.
Page 475 Clutch assembly: APTC wet clutch Overhauling the pressure plate springs Measure the length “L” of each spring (4): - minimum length: 41 mm. Renew any springs that are shorter than the above limit value. Reassembly of the clutch hub-plates-centre assembly Install the three springs (12) on the pin (E) on the drum (10).
Page 476 Clutch assembly: APTC wet clutch Install the clutch plate assembly (7) with hub (13) in the drum (10). Warning When refitting the clutch centre (10) with the hub (13), align the reference notches (H) and (L). Insert the three tools 88713.2591 to fix the hub (13) to the clutch centre (10). Screw in the three tools 88713.2591 by hand, pressing down on the clutch plates with the hub (13), so as to overcome the resistance of the springs.
Page 477 Clutch assembly: APTC wet clutch Position the hub-plates-drum assembly (B) inside the drum (A). Notes Position the last friction plate (M) so that it is offset relative to others. Locate the lock washer (9) on the gearbox input shaft, seating it against the clutch assembly. Apply the recommended grease to the contact face of the nut (8) and to thread of the gearbox input shaft, then fit the nut to the input shaft and tighten by hand.
Page 478 Clutch assembly: APTC wet clutch Install the pressure plate (5) in the clutch asembly (B) aligning the three tools 88713.2591 with the three indents (N) in the pressure plate. Check that the two codes (P) stamped on the hub (13) and the pressure plate (5) are aligned. In each cavity, fit a spring (4) and a cap (2).
Page 479 Clutch assembly: APTC wet clutch Unscrew and remove the service tools 88713.2591. Operation Section reference Refit the clutch-side crankcase N 6.2, Refitting the clutch-side crankcase cover cover Connect the oil pressure sensor P 5, Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Top up the engine oil...
Page 480 Clutch assembly: clutch-side crankcase cover 6.2 - Clutch assembly: clutch-side crankcase cover 1 Clutch-side crankcase cover 2 Bolt 3 Bolt 4 Oil level sight glass 5 Bolt 6 Panel (BLACK) 7 O-ring 8 Bush 9 Seal 10 Shim 11 Circlip 12 O-ring 13 Locating bush 14 Sealing washer, thickness 2...
Page 481 Clutch assembly: clutch-side crankcase cover Clutch-side crankcase cover Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the clutch-side crankcase cover Operation Section reference Drain the engine oil...
Page 482 Clutch assembly: clutch-side crankcase cover Unscrew the screw (20) securing the inner cover (17). Remove the inner cover (17) and sound-proofing panel (6). Remove the circlip (11) and slide off the shim (10) and the oil seal (9). The drilled bush (8) is mounted to the cover by a forced interference fit. Remove it using a suitable puller. Inspect the oil seal (9) and renew it if necessary.
Page 483 Clutch assembly: clutch-side crankcase cover If the bush has been replaced, fully seat the new bush (8) in the slot in the cover using a suitable drift and a press. If the oil seal (9) needs to be renewed, fit the new seal into the crankcase cover, positioning it so the side without a spring is facing the circlip (13).
Page 484 Clean and degrease mating surfaces on the clutch-side crankcase cover and crankcase and ensure that locating bush (13) and the O-ring (12), located in correspondence with the oil way, are installed in the crankcase. Apply a uniform continuous bead of DUCATI liquid gasket (B) onto crankcase mating surfaces, working around all the holes.
Page 485 Clutch assembly: clutch-side crankcase cover Operation Section reference Connect the oil pressure sensor P 5, Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Top up the engine oil D 4, Changing the engine oil and filter cartridge...
Page 486: Clutch Assembly: Primary Drive Gears
Clutch assembly: primary drive gears 6.3 - Clutch assembly: primary drive gears 1 Clutch drum/Primary drive gears 2 Inner ring 3 Inner bearing 4 Spacer 5 Threaded ringnut 6 Lock washer Parts catalogue Clutch connecting rods Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 487 Clutch assembly: primary drive gears Drain the engine oil D 4, Changing the engine oil and filter cartridge Disconnect the oil pressure P 5, Checking the front and rear brake sensor light switches, neutral light switch, oil pressure switch and clutch switch Remove the clutch-side N 6.2, Removal of the clutch-side...
Page 488 Clutch assembly: primary drive gears Remove the primary driving gear (B) using puller 88713.2092 and interposing a packing piece of aluminium or copper between the crankshaft and the screw of the puller. Take care to recover the key (C) from the crankshaft and the internal spacer. Refitting the primary drive gears and checking backlash Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear.
Page 489 Clutch assembly: primary drive gears Fit the driving gear (B) onto the crankshaft with the oil pump drive sprocket facing the crankcase. Temporarily secure the gear with the washer (6) and nut (5). Important If fitting a new primary driving gear (B), check the backlash. To check the gear backlash, temporarily fit the clutch drum (1) complete with internal spacer (4), driven gear (A), roller bearing (3) and internal bush (2) on the gearbox input shaft.
Page 490 Clutch assembly: primary drive gears Refit the oil pump and check the backlash between the oil pump gear and primary drive gear on the crankshaft (Sect. N 2.1, Refitting the oil pump). Thoroughly degrease the mating surfaces of the clutch drum (1), the internal bearing (3) and the bush (2). Fit the internal spacer (4) to the input shaft with its flat side facing outwards.
Page 491 Clutch assembly: primary drive gears Refit the complete clutch N 6.1, Refitting the APTC clutch assembly Refit the clutch-side crankcase N 6.2, Refitting the clutch-side crankcase cover cover Connect the oil pressure sensor P 5, Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Refill the engine with oil...
Page 492 Gearbox assembly: gearchange mechanism 7.1 - Gearbox assembly: gearchange mechanism 1 Return spring 2 Washer 3 Special bolt 4 Gear pawl assembly 5 Interlock plunger holder 6 Sealing washer 7 Detent ball spring 8 Ball 9 Circlip 10 Selector claw return spring 11 Shim 12 Circlip 13 Nut...
Page 493 Gearbox assembly: gearchange mechanism Parts catalogue Gearchange control Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Removal of the gearchange mechanism Operation Section reference Drain the engine oil...
Page 494 Gearbox assembly: gearchange mechanism Reassembly of the gearchange mechanism If the components of the gearchange mechanism were dismantled on removal, fit the spring (17) on the shaft (16) in the position indicated in the photo. Grease the threaded end of the eccentric gearchange lever pin (15) and install it on the upper part of the gearchange lever, securing it with the nut (13).
Page 495 Gearbox assembly: gearchange mechanism Ensure that the shaft with lever (16) is positioned correctly relative to stop plate (23). The edges of the plate must be equidistant from the pin of the lever; to adjust the position, loosen the locknut (13) and turn eccentric pin (15). Position the spring (10) between the shaft (16) and the fork (14).
Page 496 Gearbox assembly: gearchange mechanism Disassembly of the gear interlock plunger and pawl assembly Operation Section reference Drain the engine oil D 4, Changing the engine oil and filter cartridge Disconnect the oil pressure P 5, Checking the front and rear brake light sensor switches, neutral light switch, oil pressure switch and clutch switch...
Page 497 Gearbox assembly: gearchange mechanism Unscrew the clutch-side crankcase screw (3) and remove the pawl (4), washer (2) and spring (1). Reassembly of the gear interlock plunger and pawl assembly On the special bolt (3), fit the gear pawl lever (4), orienting it as shown in the figure, the washer (2) with the square edge side (D) facing the clutch-side crankcase, and the spring (1), positioning it so that the hook end (A) is facing the gear pawl lever.
Page 498 Gearbox assembly: gearchange mechanism Apply grease and then fit the ball (8), spring (7), and seal (6) into interlock plunger (5) and screw the interlock plunger assembly into the crankcase. Tighten the gear interlock plunger to the specified torque (Sect. C 3, Engine torque settings).
Page 499 Gearbox assembly: gearchange mechanism Locate the gearbox drum selector claw in the centre of the gearbox roller bearings. Position the gearchange mechanism (21) in the chain-side crankcase. Fit the bolts (18) and (20) with the spacer (19). Temporarily fit the gearchange lever (or a service lever) and the front sprocket, and put the gearbox in neutral. Fit the service tool no.
Page 500 Gearbox assembly: gearchange mechanism Remove the service tool and check that the pin (D) on the selector drum is aligned with mark (E) on the selector claw. 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 501 Gearbox assembly: gearbox shafts 7.2 - Gearbox assembly: gearbox shafts 1 Shim, thickness 1 2 Gearbox input shaft 3 Shim, thickness 0.5 4 Needle roller bearing 5 5 th speed driving gear. 6 Splined washer, thickness 0.5 7 Circlip 8 3 rd -4 th speed driving gear. 9 6 th speed driving gear.
Page 502 Gearbox assembly: gearbox shafts 23 6 th speed driven gear 24 2 nd speed driven gear. 25 Gearbox output shaft 26 Shim 27 Shim, thickness 1 28 1 st , 4 th -2 nd , 3 rd speed selector fork. 29 5 th , 6 th speed selector fork.
Page 503 Gearbox assembly: gearbox shafts 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. If the bearing inner races are left on the shafts, slide them off the ends of the gearbox input (2) and output (25) shafts (Sect.
Page 504 Gearbox assembly: gearbox shafts Withdraw the first speed driven gear (18) with the roller cage (17) and the shim (19). Remove the fifth speed driven gear (20).
Page 505 Gearbox assembly: gearbox shafts Use two flat blade screwdrivers to remove the circlip (7) taking care not to damage the shaft surface. Remove the circlip (7) and the splined washer (6). Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12).
Page 506 Gearbox assembly: gearbox shafts Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6). Remove the circlip (7) and remove the sixth speed driven gear (23).
Page 507 Gearbox assembly: gearbox shafts Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24). Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox output shaft (25).
Page 508 Gearbox assembly: gearbox shafts Disassembly of the gearbox input shaft Remove the chain-side shim (11) and the clutch-side shim (1) from the input shaft. Remove the second speed driving gear (10). Use two screwdrivers to prise out the circlip (7) and the splined washer (6).
Page 509 Gearbox assembly: gearbox shafts 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). Remove the splined washer (6) and the circlip (7).
Page 510 Gearbox assembly: gearbox shafts Withdraw the third and fourth speed driving gear (8). Remove the circlip (7) and the splined washer (6). Remove the fifth speed driving gear (5) with the roller cage (4).
Page 511 Gearbox assembly: gearbox shafts Slide the shim (3) off the input shaft (2). Overhaul of the gearbox Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear on the edges of the teeth. The idler gears must rotate freely on their shafts.
Page 512 Gearbox assembly: gearbox shafts Also check that the component parts of the gear selector mechanism are in good condition. Engage the gears and check that the gearchange mechanism does not stick (selector fork - gear groove, and fork pin - desmodromic drum groove) due to incorrect end float. Restore the correct endfloat by shimming the gearbox shafts and the selector drum with suitable shims.
Page 513 Gearbox assembly: gearbox shafts 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 renewed by comparing these dimensions with those of new components (Sect.
Page 514 Gearbox assembly: gearbox shafts Figure 2 shows all the parts to be reassembled on the gearbox output shaft (25), with calculated end shims (15) and (26) (Sect. N 9.2, Shimming the shafts). Reassemble the gears on the gearbox shafts by reversing the disassembly procedure. Take particular care when installing the idler gears.
Page 515 Gearbox assembly: gearbox shafts Slide the washer with three internal points (6) over the shaft until it locates against the circlip you have just fitted. To fit the needle roller cage (4) onto the shaft, first lubricate it with plenty of grease (of recommended type) and then open it slightly to make it easier to slide on to the shaft.
Page 516 Gearbox assembly: gearbox shafts Fit another needle roller cage (4) using the method already described. Fit the 4 th speed gear (21). Fit another 3-pointed washer (6) and another circlip (7) onto the shaft. Seat the circlip using the drift used previously.
Page 517 Gearbox assembly: gearbox shafts Reassembly of the gearbox To reassemble the gearbox components follow the procedure under Sect. N 9.2 relating to “Reassembly of the crankcase halves”. 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 518 Gearbox assembly: gearbox shafts Refit the cylinder heads N 4.4, Refitting the cylinder head assembly Refit the timing belts N 4.2, Refitting the timing system assembly Refit the timing belt covers N 4.2, Refitting the timing belt covers Refit the engine starter system P 3, Electric starting system Refit the alternator-side crankcase...
Page 519 Flywheel-alternator 8 - Flywheel-alternator 1 Front sprocket cover 2 Pick-up sensor inspection screw 3 Seal 4 O-ring 5 Cover 6 Bolt 7 Washer 8 Spacer 9 Cable guide 10 Bolt 11 Bolt 12 Bolt 13 Flange 14 Cable clip 15 Washer 16 Flywheel 17 Washer 18 Inner ring...
Page 520 Flywheel-alternator 25 Bolt 26 Bearing 27 Circlip 28 Alternator-side crankcase cover 29 Locating bush 30 Bracket 31 Bolt 32 Alternator stator 33 Belleville washer 34 Flanged nut Parts catalogue Alternator-side crankcase cover Electric starting and ignition Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 521 Flywheel-alternator Fix service tool no. 88713.1749 to the holes left vacant by the two bolts (6) you have just removed. Turn the tool shaft slowly to separate the cover (28) from the LH crankcase half. Disassembly of the alternator-side crankcase cover Undo the three stator retaining bolts (24) and the two bolts (31) securing the cable guide bracket (30) from inside the alternator-side crankcase cover.
Page 522 Flywheel-alternator The alternator-side crankcase cover is fitted with a bearing (26), held in place by circlip (27), which locates on the end of the crankshaft. Remove the circlip (27) with circlip pliers. Remove the bearing (26) using a universal puller. Removal of the flywheel-alternator assembly Use service tool no.
Page 523 Flywheel-alternator Remove the nut (34), the Belleville washer (33) and the flywheel assembly (22) complete with the gear (20). Remove the inner race (18), the needle roller bearing (19) and the washer (17). Important Examine the inner race (18), needle roller bearing (19) and internal washer (17) for wear. Notes The hole in the inner race (18) allows the passage of oil for lubrication of needle roller bearing (19).
Page 524 Flywheel-alternator Insert two of the bolts (25) just removed from flywheel rotor-side in their holes in order to remove the flange (13) and the starter clutch (21) from the flywheel (16). The starter clutch is a slight interference fit on the flange. To remove it, use a suitable drift. Reassembly of the flywheel-alternator assembly Install the starter clutch (21) in the flange (13), making sure it is properly seated.
Page 525 Flywheel-alternator Seat the flange (13) with the starter clutch in the flywheel (16), aligning the flange locating hole (B) with the flywheel locating hole (C). When refitting the flange to flywheel, insert a pin or a wrench inside the hole (C) for the rotor flywheel locating dowel in order to line up the flywheel holes with the flange threads.
Page 526 Flywheel-alternator Install the rotor (23) on the flywheel (16), aligning the flywheel locating hole (E) with the rotor locating hole (D). Apply threadlocker to the rotor/flywheel fixing bolts (25) and start them in their threads.
Page 527 Flywheel-alternator Tighten the bolts (25) to the specified torque (Sect. C 3, Engine torque settings). Install the driven gear (20) on the starter clutch, ensuring it is properly seated. 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 528 Flywheel-alternator Refitting the flywheel-alternator assembly Fit the washer (17) (suitably lubricated), needle roller bearing (19), and inner race (18) to the crankshaft. Make sure the inner race is centred relative to the washer. Install the flywheel-rotor-driven gear assembly on the crankshaft, taking care not to alter the position of the inner race (18) relative to the washer (17).
Page 529 Flywheel-alternator Apply the recommended threadlocker to the threads of the crankshaft and the flywheel nut (34). Restrain the rotation of the flywheel with the holding tool 88713.2036. Important Tighten the nut (34) to the specified torque (Sect. C 3, Engine torque settings).
Page 530 Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the crankcase cover. Fit the two locating bushes (29). Spread a continuous uniform bead of DUCATI liquid gasket on the mating surface of the cover (28), ensuring continuity around the holes for the retaining bolts and locating bushes.
Page 531 Flywheel-alternator Insert the retaining bolts in their holes following the indications given in the table. Ref. Description M6x20 mm bolts M6x25 mm bolts M6x30 mm bolts Under the screw (12), located in correspondence with the starter motor, fit the spacers (8), hose clips (9) and (14), and washers (15).
Page 532 Flywheel-alternator Dampen the oil seal (3) with alcohol and install it in the alternator-side crankcase cover, in correspondence with the gearchange shaft (Sect. F 5, Refitting the gearchange control), using the specific installation tool 88713.1411. Make sure that the O-ring (4) is installed in the cover (5). Apply threadlocker to the bolts (6).
Page 533 Flywheel-alternator Operation Section reference Refit the sprocket cover G 8, Refitting the front sprocket Refit the LH footrest H 4, Refitting the footrest brackets Refit the clutch slave cylinder F 2, Refitting the clutch slave cylinder Refit the gearchange control F 5, Refitting the gearchange control Top up the engine oil...
Page 534 Crankcase assembly: external components 9.1 - Crankcase assembly: external components 1 Key 2 Timing gear pair 3 Lock washer 4 Hex nut 5 Key 6 Sealing washer 7 Plug 8 Aluminium gasket 9 Plug 10 Breather valve 11 O-ring 12 Cylinder barrel-head stud bolt 13 Locating dowel 14 Connection fitting 15 Plug...
Page 535 Crankcase assembly: external components 29 Sealing washer 30 Bolt 31 Bolt 32 Washer 33 O-ring 34 Pickup sensor 35 Grub screw Parts catalogue Timing system Filters and oil pump Crankcase halves Electric starting and ignition Gearchange control Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Page 536 Crankcase assembly: external components Unscrew and remove the oil inlet and outlet connection fittings (14) from the clutch-side crankcase half and recover the seals (8). Unscrew and remove the oil filter cartridge (Sect. D 4, Changing the engine oil and filter cartridge).
Page 537 Crankcase assembly: external components Remove drain plug (9) with its seal (29). Remove the neutral switch (19) with seal (20). Remove the cylinder head studs (12) with the aid of the appropriate tool. To remove the engine sensor (34), unscrew the screw (31) and recover the shim (24) and the washer (32).
Page 538 Crankcase assembly: external components Check the condition of O-rings (33) in the crankcase half and renew them if necessary. Refitting the external components Check the condition of O-rings (11) and renew if necessary. Install the oil vapour breather valve (10) in the crankcase along with O-rings (11), previously lubricated. Tighten the bolt (30) to the specified torque (Sect.
Page 539 Crankcase assembly: external components Fit the seals (8) on the connection fittings (14) on the small diameter sides of the fittings. Apply the recommended threadlocker to the smaller diamater threads of the connections fittings (14). Tighten the connection fittings (14) to the specified torque (Sect. C 3, Engine torque settings).
Page 540 Crankcase assembly: external components Refit the neutral switch (19) with its seal (20) and tighten to the specified torque (Sect. C 3, Engine torque settings). Apply threadlocker to the plug (27), fit it with its seal (28) and tighten to the specified torque (Sect. C 3, Engine torque settings).
Page 541 Crankcase assembly: external components Check that the O-rings (33) are installed in the crankcase. Fit the engine pickup (34) in its seat in the crankcase. Insert the bolt (31) with the washer (32) and tighten to the specified torque (Sect. C 3, Engine torque settings).
Page 542 Crankcase assembly: external components Operation Section reference Refit the cylinder barrel/piston N 5, Refitting the cylinder/piston assemblies assembly Refit the cylinder heads N 4.4, Refitting the cylinder head assembly Refit the timing belts N 4.2, Refitting the timing system assembly Refit the timing belt covers N 4.2, Refitting the timing belt covers...
Page 543 Crankcase assembly: external components Remove the front sprocket cover G 8, Removal of the front sprocket Remove the alternator-side N 8, Removal of the alternator-side crankcase cover crankcase cover Remove the flywheel/alternator N 8, Removal of the flywheel-alternator assembly assembly Slide out driving gear (A) of timing gear pair (2).
Page 544 Crankcase assembly: external components Refitting is the reverse of removal. Important On completion of the refitting operations, check that tab washer (3) is staked against nut (4) in such a way as to prevent the nut from working loose. Operation Section reference Refit the flywheel/alternator N 8,...
Page 545 Crankcase assembly: external components Remove the front sprocket cover G 8, Removal of the front sprocket Remove the alternator-side N 8, Removal of the alternator-side crankcase cover crankcase cover Remove the flywheel/alternator N 8, Removal of the flywheel-alternator assembly assembly Remove the circlip (25) and the washer (24).
Page 546 Crankcase assembly: external components Operation Section reference Refit the flywheel/alternator N 8, Refitting the flywheel-alternator assembly assembly Refit the alternator-side crankcase N 8, Refitting the alternator-side cover crankcase cover Refit the sprocket cover G 8, Refitting the front sprocket Refit the LH footrest H 4, Refitting the footrest brackets Refit the clutch slave cylinder...
Page 547 Crankcase assembly: crankcase halves 9.2 - Crankcase assembly: crankcase halves 1 Circlip 2 Timing belt driveshaft 3 Alternator-side crankcase half 4 Bearing 5 O-ring 6 Circlip 7 Bearing 8 Bolt 9 Retaining plate 10 Bearing 11 Seal 12 Bearing 13 Seal 14 Bearing 15 Bearing 16 Clutch-side crankcase half...
Page 548 Crankcase assembly: crankcase halves 25 Bolt 26 Bolt Parts catalogue Timing system Crankcase halves Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram. Separation of the crankcase halves Operation Section reference...
Page 549 Crankcase assembly: crankcase halves Unscrew the crankcase bolts (22), (25) and (26) from the alternator-side crankcase half (3). Unscrew the two bolts (22) on the clutch-side crankcase half (16) near the vertical cylinder. Re-use the alternator-side crankcase cover or a service cover with puller 88713.1749. Secure it to the crankcase half using several of the original bolts and begin to separate the crankcase halves by turning the central pin of the tool.
Page 550 Crankcase assembly: crankcase halves Notes Take care not to lose the shims on the shafts and on the selector drum. Remove the gearbox shafts and gearbox selector drum from the crankcase (Sect. N 7.2, Removal of the gearbox assembly). Drive out the crankshaft (C) using a rubber mallet and taking care not to lose the shims (D). Remove the timing belt driveshaft (2).
Page 551 Crankcase assembly: crankcase halves Overhaul of the crankcase halves Carefully examine the engine crankcase halves. Check that the surfaces of the crankcases are perfectly flat using a reference surface. Check that the bearings (4) and (23) are in good condition. Note that the main bearings must always be changed in pairs (refer to the procedure below in “Overhaul of the main bearings”).
Page 552 Crankcase assembly: crankcase halves Check the condition of locating bushes (19). In the event of evident signs of distortion or excessive assembly clearance in their bores, remove the locating bushes using appropriate tools. If the removal of the bushes (19) from the casing proves difficult, use a left-handed thread tap to force the bushes out.
Page 553 Crankcase assembly: crankcase halves Overhaul of the 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 bearings are designed to bear combined loads (radial and- thrust loading).
Page 554 Crankcase assembly: crankcase halves Important After installing new main bearings, shim the crankshaft as described in the paragraph “Shimming the shafts” and “Reassembly of the crankcase halves” in this section. 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.
Page 555 Crankcase assembly: crankcase halves Notes None of the bearings except the main bearings have an obligatory assembly direction: it is good practice to install the bearings so that side with the writing is facing upwards. Shimming the shafts Before assembling the crankcase halves, calculate the shims required to obtain the correct end float of the crankshaft and gearbox shafts.
Page 556 Crankcase assembly: crankcase halves Practical method for calculating crankshaft shims In addition to the above procedure, the following is a practical shimming method, providing a guide on how to calculate the crankshaft shim thicknesses accurately. Install a shim (A) of minimum thickness (1.90 mm) on each side of the crankshaft to prevent contact between the crankshaft web and the engine block.
Page 557 Crankcase assembly: crankcase halves Place a dial gauge (B) with magnetic stand 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 (C) between the crankcase and the crank web and force the crankshaft towards the dial gauge.
Page 558 Crankcase assembly: crankcase halves Notes After assembling the crankcase, the crankshaft should turn with some interference in the new bearings. Shimming the gearbox shafts The following shim thicknesses are available as replacement parts: Position Clutch side (mm) Chain side (mm) Gearbox input shaft Gearbox output shaft 3.15...
Page 559 Crankcase assembly: crankcase halves Notes When refitting used components, before installing the gearbox assembly in the crankcase half, make sure that the inner races (A) of the gearbox shaft bearings are fitted into the correct bearings and have not been left on the shafts. Mesh the gearbox shafts and install them on the clutch-side crankcase half with the calculated shims.
Page 560 Crankcase assembly: crankcase halves Notes The two selector forks are identical. Install the 5 th -6 th gear selector fork (C) in the input shaft driven gear. Install the selector drum (D) in the crankcase with the previously calculated shim thickness. Fit the pins (E) in the previously installed selector forks.
Page 561 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 562 Crankcase assembly: crankcase halves Prepare the crankcase bolts, and insert them in the alternator-side crankcase half (3); note that the bolts are of different lengths. Ref. Description M8x75 mm bolts M6x35 mm bolts M6x75 mm bolts Progressively tighten the crankcase bolts until fully seated, starting with the bolts of the largest diameter (M8). Insert two M8 bolts (22) in the clutch-side crankcase (16).
Page 563 Crankcase assembly: crankcase halves Check that the crankshaft can be turned with a certain amount of interference with the main bearings (the crankshaft should have a pre-load of 0.15 to 0.20 mm); check also that all the parts fitted are free to rotate or move correctly. Install the oil seal (11) on the gearbox output shaft using the specific tool (T).
Page 564 Crankcase assembly: crankcase halves Refit the flywheel/alternator N 8, Refitting the flywheel-alternator assembly assembly Refit the alternator-side crankcase N 8, Refitting the alternator-side cover crankcase cover Refit the primary gear N 6.3, Refitting the primary drive gears and checking backlash Refit the oil pump N 2.1, Refitting the oil pump...
Page 565 Crankcase assembly: crankshaft/connecting rods assembly 9.3 - Crankcase assembly: crankshaft/connecting rods assembly 1 Crankshaft 2 Drilled screw 3 Plug 4 Grub screw 5 Connecting rod assembly 6 Bush 7 Half bearing 8 Special bolt 9 Shim 10 Key Parts catalogue connecting rods Important Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be...
Page 566 Crankcase assembly: crankshaft/connecting rods assembly Operation Section reference Remove the engine from the N 1, Removal of the engine frame Remove the clutch-side crankcase N 6.2, Removal of the clutch-side cover crankcase cover Remove the clutch assembly N 6.1, Removal of the APTC clutch Remove the oil pump N 2.1, Removal of the oil pump...
Page 567 Crankcase assembly: crankshaft/connecting rods assembly Overhaul of the connecting rods Make the following dimensional checks on the connecting rods: - assembly clearance with gudgeon pin at time of fitting (Sect. C 1.1, Cylinder/Piston). In case of excessive wear, renew the connecting rod. The small end bushing must be in good condition and firmly driven into its seat.
Page 568 Crankcase assembly: crankshaft/connecting rods assembly Renewal of the small end bushing To renew the bushing (6) use the tool shown in figure to simultaneously drive out the old bushing and install the new one (A). Position the new small-end bushing so that the split is at 90° relative to the upper hole in the small-end. Drill lubrication holes into the new bushing in correspondence with the existing lubrication holes on the connecting rod small end.
Page 569 Crankcase assembly: crankshaft/connecting rods assembly Crankshaft overhaul 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: 1.5 mm.
Page 570 Crankcase assembly: crankshaft/connecting rods assembly Use a hot air gun capable of reaching 150 °C. 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 571 Crankcase assembly: crankshaft/connecting rods assembly Apply DUCATI liquid gasket on the threads of plugs (3), (4) and (2) and then refit the plugs. Tighten all the plugs to the specified torque (Sect. C 3, Engine torque settings). Big-end bearing shell-journal clearance To check the assembly clearance between the bearing shells and crankshaft journals you need to lay a strip (A) of “GREEN Plastigauge PG-1”...
Page 572 Crankcase assembly: crankshaft/connecting rods assembly Reassembly of the connecting rods Before starting, 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 573 Crankcase assembly: crankshaft/connecting rods assembly Use the recommended grease to lubricate the threads and underside of the heads of the new bolts (8) and the threaded hole in the connecting rod, packing in grease from both sides of the hole. Warning The grease utilised is an irritant in contact with the skin.
Page 574 Crankcase assembly: crankshaft/connecting rods assembly Refitting the crankshaft/connecting rod assembly Install the connecting rod/crankshaft assembly in the crankcase and follow the shimming procedure as described in Sect. N 9.2, Shimming the shafts. Important Make sure that the connecting rods (5) 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 575 Crankcase assembly: crankshaft/connecting rods assembly Refit the alternator-side N 8, Refitting the alternator-side crankcase cover crankcase cover Refit the primary gear N 6.3, Refitting the primary drive gears and checking backlash Refit the oil pump N 2.1, Refitting the oil pump Refit the clutch assembly N 6.1, Refitting the APTC clutch...
Page 576: Wiring Diagram
P - Impianto elettrico 0P - Impianto elettrico 1 - Wiring diagram Key to wiring diagram 5 Wiring colour codes 6 Key to fuse box 6 Routing of wiring on frame 7 Plate A 9 Plate B 10 Plate C 13 Plate D 15 Plate E 16 Plate F 18...
Page 577 P - Impianto elettrico 4 - Lights and indicating devices Removal of the instrument panel 65 Changing bulbs 66 Headlight aim 69 5 - Indicating devices Checking the indicating devices 71 Changing bulbs 78 6 - Protection and safety devices Checking protection and safety device components 79 Checking the fuses 81 7 - Instruments...
Page 578: Usb Data Acquisition Kit
USB Data Acquisition kit 10 - USB Data Acquisition kit A USB data acquisition kit (1) is supplied. To use the kit, remove the seat (Sect. E 3, Removal of seat), locate the DDA in the clip (4) of the plate (5) fixed to the fuel tank; fit the cap (2) and connect the wiring connector (3) to the main wiring loom.
Page 579 USB Data Acquisition kit...
Page 580 Wiring diagram 1 - Wiring diagram WIRING DIAGRAM...
Page 581 Wiring diagram Key to wiring diagram 1 Right-hand handlebar switch 2 Immobilizer antenna 3 Key switch 4 Fusebox 5 Data acquisition/Diagnostics 6 Starter motor 7 Starter contactor with MASTER fuse 8 Battery 9 Engine earth/Electrical system earth 10 Regulator 11 Alternator 12 Tail light 13 Rear right turn signal 14 Number plate light...
Page 582 Wiring diagram Gr Grey G Green Bn Brown O Orange P Pink Key to fuse box Position Item Rating Key on, starter contactor, lambda, eng. stop 10 A Lights 15 A Loads 15 A Injection 20 A Instrument panel DDA and battery charging Spare 20 A Spare...
Page 583 Wiring diagram Plate C Pressure sensor lead (MAP) Plate D Pick-Up Plate E Regulator/alternator connector Plate E Voltage regulator Plate E Alternator cable Plate F Horn connector Plate F Horizontal cylinder coil connector Plate G Keyswitch connector Plate G Key-switch Plate G Immobilizer antenna connector Plate G...
Page 584 Wiring diagram Plate V Nymber plate light connector Plate V Exhaust valve actuator connector (exhaust valve not present) Plate V DDA connector Plate V Plate X Tail light connector Plate R Plate V Plate Y Negative battery lead Plate T Plate V Plate Y Starter motor/contactor cable...
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Page 646 Battery charging system 2 - Battery charging system Checking the battery charging system To check the current flow in the charging circuit, use the “DDS” tester, which is equipped with an inductive clamp-type ammeter: refer to “Testing the battery charging system”, Sect.
Page 647 Battery charging system Charge the battery if the open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could damage it. Check the battery charge with a voltmeter. Always check the condition of the battery before recharging and 1 to 2 hours afterwards. Important Pay careful attention to recharging times.
Page 648 Battery charging system Warning Make certain that the electrolyte is of the specific type for your battery. Remove the container with the electrolyte from the plastic bag. Remove the cap strip (3) from the container (2). Important Keep the cap strip (3) to hand because it will be used later as plugs for the battery cells. Warning Do not peel or perforate the sealed areas.
Page 649 Battery charging system Notes Do not tilt the electrolyte container as this could interrupt the flow temporarily or even permanently. Make certain that air bubbles emerge from all six filler holes. Leave the container in this position for at least twenty minutes.
Page 650 Battery charging 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 651 Battery charging system Warning Never remove the valve cover on the top of the battery or add more liquid to the battery. If the block, cover or terminals are broken or if the valve cover has been tampered with it is essential to change the battery. Important If the motorcycle is left unused for more than 30 days, remove the battery and store it in a safe, cool place.
Page 652 Battery charging system Replace the terminal covers (B) and reattach the rubber retaining strap (A). Refit the seat (Sect. E 3, Refitting the seat). 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.
Page 653: Removal Of The Gearchange Control
Battery charging system Engine rpm 2000 6000 effective V 27±10 78±10 Values significantly lower than those indicated above can be due to: - partially demagnetised rotor; - short-circuited windings. In the above cases the whole alternator assembly (rotor and stator) should be renewed. If checks have a favourable outcome, reconnect the alternator to the regulator with ignition key on OFF.
Page 654 Battery charging system Refill the engine with oil D 4, Changing the engine oil and filter cartridge Regulator/rectifier The regulator (1) is fixed to the motorcycle frame. The rectifier/regulator consists of an aluminium casing containing the diodes that rectify the current produced by the alternator.
Page 655 Battery charging system Important Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator. Refitting the regulator Locate the regulator (1) with the horn (3) and the spacers (4) on the frame and secure with the bolts (2). Tighten the bolts (2) to the specified torque (Sect.
Page 656 Battery charging system Regulator fuse The 30 A fuse located on the fuel tank protects the electronic regulator. To gain access to the fuse, remove the seat (Sect. E 3, Removal of the seat) and disconnect the contactor connector (A).
Page 657 Battery charging system A blown fuse can be identified by breakage of the inner filament (B). Important Switch the ignition key to OFF before replacing a fuse to avoid possible short circuits. Warning Never use a fuse with a rating other than the specified value. Failure to observe this rule may damage the electric system or even cause fire.
Page 658 Electric starting system 3 - Electric starting system Notes The references of the elements shown below are to be found in the “Wiring diagram”, Section P 1. Electric starting system The key components of the electric starting system are a contactor (1) and a starter motor (2) fed by the battery (3).
Page 659 Electric starting 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.
Page 660 Electric starting system remove the starter motor and test it under no-load conditions (no load applied to the shaft). Secure the starter motor to a test bench, making sure you do not damage the casing. Use a fully charged 12 V battery for the test. Use battery-motor connection cables which are no longer than 70 cm and with the same cross-section as the cable on the motorcycle itself.
Page 661 Electric starting system Notes The starter motor retaining bolts are assembled with threadlocker. Slide out the starter motor and gasket (2). Refitting the starter motor Inspect the condition of the gasket (2) and renew if necessary. Locate the gasket (2) and the starter motor on the crankcase and tighten the bolts (1) to the specified torque (Sect.
Page 662 Electric starting system Connect the starter motor/contactor cable (3). Important Fill the cap with protective grease before fitting it on the starter motor Operation Section reference Refit the timing gears and the starter N 9.1, Refitting the starter motor idler gear idler gear Refit the alternator-side crankcase N 8,...
Page 663 Electric starting system Operation Section reference Remove the seat E 3, Removal of the seat The contactor (1) is fixed to the fuel tank. Disconnect the battery (Sect. P 2, Battery). Disconnect the wiring connector (2) of the starter contactor from the wiring harness. Remove the protective caps (A).
Page 664 Electric starting system With a multimeter connected between the two terminals (threaded studs (+) and (-)) of the contactor, check for electrical continuity (Sect. P 9, Diagnostic instruments). If there is no electrical continuity, renew the contactor. Connect the wires (5) e (6) to the contactor terminals. On refitting, ensure that terminals (+) and (-) are not oxidized;...
Page 665 Electric starting system Insert the contactor in its seat on the fuel tank: the contactor must be inserted fully home, i.e. until the four retaining teeth of the support bracket protrude on the contactor side.
Page 666: Lights And Indicating Devices
Lights and indicating devices 4 - Lights and indicating devices Removal of the instrument panel To remove the instrument panel (1), remove the movable headlight fairing (Sect. E 1, Removal of the headlight fairing). Unscrew the nuts (2), recovering the spacer (3). Disconnect the connector (4) from the wiring.
Page 667 Lights and indicating devices Changing bulbs Changing the headlight bulbs Operation Section reference Remove the headlight fairing E 1, Removal of the headlight fairing Before replacing a burnt out light bulb, ensure that the replacement bulb has the same voltage and power rating as specified for the lighting device in question (Sect.
Page 668 Lights and indicating devices Withdraw the headlight support towards the front of the motorcycle sufficiently to release the knob (2). Unscrew the knob (2) in anti-clockwise direction. Unhook the spring (3).
Page 669 Lights and indicating devices The bulb (4) is of the bayonet-type: press and twist anti-clockwise to remove. Push in the new bulb and turn it clockwise until it clicks into place. Side lights (A) Remove the side light bulb (5) from its holder and fit a new one of the same type. Refitting the bulbs After changing the bulbs, reconnect the wiring connectors to the light terminals.
Page 670 Lights and indicating devices Reposition knob (2) of the headlight in its seating, and secure it to the headlight screwing it in clockwise. Reposition the headlight support on the motorcycle and refit the bolts (1) to the frame.
Page 671 Lights and indicating devices Operation Section reference Refit the headlight fairing E 1, Refitting the headlight fairing Changing the number plate light bulb Pull out the rubber sleeve (11) and remove the bulb. Headlight aim The motorcycle must be perfectly upright with the tires inflated to the correct pressure and with a rider seated, perfectly perpendicular to the longitudinal axis.
Page 672 Lights and indicating devices beam. Unscrew the bolts (A) with a hex socket wrench and withdraw the headlight support towards the front of the motorcycle to access the headlight aim adjuster screws. The vertical alignment of the headlamp can be adjusted manually by turning screw (1). The horizontal alignment of the headlight can be adjusted manually by turning screw (2).
Page 673 Lights and indicating devices Refit all parts removed.
Page 674: Indicating Devices
Indicating devices 5 - Indicating devices Checking the indicating devices 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 harness (Sect. P 1, Routing of wiring on frame).
Page 675 Indicating devices 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. HORN button Connect the terminals of a multimeter to the red/blue and and blue/white wires to check for electrical continuity, which must be present when the HORN is pressed (see Sect.
Page 676 Indicating devices set up pushbutton Check for continuity across the black and red wires. Refit the left-hand handlebar switch and tighten the bolts (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 bolts (1) and disconnect the wiring connector from the electrical system.
Page 677 Indicating devices 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). When the button is in RUN position, there should be electrical continuity between the two wires. When the button is in the OFF position, there should be no electrical continuity between the two wires.
Page 678 Indicating devices Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch Brake light switches To check operation of the front (1) and rear (2) brake light switches, use a multimeter to check for electrical continuity (Pos.
Page 679 Indicating devices 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 680 Indicating devices If the engine oil pressure value is outside the specified range, check the oil circuit components and service as necessary. If engine oil pressure value is within the allowed operating range and the “low engine oil pressure” warning light on the instrument panel stays off, switch on the instrument panel (ignition key set to ON) without starting the engine, and disconnect the electrical terminal from the pressure sensor and connect it to earth.
Page 681 Indicating devices The bulb (3) is of the bayonet-type: press and twist anti-clockwise to remove. Replace the burned out bulb with a new one of the same type. Press the bulb in and twist clockwise until it clicks into place. Refit the lens (2), tightening fixing bolt (1).
Page 682: Protection And Safety Devices
Protection and safety devices 6 - Protection and safety devices Checking protection and safety device components Checking the key switch Disconnect the ignition switch (A) from the wiring loom by opening its connector (Sect. P 1, Routing of wiring on frame) and use a multimeter (Sect.
Page 683 Protection and safety devices The same checks can also be performed using the “DDS” tester (Sect. D 5, tester). Checking the sidestand switch Remove the switch from the sidestand and disconnect the main wiring loom connector from the switch (see “Routing of wiring on frame”, Sect.
Page 684 Protection and safety devices Multimeter pos. Green/ Green/ Green Yellow White Black 0 = Open contact X = Closed contact Checking the fuses The main fusebox (1) is located on the right-hand side of the motorcycle and is accessed by removing the right-hand side fairing (Sect.
Page 685 Protection and safety devices Warning Never use a fuse with a rating other than the specified value. Failure to observe this rule may damage the electric system or even cause fire. As well as the fuses in the fuse box, the motorcycle has a 30 A fuse (2) located alongside the ECU to protect the electronic regulator (Sect.
Page 686 Instruments 7 - Instruments Instrument panel For removal of the instrument panel, follow the indicationns given in Section P 4, Removal of the instrument panel. Notes The instrument panel is supplied as a single component; its internal components cannot be renewed separately. Important Whenever the instrument panel is renewed, the ignition key programming procedure must be repeated.
Page 687 Instruments Indicator lights The following indicator lights are mounted on the instrument panel. 5 Neutral (N) indicator (green): illuminates when the gearbox is in neutral. 6 Fuel reserve warning light (amber): illuminates when there are only approximately 2 litres of fuel left in the tank. 7 Turn signal indicator lights (green): start flashing when the turn signals are in operation.
Page 688 Instruments At Key-On, the instrument panel always shows the following information (de-activating any previously activated functions): - Odometer - Speed - Engine rpm bargraph - Engine oil temperature bargraph At this point, by pressing switch (1) “ ” it is possible to switch from the odometer display function (TOT) to the following functions: - TRIP - TRIP FUEL (only if active)
Page 689 Instruments - BATT - RPM - Light Set - LAP (OFF or ON) - LAP MEM - DDA (OFF or ON) - Erase DDA - TIME Set - CODE (only active if at least one IMMOBILIZER error is present). Important This menu is active only if the speed of the motorcycle is less than 20 km/h.
Page 690 Instruments Motorcycle speed This function displays the motorcycle speed. The instrument panel receives actual speed value (expressed in km/h) from the ECU and displays the value increased by 8%. The maximum speed that can be displayed is 299 km/h (186 mph). Over 299 km/h (186 mph) the display will show a series of dashes “- - -“...
Page 691 Instruments Engine oil temperature indicator This function displays the engine oil temperature. Display indications: - if the temperature is between -40 °C and +70 °C, the display shows “STATUS 2”. - if the temperature is between +71 °C and +90 °C, the display shows “STATUS 3”. - if the temperature is between +91 °C and +175 °C, the display shows “STATUS 4”.
Page 692 Instruments “TRIP” meter This function displays the distance travelled since the last reset. While in this function, if you press switch (1) “ ” 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 693 Instruments...
Page 694 Instruments “TRIP FUEL” (distance travelled on reserve fuel) indicator This function displays the distance travelled on reserve fuel. When the fuel warning light (6) 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 695 Instruments Service indicator Indicates that the next service is due. The indicator ( ) signals when the next service is due. The service indicator is displayed at the following intervals: - after the first 1000 km on the odometer; - every 12000 km on the odometer.
Page 696 Instruments The service indicator will remain on the display until reset.
Page 697 Instruments Battery voltage indicator (BATT) This function displays the battery charge level. To display this function, go into the menu and select the “BAT” page. The battery voltage reading is displayed as follows: - if the reading is between 12.1 and 14.9 Volts, it is steadily illuminated on the display; - if the reading is between 10.0 and 12.0 Volts or between 15.0 and 16.0 Volts, it flashes on the display;...
Page 698 Instruments Engine idle speed adjustment (rpm) This function displays the engine idle speed adjustment. To display the function, access the menu and select the “RPM” page. In addition to the upper rev counter scale, the display also shows engine rpm numerically so that you can adjust the idle speed more precisely.
Page 699 Instruments LIGHT SET backlighting adjustment This function allows adjustment of the brightness of the display backlighting. To enable the function, enter the menu and select the “LIGHT SET” page. While in this page, press the reset button (3) for 3 seconds to enable adjustment and display the following pages in sequence: page 1 - “LIGHT MAX”...
Page 700 Instruments LAP function This function displays the recorded lap time. To activate this function, enter the menu and set the “LAP” function to “On” by pressing the reset button (3) for 3 seconds. START and STOP the timer by pressing the high beam FLASH switch (4) on the left-hand handlebar switch. When the LAP function is active, each time you press the flasher switch, the display will show the lap time for 10 seconds, before reverting to normal mode.
Page 701 Instruments When you switch the LAP function off from the menu, the lap in progress will not be saved. If the LAP function is active and the instrument panel is suddenly switched off (Key-Off), the LAP function is switched off automatically (even if the timer was ON, the lap in progress is not saved). If the timer is not stopped, when it reaches 9 minutes, 59 seconds and 99 hundredths, it restarts from 0 (zero) and continues until the function is switched off.
Page 702 Instruments LAP Memory display Displays the data saved using the LAP function: lap time, MAX speed and MAX rpm (and limiter if reached). To display the saved lap times, enter the menu and select the “LAP MEM” page. From this menu page, if you hold pressedreset (3) for 3 seconds, the data for the “1 st 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 703 Instruments During the lap, if the engine reaches one of the two thresholds before the limiter or the limiter itself, the respective warning lights (11A), (11B) or (11C) will illuminate during the display of the saved times.
Page 704 Instruments DDA data acquisition This function activates the DDA (Ducati Data Analyzer) (Sect. P 10, USB Data Acquisition kit). In order to acquire data, the DDA must be connected to the motorcycle wiring loom. To activate the DDA, go into the menu and set the “DDA” to “On” by pressing reset (3) for 3 seconds.
Page 705 Instruments Erase DDA This function enables you to delete the data saved on the DDA: in order to delete data, the DAQ must be connected to the motorcycle wiring loom. To delete the data, enter the menu and select the “Erase DDA” page. If you press reset (3) for 3 seconds and the DDA is not acquiring data, the message “WAIT…”...
Page 706 Instruments Clock setting function This function is used to set the clock time. To set the clock, enter the menu and select the “TIME Set” page. From this page, if you press reset (3) for 3 seconds, you enter clock setting mode. On entering this function, the message “AM”...
Page 707 Instruments Instrument panel diagnostics Important The instrument runs the system diagnostics correctly 60 seconds after the last Key-Off.
Page 708 Instruments Any errors detected in the behaviour 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. Warning light Error message Error Generic error of the throttle position sensor (TPS) PRESS...
Page 709 Instruments Entering the code: on entering this function, the first digit on the left starts flashing. Each time you press switch (1) “ ”, the number increases cyclically in steps of one digit every second. press button (2) “ ” to proceed to set the second digit, which now starts flashing. Each time you press switch (1) “ ”, the number increases cyclically in steps of one digit every second.
Page 710 Instruments If the code has been entered correctly, the message CODE and the code itself will flash simultaneously for 4 seconds. The “EOBD Vehicle/Engine diagnosis” warning light (10) will go off. The instrument panel then automatically exits the menu, thus allowing “temporary” starting of the motorcycle. If the error persists, at the next key-on, the instrument panel will return to an error state and immobilize the engine.
Page 711 Service Menu This MENU provides some useful functions for your DUCATI Dealer. To enter this MENU, press switch (2) “ ” and simultaneously turn the keyswitch from OFF to ON. Warning Within this “MENU”...
Page 712 Instruments If the code has been entered correctly, the message “COD” and the code entered will flash simultaneously; at this point, turn the key switch to Off. From this moment on, the immobilizer system is waiting to be programmed with the new key (or keys); at the next Key-On, reprogram the keys using the procedure described in “Programming the Immobilizer”.
Page 713 Instruments Loss of the Code Card Without knowing the electronic code on the CODE CARD, it is impossible to: - reprogram the immobilizer system in the event of loss of one or both of the keys; - temporarily override the immobilizer in the event of a fault. To restore the entire system to full operation, it is necessary to renew the KEY SET (2 black keys + new CODE CARD) and the instrument panel, and thus programming the immobilizer again.
Page 714 Instruments Each time you press switch (1) “ ” or (2) “ ”, the instrument panel scrolls through the following sequence of options, which flash on the display: Units of measurement COUNTRY Speed Air temperature Counters km/h °C °C miles °F miles km/h...
Page 715 Instruments Programming the immobilizer This instrument panel function enables programming of the Immobilizer System. Notes Only 2 keys may be programmed. Insert KEY 1 (one of the two black keys) and turn the ignition switch from Off to On: - within 3 seconds turn the ignition switch from On to Off; - within 15 seconds insert KEY 2 (the other black key) and turn the ignition switch from Off to On;...
Page 716 Instruments If the procedure was successful, the instrument panel will display the message “PROG” steadily for 3 seconds before returning to normal display mode. 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”...
Page 717 Instruments and Immobilizer Reprogramming procedures.
Page 718 Immobilizer and transponder 8 - Immobilizer and transponder The immobilizer allows the vehicle to be started only if the rider uses the special ignition key which sends the identification code to a decoder housed in the instrument panel. The transmission- receiving system is composed of a TRANSPONDER housed in the ignition key heads and an antenna in the vicinity of the ignition switch.
Page 719 Immobilizer and transponder Immobilizer operating principle At key-on (switching on the instrument panel by turning the key) the decoder (incorporated in the instrument panel) activates the antenna, which emits an electromagnetic field that serves to power the transponder in the key grip. The transponder responds by transmitting the code that is stored on its internal ROM memory, and which is picked up by the antenna and relayed to the decoder.
Page 720 Immobilizer and transponder Removal of the immobilizer and ignition switch Set the ignition switch to OFF. Disconnect the immobilizer antenna connector (A) and ignition switch connector (B). Unscrew the nuts (1) securing the ignition switch cover (2) and remove it along with the immobilizer antenna.
Page 721 Immobilizer and transponder Refitting the immobilizer and ignition switch Apply the recommended threadlocker to the bolts (3). Locate the igntion switch (4) on the frame and tighten the bolts (3) to the specified torque (Sect. C 3, Frame torque settings). Apply a drop of Loctite to the inside of cover (2).
Page 722 Immobilizer and transponder Tighten the nuts (1) to the specified torque (Sect. C 3, Frame torque settings). Disconnect the wiring connector of the ignition switch (B) and the connector of the antenna immobilizer (A) from the main wiring loom.
Page 723 Diagnostic instruments 9 - Diagnostic instruments For information on the “DDS” tester, refer to Section D 5, tester. Using a multimeter to check the electrical systems Introduction This instrument allows you to measure resistances, voltages, and current values. Multimeters can be divided into two basic types: those with an analogue display and those with a digital display.
Page 724 Diagnostic instruments Voltage measurement Voltage measurements must be carried out by connecting the terminals of the tester in parallel to the load (e.g. to the wires feeding a light bulb or a relay, the two battery terminals, or the two wires supplying power to a control unit).
Page 725 Diagnostic instruments...