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SERVICE STATION MANUAL
854146
SL 750 SHIVER

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   Summary of Contents for APRILIA SL 750 SHIVER

  • Page 1

    SERVICE STATION MANUAL 854146 SL 750 SHIVER...

  • Page 2

    The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.

  • Page 3

    SERVICE STATION MANUAL SL 750 SHIVER NOTE Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM CLU SYS LUTCH SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK...

  • Page 7

    INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    SL 750 SHIVER Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system.

  • Page 9

    SL 750 SHIVER Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.

  • Page 10

    CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Only use ORIGINAL APRILIA SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.

  • Page 11

    That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND/OR DAMAGING THE VEHICLE.

  • Page 12: Vehicle Identification

    SL 750 SHIVER Characteristics Vehicle identification Write down the chassis and engine number in the specific space of this booklet. The chassis number is handy when purchasing spare parts. CAUTION ALTERING IDENTIFICATION NUMBERS IS AN OFFENCE WHICH CAN RESULT IN SEVERE CRIMINAL AND ADMINISTRATIVE CHARGES.

  • Page 13

    SL 750 SHIVER Characteristics Specification Desc./Quantity Wheelbase 1440 mm (56.69 in) Kerb weight (full fuel tank) 210 kg (463 lb) Engine NGINE Specification Desc./Quantity Model M551M Type 90° longitudinal V-twin, 4-stroke, 4 valves per cyl- inder, 2 overhead camshafts. Cylinder quantity Overall engine capacity 749.9 cm³...

  • Page 14: Drive Chain, Electrical System

    SL 750 SHIVER Characteristics Specification Desc./Quantity Engine oil 3.0 l (without oil filter change) (0.66 UKgal; 0.79 USgal) 3.2 l (without oil filter change) (0.70 UKgal; 0.85 USgal) Fork oil quantity (for each stem): 535 cm³ (32.65 cu.in) Coolant 1.8 l (0.40 UKgal; 0.48 USgal) Seats Vehicle max.

  • Page 15

    SL 750 SHIVER Characteristics Specification Desc./Quantity Side stand down Fuel reserve Frame and suspensions CHASSIS Specification Desc./Quantity Type Die-cast aluminium plates and high-strength steel tubular chassis. Steering inclination angle 24.9° Trail 109.6° SUSPENSIONS Specification Desc./Quantity Front Upside-down hydraulic action telescopic fork, Ø...

  • Page 16: Wheels And Tyres, Tightening Torques

    SL 750 SHIVER Characteristics Wheels and tyres HEEL RIMS Specification Desc./Quantity Type Light alloy rims with extractable bolt Front 3.50 x 17" Rear 6.00 x 17" YRES Specification Desc./Quantity Tyre type (standard) DUNLOP SPORTMAX QUALIFIER - METZELER Front 120/70 ZR17" (58W) Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI)

  • Page 17

    SL 750 SHIVER Characteristics FOOTREST UNIT Name Torque in Nm TCEI sunken screw fixing Footrest Support to 18 Nm (13.27 lbf ft) chassis - M8x30 (6) Non-slip bolt (fit on driver footrest) - M8 (2) 25 Nm (18.44 lbf ft) Self-tapping TE screw for Footrest finish - M6x12 10 Nm (7.37 lbf ft)

  • Page 18

    SL 750 SHIVER Characteristics FILTER CASE UNIT Name Torque in Nm SWP Self-tapping screw - M2.9x12 TCCR (2) 3 Nm (2.21 lbf ft) TCEI screw fixing negative on engine - M6x12 (1) 10 Nm (7.37 lbf ft) FILTER CASING SMALL PARTS UNIT...

  • Page 19

    SL 750 SHIVER Characteristics FRONT BRAKE UNIT Name Torque in Nm Brake pipe union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft) Filler with bleed (Heng Tong) - M10x1 (2) 25 Nm (18.44 lbf ft) Self-tapping TE screw fixing Calliper - 50 Nm (36.88 lbf ft)

  • Page 20

    SL 750 SHIVER Characteristics TANK UNIT Name Torque in Nm Self-locking nut - M5 (6) 6 Nm (4.42 lbf ft) Self-tapping TE screw - M6x30 (2) 6 Nm (4.42 lbf ft) FRONT BODYWORK UNIT Name Torque in Nm TBEI screw fixing Under grab handles/ Tail sec- 4 Nm (2.95 lbf ft)

  • Page 21

    SL 750 SHIVER Characteristics Name Torque in Nm Map sensor fitting (brass) (2) 2 Nm (1.48 lbf ft) (Loctite 243) Map sensor fitting (steel) (2) 3.50 Nm (2.58 lbf ft) (Loctite 243) H20 Bleed fitting (brass) (1) 2 Nm (1.48 lbf ft) (Loctite 243) H20 Bleed fitting (steel) (1) 3.50 Nm (2.58 lbf ft) (Loctite 243)

  • Page 22

    SL 750 SHIVER Characteristics Name Torque in Nm Screw fixing Gear locking pawl - M6 (1) 12 Nm (8.85 lbf ft) Screw fixing Desmodromic / Sprocket Selector - 23 Nm (16.96 lbf ft) M8 (1) Selector Plate fixing screw - M5 (3) 5.50 Nm (4.06 lbf ft)

  • Page 23

    SL 750 SHIVER Characteristics Name Torque in Nm Screw fixing engine Bracket / clutch side crank- 12 Nm (8.85 lbf ft) case half - M6 (2) Crankshaft access cover (1) 4 Nm (2.95 lbf ft) H20 Pump Rotor (1) 4.50 Nm (3.32 lbf ft) Screw fixing Stick-coil / Head cover - M6 (2) 5.50 Nm (4.06 lbf ft)

  • Page 24

    SL 750 SHIVER Characteristics YLINDER PISTON COUPLING Specification Desc./Quantity Piston - cylinder coupling Type A Cylinder: 91.990 - 91.977 mm (3.6216 - 3.6219 in) Piston: 91.933 - 91.940 mm (3.6217 - 3.6197 in) Piston - cylinder coupling Type B Cylinder: 91.997 - 92.004 mm (3.6219 - 3.6222 in) Piston: 91.940 - 91.947 mm (3.6197 - 3.6199 in)

  • Page 25

    SL 750 SHIVER Characteristics There are two types of crankshaft for each bearing: • 4 - 5 for flywheel side; • 7 - 8 for clutch side. The category type is stamped on one crankshaft counterweight. NOTE THE SHAFT MAY HAVE TWO DIFFERENT CLASSES ON THE TWO BEARINGS.

  • Page 26

    SL 750 SHIVER Characteristics RANKCASE SELECTION TYPE Specification Desc./Quantity Type A crankcase Centre to centre distance: 110.50 - 110.54 mm (4.3504 - 4.3519 in) Type B crankcase Centre to centre distance: 110.46 - 110.50 mm (4.3488 - 4.3504 in) Primary category...

  • Page 27

    SL 750 SHIVER Characteristics CONNECTING RODS Specification Desc./Quantity Type E1 crankshaft Original connecting rod type: brown Spare connecting rod type: brown Type E2 crankshaft Original connecting rod type: blue Spare connecting rod type: blue Type E3 crankshaft Original connecting rod type: yellow...

  • Page 28

    SL 750 SHIVER Characteristics CHAR - 22...

  • Page 29

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 30

    SL 750 SHIVER Special tools PECIAL TOOLS Stores code Description 020709Y Engine support 020710Y Engine plate AP8140187 Engine support stand 020711Y Engine pinion locking 020712Y Handle for Flywheel cover re- moval 020713Y Flywheel extractor S-TOOLS - 2...

  • Page 31

    SL 750 SHIVER Special tools Stores code Description 020714Y Comparator support 020715Y Tone wheel removal 9100896 Clutch bell locking tool 020716Y Connecting rod locking 020717Y Piston ring driver AP8140302 tool for sealing ring fitting S-TOOLS - 3...

  • Page 32

    SL 750 SHIVER Special tools Stores code Description 020718Y Camshaft gear alignment pin 020719Y Timing pin 020720Y Timing tool AP8140179 Valve spring compressor 020721Y Adaptor for valve removal 020722Y Guide for oil seal 020376Y Punch adaptor S-TOOLS - 4...

  • Page 33

    SL 750 SHIVER Special tools Stores code Description 020629Y 8 mm (0.31 in) guide 020412Y 15-mm Oil seal guide 020439Y 17-mm guide for oil seal 020263Y Sheath for fitting the driven pulley 020365Y 22 mm (0.87 in) guide 020364Y 25 mm oil seal guide...

  • Page 34

    SL 750 SHIVER Special tools Stores code Description 020483Y 30 mm punch 020441Y Oil seal punch 020358Y 37 x 40 mm punch 020357Y 32 x 35 mm adaptor 020359Y 42 x 47 mm punch 020360Y 52 x 55 mm punch...

  • Page 35

    SL 750 SHIVER Special tools Stores code Description 020723Y Template for timing overhead camshafts 020724Y Gear control rod roller cage punch 020725Y Punch for water pump overall sealing 020726Y Extractor for bushings 020727Y Punch for bushings 8140180 Extractor for bushings...

  • Page 36

    SL 750 SHIVER Special tools Stores code Description 8140181 manometer for fuel - oil - com- pression pressure 8140199 Tool panel 8202222 Generic adhesive film for panel 8140426 Hooks for panel XXXXXXX Tool for inserting the entire rotor shaft (being coded)

  • Page 37

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 38: Maintenance Chart

    Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, aprilia offers a set of checks and maintenance services (at the owner's expense) that are summarised in the table shown on the following page. Any minor faults should be reported without delay...

  • Page 39

    SL 750 SHIVER Maintenance EVERY 5000 (3100 ) OR 1 MONTH Action Tyre pressure and wear - check EVERY 5000 (3100 Action Brake pad wear - Check and clean, adjust or replace if necessary EVERY 10,000 (6,215 Action Air filter - Check and clean, replace if necessary...

  • Page 40: Spark Plug

    SL 750 SHIVER Maintenance EVERY 4 YEARS Action Fuel pipes - Replace Spark plug At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required. CAUTION ALWAYS REPLACE BOTH SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING.

  • Page 41

    SL 750 SHIVER Maintenance • Detach the radiator towards the vehicle right-hand side and lower it so as to be able to work on the coil. • Undo and remove the screw. • Slide off the front coil. • Unscrew and remove the front spark plug.

  • Page 42

    SL 750 SHIVER Maintenance • Working from both sides, undo and re- move the screw. • Remove at least one side air deflector. • Slide off the key lock plate. • Undo and remove the two screws and collect the two collars.

  • Page 43

    SL 750 SHIVER Maintenance • Lift the tank. • Undo and remove the rear coil fixing screw. • Slide off the rear coil. • Unscrew and slide off the rear spark plug. • Check the gap between the electrodes with a feeler thickness gauge.

  • Page 44: Engine Oil

    SL 750 SHIVER Maintenance complete 1/2 of a turn to compress the washer. CAUTION IT IS ESSENTIAL TO TIGHTEN THE SPARK PLUG (2) PROPERLY. A LOOSE SPARK PLUG MAY CAUSE ENGINE OVERHEATING AND RE- SULT IN SEVERE DAMAGE. Locking torques (N*m) Spark plug (2) 13 Nm (9.59 lbf ft)

  • Page 45: Engine Oil Filter

    SL 750 SHIVER Maintenance Replacement Check the engine oil level frequently. To change the oil: CAUTION HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY; IDE- AL TEMPERATURE IS REACHED AFTER THE ENGINE HAS RUN FOR ABOUT TWENTY MI- NUTES.

  • Page 46: Air Filter

    SL 750 SHIVER Maintenance Replacement Air filter • Remove the fuel tank. • Disconnect the air temperature sensor. • Undo and remove the eight screws. • Remove the clamp and slide off the blow-by tube. • Remove the filter casing cover.

  • Page 47: Checking The Valve Clearance

    SL 750 SHIVER Maintenance • Working on both ducts, turn the upper part of the intake ducts anticlockwise and remove it. • Remove the filtering element. COVER THE INTAKE DUCTS WITH A CLEAN CLOTH SO THAT FOREIGN BODIES DO NOT GET INTO THE INLET DUCTS.

  • Page 48

    SL 750 SHIVER Maintenance • Using a thickness gauge, measure the distance between the tip of the crank- shaft and the valve bowl. • Take note of the measurement. If valve clearance is not within the tolerance range, adjust as follows: •...

  • Page 49

    SL 750 SHIVER Maintenance 6. Calibrated pad 2.85 7. Calibrated pad 2.90 8. Calibrated pad 2.95 9. Calibrated pad 3.00 10.Calibrated pad 3.05 11.Calibrated pad 3.10 12.Calibrated pad 3.15 13.Calibrated pad 3.20 14.Calibrated pad 3.25 15.Calibrated pad 3.30 16.Calibrated pad 3.35 17.Calibrated pad 3.40...

  • Page 50

    SL 750 SHIVER Maintenance MAIN - 14...

  • Page 51

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 52

    THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE CONTROL UNIT THROUGH AXONE (MINIMUM VERSION: 5.1.5) BY SELECTING "SELF- DIAGNOSIS, APRILIA, SL 750 SHIVER" • 3 - ARE CURRENT "ATT" or STORED "MEM" ERRORS SHOWN IN THE "ERRORS DIS- PLAY"...

  • Page 53

    SL 750 SHIVER Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAILURE AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...

  • Page 54

    SL 750 SHIVER Troubleshooting Engine The engine does not start THE ENGINE DOES NOT START CAUTION AXONE SHOULD BE WORKING PROPERLY AND UPGRADED TO THE 5.1.5 VERSION MINIMUM. CAUTION BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V;...

  • Page 55

    SL 750 SHIVER Troubleshooting • 11 - REPLACE THE MAIN INJECTOR RELAY (POLARISED) 41 - END • 12 - CHECK IF THERE IS VOLTAGE ON THE ORANGE/RED CABLE OF THE AUXILIARY INJECTION RELAY (POLARISED) 42. YES, go to 13; OK, go to 14 •...

  • Page 56

    SL 750 SHIVER Troubleshooting • 29 - VOLTAGE TO THE YELLOW/PINK CABLE OF THE RETENTION RELAY (START-UP LOGIC) 39 OK, go to 30; NOT OK, go to 31 • 30 - WITH THE RETENTION RELAY (START-UP LOGIC) 39 DISCONNECTED, KEEP THE STARTER BUTTON PRESSED AND CHECK IF THERE IS APPROX.

  • Page 57

    SL 750 SHIVER Troubleshooting • 44 - CHECK IF THERE IS VOLTAGE IN THE RED/BLACK CABLES ON THE CONTROL RELAY (START-UP LOGIC) 40 YES, go to 50; NO, go to 51 • 45 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/PINK CABLE FROM THE RELAY TO THE ENGINE CONNECTOR (PIN 2) OK, go to 47;...

  • Page 58

    SL 750 SHIVER Troubleshooting • 61 - REPLACE THE START-UP RELAY 36 - END • 62 - REPLACE THE STARTER MOTOR - END • 63 - RESTORE THE CABLE HARNESS - END • 64 - WHAT DOES THE "FALL SENSOR" STATUS ON AXONE (DEVICE STATUS/ICON "0/1"...

  • Page 59

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 60

    SL 750 SHIVER Electrical system Components arrangement 1. Revolution sensor 2. Intake air pressure sensor 3. Intake air temperature sensor ELE SYS - 2...

  • Page 61

    SL 750 SHIVER Electrical system 4. Instrument panel 5. Air temperature sensor for instrument panel indication 6. Front headlamp 7. Start-up relay 8. Coils 9. Spark plugs 10.Starter motor 11.Rear light 12.Auxiliary fuses 13.Main fuses 14.Throttle grip position sensor 15.Gear in neutral sensor 16.Revolution sensor - pick up...

  • Page 62

    SL 750 SHIVER Electrical system • Location on the wiring diagram: 41 • Location on the vehicle: under the saddle. AUXILIARY INJECTION RELAY • Location on the wiring diagram: 42 • Location on the vehicle: under the fuel tank, right side, third relay starting from the front.

  • Page 63

    SL 750 SHIVER Electrical system 1. Front section 2. Central section 3. Rear section SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Carry out the checks described below once the electrical system is refitted, connectors recon- nected and clamps and retainers restored.

  • Page 64

    SL 750 SHIVER Electrical system TABLE A - SWITCHES 1. Right switch cable harness 2. Left switch cable harness • Introduce carefully the cap on the cable harnesses (1 and 2) of the switches. TABLE B - RIGHT SWITCH CABLE HARNESS RETAINER •...

  • Page 65

    SL 750 SHIVER Electrical system TABLE D - CLUTCH CABLE, THROTTLE CA- • With a small clamp, not pulled clamp, fasten the clutch cable to the throttle cable. TABLE E - INSTRUMENT PANEL CABLES • Fasten the instrument panel cable braid to the chassis with a medium clamp.

  • Page 66

    SL 750 SHIVER Electrical system TABLE F - INSTRUMENT PANEL CABLES 1. The two medium clamps shall be positioned so that they match the corresponding sec- tions of chassis indicated through two turns of red belt. 2. Place the clamp as close as possible to the chassis vertical tube.

  • Page 67

    SL 750 SHIVER Electrical system TABLE J - INSTRUMENT PANEL 1. Place a small clamp on the left turn indicator connector and the main trunk. 2. The immobilizer aerial connector is fitted between the plate and the instrument panel. 3. Lift the external air temperature sensor upwards once it is connected.

  • Page 68

    SL 750 SHIVER Electrical system ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE- CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELEC- TRICAL SYSTEM INSTALLATION" SECTION.

  • Page 69

    SL 750 SHIVER Electrical system TABLE C - MAIN CABLE HARNESS • The main cable harness is laid be- tween the relay and the fall sensor, under the fall sensor connector. TABLE D - DIAGNOSIS CONNECTORS • Fasten both diagnosis connectors with a small clamp, under the cable harness main branch.

  • Page 70

    SL 750 SHIVER Electrical system TABLE F - CABLE HARNESSES UNDER THE TANK 1. Place clamps at the connector sides. 2. Mark the connection on the left side using the BLUE belt. 3. Mark the connection on the right side using the WHITE belt.

  • Page 71

    SL 750 SHIVER Electrical system 3. Fasten the cables with a clamp and hold also the control unit upper branch. TABLE I - PICK-UP AND ENGINE CONTROL UNIT CABLE HARNESSES 1. Cable harness path towards the engine control unit connectors.

  • Page 72

    SL 750 SHIVER Electrical system 1. Use a small clamp to keep the cable fixed to the oil bulb cap. 2. Use a small clamp behind the pipe so that the oil and start-up cable is tightened to the rear pipe.

  • Page 73

    SL 750 SHIVER Electrical system TABLE L - LAMBDA PROBE • Place two clamps to fasten the cable harness to the chassis, as indicated: 1. medium clamp; 2. small clamp. TABLE M1 - FILTER CASING CABLE HAR- NESS • Place both throttle valve position sen- sors.

  • Page 74

    SL 750 SHIVER Electrical system TABLE M4 - FILTER HOUSING • Insert the throttle body, with the cable harness correctly fixed, in the filter cas- ing. TABLE N - GROUND LEAD AND START-UP CABLE • Fit the ground lead following the path drawn in figure that will not be visible on the vehicle once fully assembled.

  • Page 75

    SL 750 SHIVER Electrical system TABLE O - GROUND LEAD AND START-UP CABLE 1. Direct the cable as shown in figure. 2. Before fitting the cable, push the sheath to the panel terminal so as to hide the RED ca- ble (see box).

  • Page 76

    SL 750 SHIVER Electrical system ELE SYS - 18...

  • Page 77

    SL 750 SHIVER Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. RIGHT FRONT TURN INDICATOR 3. COMPLETE FRONT HEADLAMP 4. TAIL LIGHT BULB ELE SYS - 19...

  • Page 78

    SL 750 SHIVER Electrical system 5. LOW-BEAM BULB 6. HIGH-BEAM BULB 7. FRONT LEFT TURN INDICATOR 8. AMBIENT AIR TEMPERATURE SENSOR 9. SWITCH LIGHTS LOGIC RELAY 10.CLUTCH 11.HORN 12.LEFT LIGHT SWITCH 13.INSTRUMENT PANEL 14.RIGHT LIGHT SWITCH 15.OIL PRESSURE SENSOR 16.INSTRUMENT PANEL DIAGNOSIS 17.SIDE STAND SWITCH...

  • Page 79

    SL 750 SHIVER Electrical system 43.FAN 44.FAN CONTROL RELAY 45.FUEL LEVEL SENSOR 46.FUEL PUMP 47.REAR CYLINDER COIL 48.FRONT CYLINDER COIL 49.REAR CYLINDER SPARK PLUG 50.FRONT CYLINDER SPARK PLUG 51.INTAKE AIR TEMPERATURE SENSOR 52.ENGINE TEMPERATURE SENSOR 53.LAMBDA PROBE 54.PURGE VALVE (OPTIONAL) 55.REAR CYLINDER PRESSURE SENSOR...

  • Page 80

    SL 750 SHIVER Electrical system Vi Purple Conceptual diagrams Checks and inspections GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN"...

  • Page 81: Diagnosis

    SL 750 SHIVER Electrical system Tester: set the tester on the "continuity" symbol and place the tester probes on the two circuit ends: the tester emits a sound signal only if there is continuity; the tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm.

  • Page 82: Ecu Diagnosis, Instrument Panel Errors

    SL 750 SHIVER Electrical system • INCORRECT CODE and the instrument panel goes back to the main menu. Otherwise, the following menu is displayed: • EXIT • ECU DIAGNOSIS • INSTRUMENT PANEL ERRORS • ERROR CLEARING • VEHICLE SERVICING RESET •...

  • Page 83

    SL 750 SHIVER Electrical system • An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive. DSB 07 - Oil pressure sensor Error cause An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open.

  • Page 84

    SL 750 SHIVER Electrical system KM / MILES This menu selects the unit of measurement, either for the speed or the total or partial odometers. • • MILES LANGUAGES Select the user interface language from this menu. • ITALIANO •...

  • Page 85

    SL 750 SHIVER Electrical system Lights list Front headlamp Characteristic Front tail light 12V - 5W x 2 Low-beam light 12 V - 55 W H7 High-beam light 12 V - 55 W H7 Rear light Characteristic Rear tail light / stop light...

  • Page 86: Control Unit

    SL 750 SHIVER Electrical system Control unit MARELLI CONTROL UNIT Function It controls the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function. Location: • left side, next to the engine Connector location: •...

  • Page 87

    SL 750 SHIVER Electrical system PARAMETERS Target idle rpm AXONE: ELECTRICAL ERRORS EEPROM Error P0601 - circuit not operational. Error cause • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status.

  • Page 88: Battery Installation

    SL 750 SHIVER Electrical system • Check the VEHICLE connector of the Marelli control unit, the filter housing large connector and the throttle control unit connector: if not OK, restore. If OK, check continuity between the Marelli control unit and the throttle control unit connector from VEHICLE PIN 55 to PIN B7 and from PIN 56 to PIN A7: if not OK, restore.

  • Page 89: Speed Sensor, Battery Installation

    SL 750 SHIVER Electrical system THE FIRST TIME THE ENGINE IS STARTED AFTER RECONNECTING THE BATTERY LEADS, WAIT 20 SECONDS BETWEEN THE MOMENT THE KEY IS SET TO "KEY ON" AND THE MOMENT THE STARTER BUTTON CAN BE PUSHED. THE ENGINE WILL NOT START IF START-UP IS ATTEMPTED BEFORE THE PRE-SET 20 SEC- ONDS.

  • Page 90

    SL 750 SHIVER Electrical system tected at VEHICLE PIN 49. This requires a longer recognition time that is counted from zero each time the clutch is operated, the gear is set to neutral or the engine is shut off. Troubleshooting •...

  • Page 91: Engine Rpm Sensor

    SL 750 SHIVER Electrical system Removing Engine rpm sensor ENGINE REVOLUTION SENSOR Function It informs crankshaft position and speed to the Marelli control unit. Operation / Operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position.

  • Page 92: Twistgrip Position Sensor

    SL 750 SHIVER Electrical system AXONE: ELECTRICAL ERRORS CAUTION IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT-CIRCUITED OR NO ERROR IS DIS- PLAYED, CHECK THE REVOLUTION SENSOR CONNECTOR AND THE MARELLI CONTROL UNIT CONNECTOR: IF NOT OK, RESTORE; IF OK, CHECK THE SENSOR ELECTRIC CHARACTERIS- TIC IS THE CORRECT ONE: IF IT IS NOT, REPLACE THE SENSOR.

  • Page 93

    SL 750 SHIVER Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. CAUTION THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED.

  • Page 94

    SL 750 SHIVER Electrical system With a released throttle grip, the value read should be 0%, whereas 100 % should be read with throttle grip fully twisted. AXONE: STATUSES Throttle grip Example value:Slightly twisted_choked_fully twisted Throttle grip autodetection Example value: carried out/not carried out...

  • Page 95

    SL 750 SHIVER Electrical system if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, short circuit to negative: check the throttle grip sensor connector and the Marelli control unit connector.

  • Page 96

    SL 750 SHIVER Electrical system • if shorted to positive: check the value shown by the parameter of the right Throttle Grip Position Sensor - track D: disconnect the right side connector and see the value displayed by the Axone: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero.

  • Page 97: Intake Pressure Sensor

    SL 750 SHIVER Electrical system • The value of the left side sensor (tracks A-B) does not coincide with the value of the right side sensor (tracks C-D). Troubleshooting • Replace the throttle grip sensor RESET PROCEDURE If the Marelli control unit or the throttle grip sensor is replaced, check the Throttle grip Autodetection with the diagnosis instrument: once the check is completed, make sure that the throttle grip Autode- tection status indicates: carried out.

  • Page 98

    SL 750 SHIVER Electrical system 1. Supply 2. Ground connection 3. Output signal AXONE: PARAMETERS Front Cylinder Intake Pressure Example value: 1003 mbar Pressure read by the front sensor. Rear Cylinder Intake Pressure Example value: 1004 mbar Pressure read by the rear sensor.

  • Page 99

    SL 750 SHIVER Electrical system • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 34 of the VEHICLE connector. Troubleshooting • If short circuit to positive, see that the parameter of the front Cylinder Intake Pressure on the diagnosis instrument reads approx.

  • Page 100

    SL 750 SHIVER Electrical system • If the circuit is open, short circuit to negative, check the filter casing large connector, the Marelli control unit connector and the sensor connector; If not OK, restore. If everything is OK, and with key set to OFF, check if there is continuity between the VEHICLE PIN 5 of the Marelli control unit and the sensor connector PIN 3: if there is no continuity, restore the cable harness.

  • Page 101

    SL 750 SHIVER Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, cut or wrongly connected pipe between sensor and throttle body or a hole in the intake manifold).

  • Page 102

    SL 750 SHIVER Electrical system • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean: there is an evident defect in the intake and pressure reading systems.

  • Page 103

    SL 750 SHIVER Electrical system • Resistance at 25°: 2.05 kOhm +/- 100 • Resistance at 60°: 575 Ohm +/- 15 • Resistance at 90°: 230 Ohm +/- 5 Ohm Pin-out: 1. Yellow brown: 0-5 V signal: PIN B1 2. Brown: PIN B2 ground connection...

  • Page 104

    SL 750 SHIVER Electrical system the vehicle ground connection: if it is correct, it means that the error cause is that the cable is short circuit to positive and it is necessary to restore the cable harness between the EN- GINE PIN 45 and the sensor PIN 1;...

  • Page 105

    SL 750 SHIVER Electrical system • on the vehicle: on filter casing • on connector sensor: near the probes Electrical characteristics: • Resistance at 0°: 32.5 k +/- 5% • Resistance at 25°: 10.0 k +/- 5% Pin-out: 1. 0-5 V signal: PIN 1 2.

  • Page 106

    SL 750 SHIVER Electrical system If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. • If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;...

  • Page 107

    SL 750 SHIVER Electrical system 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN"...

  • Page 108

    SL 750 SHIVER Electrical system AXONE: ELECTRICAL ERRORS Lambda probe P0130 - short circuit to positive. Error cause • Excessive voltage (battery voltage) has been detected at PIN 43 of the ENGINE connector. Caution: the "lambda probe" parameter is not the real value that is read; a recovery value is displayed instead.

  • Page 109

    SL 750 SHIVER Electrical system • Check circuit continuity from probe connector (PIN 1 and PIN 2) toward the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the ENGINE connector PIN 43 and PIN 60 and restore the cable harness.

  • Page 110

    SL 750 SHIVER Electrical system energised for 5 seconds and the grey/green cable of the injector is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation.

  • Page 111

    SL 750 SHIVER Electrical system • If shorted to positive: excessive voltage has been detected at PIN 34 of the ENGINE con- nector. • If shorted to negative: no voltage has been detected. • If the circuit is open: an interruption has been detected.

  • Page 112

    SL 750 SHIVER Electrical system • Secondary circuit resistance: MOhm value range (with positive probe on coil). Pin-out: 1. Supply + batt V 2. Secondary circuit ground connection 3. Activation from control unit CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER.

  • Page 113

    SL 750 SHIVER Electrical system AXONE: ELECTRICAL ERRORS Lambda probe P0130 - short circuit to positive / circuit, short circuit to negative Error cause • If shorted to positive: excessive voltage has been detected at PIN 17 of the ENGINE con- nector.

  • Page 114: Throttle Body

    SL 750 SHIVER Electrical system Throttle body THROTTLE BODY Function To inform the throttle control unit the position of the two throttle valves and to drive them both. Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless; therefore, no electrical diagnosis is possible for the throttle body, only for the circuits connected to it.

  • Page 115

    SL 750 SHIVER Electrical system The value in the example refers to engine conditions with key set to ON. Rear throttle Potentiometer 1 (voltage) Example value: 780 mV The value in the example refers to engine conditions with key set to ON.

  • Page 116

    SL 750 SHIVER Electrical system • If shorted to positive: excessive voltage has been detected at PIN A6 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN A6 of the throttle control unit.

  • Page 117

    SL 750 SHIVER Electrical system • If shorted to positive: excessive voltage has been detected at PIN B6 of the throttle control unit. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN B6 of the throttle control unit.

  • Page 118

    SL 750 SHIVER Electrical system • The throttle power supply is too low to carry out the autodetection test correctly (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status.

  • Page 119

    SL 750 SHIVER Electrical system • The throttle test is not carried out when the key is set to ON because the test could show unreal errors (because the voltage is too low). Voltage is detected by the Marelli control unit.

  • Page 120

    SL 750 SHIVER Electrical system is a few tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the complete throttle body. Potentiometer 2 sensor, front throttle position P0123 - signal not valid.

  • Page 121

    SL 750 SHIVER Electrical system • Signal not within the expected value drawn according to the values of the intake pressure. Troubleshooting • Check the parameter of the Potentiometer 2 Rear throttle (voltage) to get which signal the control unit receives and to compare it to the Potentiometer 2 Front throttle (voltage). Check the throttle body connector as well as the throttle control unit connector.

  • Page 122

    SL 750 SHIVER Electrical system • Check if the throttle body and the intake duct are clean. If they are, replace the throttle body. Detection of front throttle valve Recovery conditions (air Tº,water Tº) P0163 - possible presence of ice.

  • Page 123

    SL 750 SHIVER Electrical system Error cause • Position of the throttle stop not within the expected range (at each key ON). Troubleshooting. • Check if the throttle body and the intake duct are clean. If they are, replace the throttle body.

  • Page 124

    SL 750 SHIVER Electrical system Engine oil pressure sensor ENGINE OIL PRESSURE SENSOR Function: it indicates to the instrument panel if there is enough oil pressure (0.5 +/- 0.2 bar (7.25 +/- 2.9 PSI)) in the engine. Operation / Operating principle: normally closed switch.

  • Page 125

    SL 750 SHIVER Electrical system Error DSB 08 Error cause • An oil sensor failure is signalled when, with engine running, it is detected that the sensor circuit is closed. This error is signalled by the bulb icon and the general warning light turns on as well.

  • Page 126

    SL 750 SHIVER Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: STATUSES Gear in neutral Example value:yes/no AXONE: NOTES •...

  • Page 127

    SL 750 SHIVER Electrical system • Clutch pulled: closed circuit (continuity) • Clutch released: open circuit (infinite resistance) Pin-out: 1. Voltage 12V 2. Ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLE- SHOOTING, CAREFULLY READ THE GENER- AL CONCEPTS OF ELECTRICAL TROUBLE-...

  • Page 128

    SL 750 SHIVER Electrical system Side stand sensor SIDE STAND SENSOR Function It tells the side stand position to the control unit. Operation / Operating principle If the gear is engaged and the side stand is unfol- ded, and therefore the circuit is open, the control unit does not enable vehicle start-up or shuts off the engine if it is rotating.

  • Page 129: Bank Angle Sensor

    SL 750 SHIVER Electrical system Bank angle sensor FALL SENSOR Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: When the Marelli control unit detects this ground connection, it does not enable start-up or shuts off the engine.

  • Page 130

    SL 750 SHIVER Electrical system not, it means that, with key set to ON, there is no 5V voltage at PIN 2: restore the cable harness whose pink/white cable will be short circuit to ground Air temperature sensor - instrument panel...

  • Page 131

    SL 750 SHIVER Electrical system If there is 5V voltage, connect a 10 kOhm resistance to sensor connector PIN 1 and to the vehicle ground connection: if, with key set to ON, the voltage measured upstream the re- sistance decreases, replace the instrument panel. If voltage continues to be approximately...

  • Page 132

    SL 750 SHIVER Electrical system • If shorted to positive: excessive voltage has been detected at PIN 54 of the VEHICLE con- nector. • If shorted to negative: short circuit to ground detected. • If the circuit is open: interrupted circuit detected. Excessive voltage can only be detected after the fan relay gets activated.

  • Page 133

    SL 750 SHIVER Electrical system • on the vehicle: right light switch • connector: inside the rubber protection located between the water radiator and the fuel tank, to the right. Electrical characteristics: • STOP position: the circuit is open •...

  • Page 134

    SL 750 SHIVER Electrical system Level in wiring diagram:throttle control unit Location: • on the vehicle: inside the filter casing • connector: on the control unit Pin-out: see the CONNECTORS section See also Throttle control unit Connectors PIN OUT ARELLI CONTROL UNIT Specification Desc./Quantity...

  • Page 135

    SL 750 SHIVER Electrical system Specification Desc./Quantity Side stand input Vehicle connector: 6 "start engine" input Vehicle connector: 14 Clutch sensor input Vehicle connector: 50 Fall sensor input Engine connector: 8 Gear/neutral input Engine connector: 16 Start-up control output Engine connector: 2...

  • Page 136

    SL 750 SHIVER Electrical system NOTE THE CONNECTOR CAN BE VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNEC- TOR. ELE SYS - 78...

  • Page 137

    SL 750 SHIVER Electrical system Throttle control unit PIN OUT THROTTLE CONTROL UNIT Specification Desc./Quantity 1A - Front throttle motor control (-) Front throttle body PIN: 5 2A - CAN L 3A - Voltage for front throttle potentiometers Front throttle body PIN: 2...

  • Page 138

    SL 750 SHIVER Electrical system Dashboard NSTRUMENT PANEL Specification Desc./Quantity GREY BODY: + Live PIN 1 GREY BODY: Right indicator control PIN 2 GREY BODY: * PIN 3 GREY BODY: High-beam lights input PIN 4 GREY BODY: * PIN 5...

  • Page 139

    SL 750 SHIVER Electrical system Specification Desc./Quantity BLACK BODY: Aerial 1 PIN 34 BLACK BODY: Light relay activation PIN 35 BLACK BODY: * PIN 36 BLACK BODY: * PIN 37 BLACK BODY: General ground PIN 38 BLACK BODY: General ground...

  • Page 140

    SL 750 SHIVER Electrical system Error cause • The injection ECU cannot send CAN signals; it receives signals from the instrument panel and the throttle control unit: the control unit may need replacing. Troubleshooting • Replace the Marelli control unit.

  • Page 141

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 142

    SL 750 SHIVER Engine from vehicle Vehicle preparation • Remove the air filter case. • Remove the coolant radiator. • Remove the exhaust system. • Place the optional under-sump and rear wheel service stands. • Undo and remove the screw and move the coil.

  • Page 143

    SL 750 SHIVER Engine from vehicle • Undo and remove the screw and col- lect the washer. • Disconnect the ground leads. • Move the breather pipe. • Disconnect the speed sensor connec- tor. • Undo and remove the three screws.

  • Page 144

    SL 750 SHIVER Engine from vehicle • Undo and remove the two screws. • Remove the chain guard. • Undo and remove the three screws fix- ing the chain guide. • Remove the clutch pin. CAUTION UPON REFITTING, PROPERLY GREASE THE O-RING INDICATED WITH THE ARROW AND BE CAREFUL NOT TO PINCH IT.

  • Page 145

    SL 750 SHIVER Engine from vehicle • Disconnect the side stand sensor con- nector. • Loosen the screw and slide off the gear transmission connecting rod keeping it linked to the gear shift lever through the rod. • Slacken the gearing chain tension.

  • Page 146

    SL 750 SHIVER Engine from vehicle See also Air box Removing the radiator Removing the engine from the vehicle • Carry out the operations described un- der Vehicle preparation. • Support the engine by means of belt and hoist. •...

  • Page 147

    SL 750 SHIVER Engine from vehicle • Working on the right side, insert the three bolts with their washers. • Working on the right side, place the spacers on the three bolts between the engine block and the chassis. CAUTION THE SPACERS HAVE DIFFERENT SIZES.

  • Page 148

    SL 750 SHIVER Engine from vehicle ENG VE - 8...

  • Page 149

    INDEX OF TOPICS NGINE...

  • Page 150

    SL 750 SHIVER Engine Gearbox Diagram 1. Complete gear shaft and spring 2. Selector lock 3. Selector sprocket wheel 4. M5x16 Screw 5. Sprocket wheel pawl 6. Spring 7. Pin for spring 8. Tone wheel 9. Complete transmission gear shaft 10.Forks...

  • Page 151

    SL 750 SHIVER Engine 17.Gear selector drum 18.M8x1.25 threaded pin 19.Selector locking plate 20.Complete main gear shaft 21.TE flanged screw, M6x15 22.Complete index lever 23.Spring Gearbox shafts Gearbox shafts diagram Key: 1. Main gear shaft Z=14 2. 2nd gear on primary Z=17 3.

  • Page 152

    SL 750 SHIVER Engine 10.Circlip 11.Transmission shaft 12.1st gear on primary Z=36 13.2nd gear on secondary Z=32 14.3rd gear on secondary Z=30 15.4th gear on secondary Z=28 16.5th gear on secondary Z=26 17.6th gear on secondary Z=25 18.Thrust washer 19.Circlip 20.Thrust washer...

  • Page 153

    SL 750 SHIVER Engine • Slide off the desmodromic drum con- trol. • Remove the three gear selection forks. CAUTION THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF THE SECONDARY SHAFT. ALL THE SECONDARY SHAFT FORKS ARE THE SAME SIZE.

  • Page 154

    SL 750 SHIVER Engine • Carefully slide off the whole gear unit. Refitting • Repeat the removal operations but in reverse order, make sure that the shim washer is fitted to the secondary shaft. See also Splitting the crankcase halves...

  • Page 155: Starter Motor

    SL 750 SHIVER Engine Pawl Make sure that both pawl tips run free, without jamming Selector plate spring With a thickness gauge, check that the spring is not deformed by over-stretching. Starter motor Removing the starter motor • Disconnect the starter motor power supply cable.

  • Page 156

    SL 750 SHIVER Engine Generator side Key: 1. Complete starter motor 2. Complete torque limiter 3. Starting ring gear 4. Freewheel flange 5. Freewheel 6. Complete rotor 7. Complete stator 8. Flywheel cover gasket 9. Flywheel cover 10.TCEI low head screw M6x30 11.TBIC screw M5x12...

  • Page 157

    SL 750 SHIVER Engine 19.Plate 20.TE flanged screw 21.NGK R CR7EK spark plug 22.Reference dowel 23.TE flanged screw Removing the flywheel cover • Remove the flywheel cover inspection cap. • Unscrew and remove the ten screws (1 - 2). NOTE THE FLYWHEEL COVER SCREW (2) IS SHORTER THAN SCREWS (1).

  • Page 158

    SL 750 SHIVER Engine Removing the flywheel cover components • Remove the two pick-up fixing screws. • Remove the three stator fixing screws. CAUTION THE PICK-UP AND STATOR SHALL BE RE- MOVED SIMULTANEOUSLY AS THEY ARE PART OF THE SAME ELECTRICAL BRANCH.

  • Page 159

    SL 750 SHIVER Engine • Screw the anticlockwise bolt of the special tool on the external body. • Keeping the external body blocked and gripping the key, screw the anticlock- wise bolt so as to remove the flywheel from the crankshaft.

  • Page 160

    SL 750 SHIVER Engine Freewheel removal • Heat the magneto flywheel with the specific heater. • Undo and remove the six screws. • Remove the freewheel from the mag- neto flywheel. Installing the flywheel • Insert the woodruff key on the crank- shaft.

  • Page 161

    SL 750 SHIVER Engine • Place the appropriate tool for locking the flywheel. • Locking the flywheel in position, using the specific tool, tighten the screw on the crankshaft. • Remove the special tool. Specific tooling 020713Y Flywheel extractor Locking torques (N*m) Screw fixing Rotor - Crankshaft - M12x1.25 (1)

  • Page 162

    SL 750 SHIVER Engine Removing the clutch cover • Undo and remove the side fixing screws. • Remove the clutch cover. It is advisable to remove only the clutch cover in order to replace the clutch discs. Should the com- plete clutch assembly be removed, remove the crankcase, clutch side.

  • Page 163

    SL 750 SHIVER Engine Disassembling the clutch Key: 1. Complete clutch bell 2. Washer 3. Clutch hub 4. Clutch pressure plate 5. Clutch spring 6. Washer 7. TCEI screw M6 8. Spacer 9. Anti-juddering 10.Belleville spring 11.Anti-juddering 12.Nitrided driven disc 13.Lathed drive disc...

  • Page 164

    SL 750 SHIVER Engine • Remove the clutch side crankcase half. • Undo and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and collect the washers and the clutch springs.

  • Page 165

    SL 750 SHIVER Engine • Lock the clutch bell using the specific tool. Specific tooling 9100896 Clutch bell locking tool • Unscrew and remove the clutch hub nut and collect the washer. • Remove the clutch hub. • Collect the special washer between the clutch hub and the bell.

  • Page 166: Checking The Clutch Plates

    SL 750 SHIVER Engine • Collect the spacer and the needle bearings. • Collect the shim washer. Checking the clutch plates • Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions.

  • Page 167

    SL 750 SHIVER Engine MUSHROOM VALVE CHECK • Check if the valve slides freely, without jamming. • Blow compressed air into the valve and check that the lubricating oil passage holes open. Checking the clutch housing • Remove the clutch bell.

  • Page 168

    SL 750 SHIVER Engine Check the main driven gear for damage and wear and, if necessary, replace the main transmission driving gear and the clutch bell all together. Make sure there is not excessive noise during operation; if necessary, replace the main transmission driving gear and the clutch bell all together.

  • Page 169

    SL 750 SHIVER Engine Assembling the clutch • Fit the shim washer. • Fit the needle bearing and the spacer. • Fit the clutch bell. • Make sure that the oil pump control drive gear of the clutch bell engages correctly with the oil pump driven gear.

  • Page 170

    SL 750 SHIVER Engine • Place the clutch hub. • Fit the clutch cover. • Check that the measurement has not changed compared with the one car- ried out upon removal; tighten the clutch nut afterwards. If it has changed,...

  • Page 171

    SL 750 SHIVER Engine • Fit the lathed driven disc (3). • Fit the nitrided steel disc (4). • Fit the clutch discs. Start with the fric- tion material discs and alternate with steel discs. • Position all friction material discs with their teeth aligned in one of the long slots of the clutch bell.

  • Page 172: Removing The Cylinder Head

    SL 750 SHIVER Engine Removing the head cover The operations described below are valid for both heads. • Undo and remove the four screws and collect the rubber rings. • Remove the head cover. Removing the cylinder head NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.

  • Page 173: Cylinder Head

    SL 750 SHIVER Engine • Separate the cylinder from the head. • Collect the washer. See also Removing the cylinder Cylinder head Key: 1. Complete cylinder head 2. Inlet valve 3. Outlet valve 4. External valve spring 5. Internal valve spring 6.

  • Page 174

    SL 750 SHIVER Engine 9. Stud bolt 10.Water pipe fitting 11.TBEI screw 12.Joint 13.O-ring 14.Flanged nut M8X1.25 15.Flanged nut 16.Valve sealing ring 17.TE flanged screw 18.Lock nut M10x1.25 19.Water Temperature Sensor 20.Threaded cap M6X10 21.Threaded cap 22.TE flanged screw 23.To radiator Removing the overhead camshaft •...

  • Page 175: Removing The Valves

    SL 750 SHIVER Engine • Remove the cam cap carefully so as not to go through it and damage the seats of the calibrated dowels. • Remove the camshafts with the gears. Removing the valves • When removing the valve, mark the components according to the position and the cylinder they belong to, in order to refit the components to their correct positions.

  • Page 176

    SL 750 SHIVER Engine • Compress the valve springs with the specific tightening bow and with the spring compressing tool. Specific tooling AP8140179 Valve spring compressor 020721Y Adaptor for valve removal • Remove the cotters using a magnet. • Release the valve springs.

  • Page 177

    SL 750 SHIVER Engine Checking the overhead camshaft Check that the camshaft toothed wheel works properly: if it is damaged or does not move smoothly, replace both the timing chain and the camshaft toothed wheel. CAMSHAFT LOBES • Check that they do not show blue col- ouring, pitting or scratches;...

  • Page 178: Checking The Cylinder Head

    SL 750 SHIVER Engine Clean off any combustion residues from the valves. Check the seat (1) on the valve head with a ruler flush. The surface of the seat must not be concave; re- place the valve if necessary. Check the clearance between the stem and the valve guide: inlet: 0.013 - 0.040 mm (0.00051 - 0.00157 in);...

  • Page 179

    SL 750 SHIVER Engine • Check there are no mineral deposits or rust in the head water cooled jacket; clean off if required. • Use a checking ruler and a thickness gauge positioned diagonally to the ruler to measure the cylinder head distortion.

  • Page 180

    SL 750 SHIVER Engine 7. Shim washer 8. Right nut M15x1 9. Special screw 10.Safety washer 11.Sealing ring 12.Camshaft support 13.Torx screw M6X35 14.Timing system chain 15.Chain guide slider 16.Chain tightener rod 17.Camshaft - rear inlet 18.Camshaft - rear outlet 19.Left nut M15x1...

  • Page 181

    SL 750 SHIVER Engine Chain removal • Remove the chain tensioner. • Remove the main pinion. • Remove the movable chain slider and release the fixed chain slider from the clamp. • Unscrew and remove the pin of the tim- ing chain intermediate gear paying at- tention not to damage the O-ring.

  • Page 182

    SL 750 SHIVER Engine Removing the chain sliders • Remove the chain tensioner and the camshafts from the corresponding head. FRONT HEAD • First remove the clutch cover in order to remove the chain sliders from the front head. •...

  • Page 183

    SL 750 SHIVER Engine Removing the head cover Clutch side Magneto flywheel removal Checking the chain Check the timing chain for damage or stiffness while moving. If required, replace both the timing chain and the camshaft sprocket wheels. Check the timing chain guide for damage. If necessary, replace the parts.

  • Page 184

    SL 750 SHIVER Engine Timing • Rotate the crankshaft until the front cylinder piston reaches the top dead centre. • Lock the crankshaft with the specific special tool Specific tooling 020720Y Timing tool If necessary, remove the timing system gears from the camshafts: •...

  • Page 185

    SL 750 SHIVER Engine • Using the specific template, check the correct position of the cams. NOTE USE OF THE TEMPLATE: THIS TOOL IS PLACED ON THE CAMS WITHOUT THE CAM CAPS, USING THE PROFILE MARKED WITH THE NUMBER OF THE CYLINDER BEING USED, WITH THE MARKINGS FACING THE FLYWHEEL SIDE.

  • Page 186

    SL 750 SHIVER Engine • Remove the camshaft, lock it on a vice with aluminium jaws, then tighten it to the prescribed torque. DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE ULTIMATE TIGHTENING TORQUE WITH THE SHAFT MOUNTED ON THE CYLIN- DER.

  • Page 187

    SL 750 SHIVER Engine Key: 1. Cylinder - Piston 2. Piston 3. Compression ring 4. Oil scraper ring 5. Oil scraper ring 6. Pin 7. Pin stop ring 8. Gasket 9. Plate 10.TE flanged screw 11.Complete chain tensioner 12.TE flanged screw 13.Head-cylinder gasket...

  • Page 188

    SL 750 SHIVER Engine • Unscrew and remove the four nuts, working in a diagonal sequence and in stages. • Slide off the head-cylinder unit from the stud bolts. • Remove the three fixing screws of the cylinder head to the discharge and in- take sides.

  • Page 189

    SL 750 SHIVER Engine • Lock the connecting rod using circlips. FOR SAFETY REASONS COVER THE CRANK- CASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE. • Remove the top ring, the intermediate ring and the three oil scraper rings.

  • Page 190

    SL 750 SHIVER Engine See also Removing the cylinder head Removing the cylinder Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions. • Check cylinder sliding surface for signs of friction and scratches. Also check the seal sur- faces for damages.

  • Page 191

    SL 750 SHIVER Engine Checking the piston • Measure the piston skirt diameter "P" with a micrometer (a=10 mm (0.39 in) from the piston lower border). • Calculate the clearance between pis- ton and cylinder as follows: Piston - cylinder clearance C = C - P Piston - cylinder clearance: 0.050 - 0.064 mm...

  • Page 192

    SL 750 SHIVER Engine Piston ring end gap: Top ring: 0.25 - 0.40 mm (0.0079 - 0.0157 in) Intermediate ring: 0.35 - 0.55 mm (0.0138 - 0.0216 in) Oil scraper ring: 0.20 - 0.70 mm (0.0079 - 0.0276 • Clean off combustion residues from the piston crown and from the area above the top ring.

  • Page 193

    SL 750 SHIVER Engine Specification Desc./Quantity Piston: 91.933 - 91.940 mm (3.6217 - 3.6197 in) Piston - cylinder coupling Type B Cylinder: 91.997 - 92.004 mm (3.6219 - 3.6222 in) Piston: 91.940 - 91.947 mm (3.6197 - 3.6199 in) Piston - cylinder coupling Type C Cylinder: 92.004 - 92.011 mm (3.6222 - 3.6225 in)

  • Page 194

    SL 750 SHIVER Engine 020717Y Piston ring driver Installing the cylinder Fit the stud bolts, if previously removed. CAUTION THE STUD BOLTS SHOULD BE FITTED SO THAT THEY PROTRUDE. DISTRIBUTE Loctite 270 (high-strength) ON THE THREAD AND SCREW THE STUD BOLT ON THE CRANKCASE UNTIL THEY PROTRUDE BY 137 mm (5.39 in), THEN MAKE SURE THE Loctite...

  • Page 195

    SL 750 SHIVER Engine • Screw the screw located outside the cylinder. • Tighten the three screws on the intake and discharge sides. • Screw the two head fixing screws lo- cated inside the timing chain compart- ment. • Check that the intermediate gear pin lubrication holes are clean.

  • Page 196

    SL 750 SHIVER Engine • Check that the axial clearance be- tween the pin and the gear is between 0.30 and 0.60 mm (0.0118 - 0.0236 in). • Tighten the intermediate gear pin once Loctite residues are thoroughly re- moved and a high-strength threadlock is applied on the thread.

  • Page 197

    SL 750 SHIVER Engine • Fit a dial gauge on the specific tool. • Set the dial gauge to zero on a refer- ence surface with a medium preload, e.g. 5 mm (0.2 in). Keeping the zero setting, fit the tool on the cylinder and lock it with two nuts (10 Nm - 7.38 lb ft)

  • Page 198: Installing The Cylinder Head

    SL 750 SHIVER Engine Installing the cylinder head • Place the fixed chain tensioner slider on the cylinder timing chain compart- ment, opposite to the chain tensioner. • Fit a new gasket between the cylinder and the head. • Couple the cylinder and the head.

  • Page 199

    SL 750 SHIVER Engine • Apply THREEBOND on the head cover perimeter along the gasket housing. • Apply THREEBOND on the head in the areas indicated in the figure. • For the remaining operations, follow the removal operations but in reverse order.

  • Page 200

    SL 750 SHIVER Engine 2. Lower bushing 3. Ball bearing 25x62x17 4. Ball bearing 30x62x23.8 5. Ball bearing 25x42x9 6. Ball bearing 20x47x14 7. Roller casing 30x37x12 8. Roller casing 9. Washer 10.TSPEI screw M6x12 11.Sealing ring 12.Sealing ring 8x16x7 13.Sealing ring 14x22x5...

  • Page 201

    SL 750 SHIVER Engine • Using a commercial available extrac- tor, remove the crankshaft gear. • Remove the gear control rod and col- lect the washer. ENG - 53...

  • Page 202

    SL 750 SHIVER Engine • Undo and remove the screw fixing the speed sensor. • Carefully remove the speed sensor. • Heat the screws of the gear selector supporting plate. • Undo and remove the three screws fix- ing the gear selector plate.

  • Page 203

    SL 750 SHIVER Engine • Undo and remove the two screws fixing the neutral sensor. • Remove the neutral sensor. • Collect the sensor contact together with its spring. • If the pinion has been removed, refit and lock it with a special tool.

  • Page 204

    SL 750 SHIVER Engine The tone wheel is sealed with Loctite. Heat it with a suitable blower, paying special attention not to reach high temperatures. • Remove the speed sensor catch with the specific special tool. Reposition the tone wheel and seal it with high- strength Loctite upon refitting.

  • Page 205

    SL 750 SHIVER Engine • Remove the pinion. • Slide off the clutch control rod. • Working on the left side, undo and re- move the nine M8 screws fixing the crankcase. • Working on the left side, undo and re- move the nine M6 screws fixing the crankcase.

  • Page 206

    SL 750 SHIVER Engine • Remove the fuel breather clamping plate. CAUTION UPON REFITTING THE FUEL BREATHER CLAMPING PLATE, REMEMBER TO INSTALL IT IN THE PINION AREA. • Rotate the engine and the engine sup- port into horizontal position. •...

  • Page 207

    SL 750 SHIVER Engine • Separate the crankcase halves by giv- ing a few taps with a rubber hammer. • Open the crankcase halves. • Fix the two screws to the engine sup- port again. ENG - 59...

  • Page 208

    SL 750 SHIVER Engine • If necessary, undo and remove the two screws fixing the strum box. • Remove the strum box. See also Removing the cylinder Magneto flywheel removal Disassembling the clutch Removing the crankshaft Key: 1. Complete crankshaft 2.

  • Page 209

    SL 750 SHIVER Engine 8. Plain washer 9. Nut 10.Roller 11.Bushing • Slide off the crankshaft. See also Splitting the crankcase halves Inspecting the crankcase halves BEARINGS AND OIL SEAL CHECK Thoroughly clean the two sections of the crankcase, the ball bearings, the threads of the crankcase fixing screws and the bearing seats with a non-aggressive solvent.

  • Page 210

    SL 750 SHIVER Engine CHECK THE ENGINE OIL FILTER O-RING. LUBRICATION CHECK • Working on both crankcase halves, re- move and thoroughly clean the nozzle that lubricates the piston crown. REPLACE THE SPRAY NOZZLE O-RING IF NECESSARY. • Replace the O-ring on the oil passage duct.

  • Page 211

    SL 750 SHIVER Engine Inspecting the crankshaft components Crankshaft axial clearance check • The shaft axial clearance on the crank- case should be checked with a com- parator mounted on the specific com- parator support. • The clearance should be between 0.1 - 0.4 mm (0.0039 - 0.0157 in).

  • Page 212

    SL 750 SHIVER Engine Refitting the crankcase halves • Fit the strum box, if previously re- moved. • Tighten the two strum box fixing screws. • Turn the engine support into horizontal position. • Place the left crankcase half on the engine support, fitting it on the engine support pins.

  • Page 213

    SL 750 SHIVER Engine • Tighten the two fixing pins. • Rotate the engine and the engine support into vertical position. • Working on the left side, place the nine M6 screws fixing the crankcase. • Working on the left side, place the nine M8 screws fixing the crankcase.

  • Page 214

    SL 750 SHIVER Engine • Slide in the clutch control rod. • Place the pinion. • Place the gear selector drum and check that it is correctly timed; thrust the desmo drum axially from the fly- wheel side so that the timing roller pro- trudes.

  • Page 215

    SL 750 SHIVER Engine • Position the tone wheel. • Tighten the tone wheel with the special tool. Use Loctite medium-strength for sealing. Specific tooling 020715Y Tone wheel removal • Tighten the pinion fixing nut using the special tool. Specific tooling 9100896 Clutch bell locking tool •...

  • Page 216

    SL 750 SHIVER Engine • Place the neutral sensor and lubricate its seat to facilitate refitting. BE CAREFUL NOT TO DAMAGE THE O-RING WHEN INSERTING THE SENSOR IN ITS POSI- TION. • Tighten the two screws fixing the neu- tral sensor.

  • Page 217

    SL 750 SHIVER Engine • Place the speed sensor with caution. • Tighten the speed sensor fixing screw. • Place the transmission control rod with the washer. • Remove the grease off the primary pin- ion tapered pins - crankshaft coupling surfaces .

  • Page 218: Oil Pump

    SL 750 SHIVER Engine Lubrication Oil pump Removing • Lock the pump gear with the commer- cially available hook spanner and undo the screw; collect the washer. ENG - 70...

  • Page 219

    SL 750 SHIVER Engine • Collect the shim washer. • Undo and remove the two screws fixing the oil pump. • Remove the entire pump. Inspection • Undo and remove the two fixing screws. ENG - 71...

  • Page 220

    SL 750 SHIVER Engine • Using a thickness gauge check clear- ance between rotor and stator and re- place the rotor / stator unit if required. clearance between rotor and stator: 0.04 ± 0.10 mm (0.0016 in ± 0.0039 in) •...

  • Page 221

    SL 750 SHIVER Engine • Remove the oil pump stator. CAUTION CHECK THAT THE ROTOR AND STATOR ARE NOT DAMAGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTHER MARKS). Installing • Follow the oil pump removal opera- tions; carefully align the stator and ro- tor references upon fitting and check clearance with a thickness gauge.

  • Page 222

    SL 750 SHIVER Engine ENG - 74...

  • Page 223

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 224: Fuel Pump

    SL 750 SHIVER Power supply Fuel pump Key: 1. Complete fuel pump unit 2. Lower self-locking nut M5 3. Brake pipe plate 4. Flange gasket 5. Fuel filter 6. Fuel delivery pipe Electrical characteristics: • Resistance: 0.7 +/- 0.2 Ohm...

  • Page 225

    SL 750 SHIVER Power supply Injection Ride by Wire RIDE BY WIRE Operating logic Those riding motorbikes do not require a specific throttle valve opening from their engines but actually a specific torque. The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control;...

  • Page 226

    SL 750 SHIVER Power supply Throttle Body The two throttle bodies are made up of: • Throttle valve with 2 return springs for the controlled minimum opening position. • DC electrical motor • Tinned double throttle position sensors with magnetic control (contactless) The throttle bodies do not require any maintenance and cannot be overhauled.

  • Page 227

    SL 750 SHIVER Power supply the position exclusively depending on the springs are not moved. The engine may shut off during the operation if it is running at idle speed and the gear is in neutral. D the malfunction may affect riding in safety, the warning light turns on, the message Urgent Service is displayed, the engine stops running.

  • Page 228

    SL 750 SHIVER Power supply • Working on both bodies, undo and re- move the two plate screws. • Remove the plate. • Working on both bodies, undo and re- move the screw and detach the body. • Working on the body in question, re- move the injector, slide off the clip and the injector itself.

  • Page 229

    SL 750 SHIVER Power supply Using axone for injection system The complete list of all the parameters- device status, errors, etc.- is available at the home page of the website www.serviceaprilia.com in the search section: Axone Parameters. The same parameters- device status, errors, etc. -are grouped per type of component they refer to in...

  • Page 230

    SL 750 SHIVER Power supply P SUPP - 8...

  • Page 231

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 232: Removing The Front Wheel

    SL 750 SHIVER Suspensions Front Removing the front wheel Key: 1. Front wheel 3.5"x17" 2. Tubeless valve 3. Internal spacer 4. Bearing 5. Sealing ring 30x47x7 6. Seeger ring 7. Front wheel right external spacer 8. Front brake disc 9. Washer 25.2x36x1 10.Wheel pin nut...

  • Page 233

    SL 750 SHIVER Suspensions • Undo the screws fixing the front mud- guard and remove it. • Undo the screws fixing the front pliers and slide them off the disc. • Remove the wheel pin fixing nut. • Collect the sealing washer.

  • Page 234

    SL 750 SHIVER Suspensions • Tap the wheel pin with a rubber ham- mer so that the holes on the opposite side are exposed. • Remove the wheel pin by inserting a screwdriver in the holes on the pin. •...

  • Page 235

    SL 750 SHIVER Suspensions ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. GASKETS • Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear. ALWAYS REPLACE BOTH GASKETS.

  • Page 236: Front Fork

    SL 750 SHIVER Suspensions Handlebar Key: 1. Handlebar 2. Right light switch 3. Left light switch 4. Anti-vibration weight terminal 5. Anti-vibration weight 6. TCEI screw M6x40 7. Upper U-bolt 8. Screw M8x25 9. Handgrips 10.Right rear-view mirror 11.Left rear-view mirror 12.Throttle opening cable...

  • Page 237

    SL 750 SHIVER Suspensions Diagram Key: 1. Fork right stem 2. Fork left stem 3. Sleeve 4. Spring 5. Preloading pipe 6. Right pumping member assembly 7. Left pumping member assembly 8. Sleeve cap assembly 9. O-ring 10.Rubber ring 11.Nut 12.Snap ring...

  • Page 238: Removing The Fork Legs

    SL 750 SHIVER Suspensions 20.Sliding bushing 21.Special washer 22.Screw M10x1.5 23.TE flanged screw M8x40 24.Spring Centring Removing the fork legs • Remove the front wheel. • Support the fork stem and loosen the screws on the upper and then the lower plate.

  • Page 239

    SL 750 SHIVER Suspensions • Being careful not to damage the fork stem when placing it in a vice, in verti- cal position, using the appropriate pro- tection. Specific tooling AP8140149 Protection for fitting operations • Unscrew the sleeve cap.

  • Page 240

    SL 750 SHIVER Suspensions NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. • Drain the fork oil. • Place the fork stem on a work table in upright position. • Fit the special tool. Specific tooling AP8140147 Spacer tool With the help of a second operator: •...

  • Page 241

    SL 750 SHIVER Suspensions With the help of a second operator: • Insert the special tool between the nut and the preloading pipe. Specific tooling AP8140148 Spacer-pumping element separat- ing plate • Loosen the nut. • Remove the sleeve cap.

  • Page 242

    SL 750 SHIVER Suspensions • Be careful not to damage the fork stem when placing it in a vice, in horizontal position, using the appropriate protec- tions. Specific tooling AP8140149 Protection for fitting operations • Unscrew and remove the bottom screw and collect the special washer.

  • Page 243

    SL 750 SHIVER Suspensions • Remove the Seeger ring from inside the sleeve with the aid of a screwdriver. CAUTION DO NOT DAMAGE THE STEM DURING THE OPERATION. • Slide off the stem forcefully. • If necessary, remove the sliding bush- ing, guide bushing, ring, oil seal, Seeg- er ring and dust guard from the stem.

  • Page 244

    SL 750 SHIVER Suspensions Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check that the spring is in good conditions. Check that the spring length is within the limit value.

  • Page 245

    SL 750 SHIVER Suspensions • Fit the stem to the sleeve and place the special fitting tool for fitting the D.43 oil seal between the Seeger ring and the oil seal. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) holes...

  • Page 246

    SL 750 SHIVER Suspensions • Screw the specific perforated rod on the pumping member threaded rod. Specific tooling AP8140150 Perforated rod for pumping mem- ber air bleed • Fit the centring plate. • Fit the pumping member together with the centring plate in the sleeve.

  • Page 247

    SL 750 SHIVER Suspensions Oil level (from sleeve rim, without the spring and with pumping member fully down) 122 mm (4.80 in). • Fit the spring. • Fit the preloading pipe together with the spring centring. • Fit the special tool.

  • Page 248

    SL 750 SHIVER Suspensions • Insert the sleeve cap and screw the nut. • Being careful not to damage the fork stem when placing it in a vice, in verti- cal position, using the appropriate pro- tection. Specific tooling AP8140149 Protection for fitting operations •...

  • Page 249

    SL 750 SHIVER Suspensions Steering bearing Key: 1. Folk lower plate 2. Screw M8x30 3. Washer 4. Roller bearing 5. Sealing ring 6. Ring nut 7. Headstock cap washer 8. Headstock cap 9. TCEI screw M10x60 10.Cap 11.Rubber ring 12.Lower U-bolt 13.Fork upper plate...

  • Page 250

    SL 750 SHIVER Suspensions • Adjust if clearance is detected. • Unscrew and remove the four screws of the fixing U-bolt. • Remove the U-bolt. • Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out.

  • Page 251

    SL 750 SHIVER Suspensions • Undo and remove the two screws fixing the instrument panel support to the fork upper plate. • Slide off the fork upper plate by moving it towards the instrument panel. • Adjust the steering bearings preload- ing by tightening the ring nut with the specific tool.

  • Page 252: Removing The Rear Wheel

    SL 750 SHIVER Suspensions Removing the rear wheel Key: 1. Chain with master link 2. Crown 3. Rear wheel 6"x17" 4. Rear wheel anti-vibration buffer 5. Rear cover 180/55 ZR 17" 6. Anti-vibration rubber buffer 7. Tubeless valve 8. Rear wheel spacer 9.

  • Page 253

    SL 750 SHIVER Suspensions 20.TCEI screw M10x30 21.Sealing ring 38x52x7 22.Master link • Place the vehicle on its rear service stand. • In order to work faster, remove that the chain cover. • Fully slacken the gearing chain ten- sion.

  • Page 254: Checking The Rear Wheel

    SL 750 SHIVER Suspensions • Working from the left side, unscrew and remove the five nuts and remove the crown and the bolts. • Undo and remove the five screws and remove the anti-vibration buffer holder. • Check the anti-vibration buffers ac- cording to the routine maintenance ta- ble.

  • Page 255

    SL 750 SHIVER Suspensions • Replace both wheel bearings. ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none.

  • Page 256: Shock Absorbers

    SL 750 SHIVER Suspensions Shock absorbers Removing • Place the optional under-sump and rear wheel service stands. • Unscrew and remove the upper screw and collect the washer. • Loosen the under-sump optional serv- ice stand to lower the engine.

  • Page 257

    INDEX OF TOPICS CHAS HASSIS...

  • Page 258

    SL 750 SHIVER Chassis Swinging arm Key: 1. Swingarm 2. Roller casing 3. Ball bearing 4. Internal spacer 5. Sealing ring 6. Seeger ring for hole 7. O-ring 8. Sealing ring 9. Swing arm pin 10.Adjustment bushing 11.Swingarm pin internal bushing 12.Swingarm pin ring nut...

  • Page 259

    SL 750 SHIVER Chassis 19.Rear stand bushing 20.TSPEI screw M6x40 21.Chain guide slider 22.TBEI screw M5x12 10.9 23.Slider cap 24.Chain guard 25.TBEI special screw M5x12 26.Rear wheel pin 27.Washer 25.2x36x1 28.Wheel bolt nut M25x1.5 29.Counterslider 30.TBEI special screw M5x12 Removing •...

  • Page 260

    SL 750 SHIVER Chassis • With the specific box-spanner, un- screw and remove the locking ring nut. • Working from the left side, unscrew and remove the nut and collect the washer. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION.

  • Page 261

    SL 750 SHIVER Chassis Drive chain Adjusting The vehicle is fitted with an endless chain, without master link. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS.

  • Page 262

    SL 750 SHIVER Chassis THE SEATS OF THE CHAIN TENSIONER PADS ON THE SWING ARMS, IN FRONT OF THE WHEEL PIN. CHECKING THE CHAIN, THE PINION AND THE CROWN FOR WEAR Furthermore, check the following parts and make sure the chain, the pinion and the crown do not show: •...

  • Page 263

    SL 750 SHIVER Chassis Exhaust Key: 1. Central exhaust manifold 2. Rear main exhaust manifold 3. Front main exhaust manifold 4. Self-locking nut M8 5. Head exhaust gasket 6. Manifold exhaust gasket 7. Manifold clamp 8. Silencer 9. Silencer gasket 10.Silencer clamp...

  • Page 264

    SL 750 SHIVER Chassis Removing the tail pipe • Loosen the clamp between the ex- haust end and the manifold. • Undo and remove the upper screw. • Protect the swingarm so as not to spoil it while removing the exhaust end.

  • Page 265

    SL 750 SHIVER Chassis • Remove the manifold - end coupling. See also Removing the exhaust manifold Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.

  • Page 266

    SL 750 SHIVER Chassis REAR • Loosen the exhaust pipe between the manifold and the exhaust end. • Unscrew and remove the two nuts on the head exhaust stud bolts. See also Removing the manifold - tail pipe Removing the lambda sensor •...

  • Page 267

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 268

    SL 750 SHIVER Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. Rear brake calliper Key: 1. Brake pump together with reservoir 2. Rear brake calliper 3. Rear brake lever 4.

  • Page 269

    SL 750 SHIVER Braking system 15.TCEI screw M6x16 16.TE flanged screw M6x16 17.Flanged self- locking nut M6 18.TE flanged screw M6x20 19.Rear brake pipe 20.Brake plate stop pin 21.Oil pipe screw 22.Washer 10x14x1.6 23.Brake pipe protection 24.TBEI flanged screw M5x9 25.Rear brake pads - pair...

  • Page 270: Front Brake Pads, Rear Brake Pads

    SL 750 SHIVER Braking system 2. Front brake calliper 3. Front brake pads - pair 4. Pin + calliper spring 5. Bleeding Kit 6. TE flanged screw M10x1.25x55 7. Copper washer Front brake pads Removal • Turn the pins and remove both split pins.

  • Page 271

    SL 750 SHIVER Braking system Removal • Remove the safety circlip. • Unscrew and remove the pin. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OP- ERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.

  • Page 272

    SL 750 SHIVER Braking system THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY TO BOTH CALLIPERS. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.

  • Page 273

    SL 750 SHIVER Braking system CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON- DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED.

  • Page 274

    SL 750 SHIVER Braking system BRAK SYS - 8...

  • Page 275

    INDEX OF TOPICS CLU SYS LUTCH SYSTEM...

  • Page 276

    SL 750 SHIVER Clutch system Key: 1. Clutch pump 2. Clutch lever 3. Cover 4. U-bolt 5. Clutch pipe 6. Oil pipe screw 7. Washer 10x14x1.6 8. Clutch control cylinder 9. Bleeding Kit 10.TSPEI screw 11.TSPEI screw 12.Stop switch 13.Rubber ring...

  • Page 277

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 278: Circuit Diagram

    SL 750 SHIVER Cooling system Circuit diagram Key: 1. Radiator 2. Opening 3. Cap 4. Expansion tank 5. Expansion tank cap 6. Water pipe 7. Thermostat-radiator pipe 8. Radiator-pump pipe 9. Radiator filling pipe 10.Bleed pipe 11.Valve-motor pump pipe 12.Bleed pipe 13.Y-shape coupling...

  • Page 279

    SL 750 SHIVER Cooling system 19.Fan assembly 20.TCB screw 4.2x22 21.Washer 5.3x10x1 22.Front headlamp set spring 23.Rubber ring 10x20x10 24.Clic clamp 25.Clic clamp 26.Pipe clamp 27.TE flanged screw M6x25 28.TE flanged screw M6x20 29.Fuel pipe 5.5x10 30.Radiator support 31.Clic clamp 32.From front cylinder...

  • Page 280: Coolant Replacement

    SL 750 SHIVER Cooling system Coolant replacement • Remove the right side fairing. • Undo and remove the screw and re- move the protection. • Place a container of suitable capacity. • Loosen the screw, move the clamp and slide off the sleeve.

  • Page 281

    SL 750 SHIVER Cooling system • Slide off the sleeve and empty the sys- tem completely. • Refit both sleeves, place the corresponding clamps and tighten their screws. • Fill the expansion tank up to the marked level. • After bleeding the air from the tank, place the expansion tank cap.

  • Page 282

    SL 750 SHIVER Cooling system • Unscrew and remove the rotor control gear fixing nut and act on the gear hex- agonal insert. • Remove the rotor control gear. • From the cover inside to the outside, remove the rotor control shaft with a punch and a rubber hammer.

  • Page 283

    SL 750 SHIVER Cooling system • Place the radiator cap on its seat (to avoid accidental leaks) but do not screw it and start the engine. • Remove the radiator cap and refill until the radiator plates are completely covered and the water jet from the system breather pipe is continuous.

  • Page 284

    SL 750 SHIVER Cooling system • Disconnect the electric fan connector. • Undo and remove the fixing screw to chassis. • Lower the radiator from the upper fixing side to the chassis and remove it by sliding it off toward the vehicle right- hand side.

  • Page 285

    SL 750 SHIVER Cooling system Removing the expansion tank • Remove the right side fairing. • Undo and remove the screw and re- move the protection. • Loosen and move the clamp. • Slide off the pipe. • Undo and remove the screw and col- lect the washer.

  • Page 286

    SL 750 SHIVER Cooling system COOL SYS - 10...

  • Page 287

    INDEX OF TOPICS BODYW ODYWORK...

  • Page 288

    SL 750 SHIVER Bodywork Seat SADDLE REMOVAL • Place the vehicle on the service stand. • Insert the key (1) in the lock. • Turn the key (1) anticlockwise • Paying attention to the belt position, re- lease and lift the saddle (2).

  • Page 289

    SL 750 SHIVER Bodywork • Disconnect the front headlight connec- tor and remove the front headlight as- sembly. See also Instrument cluster support Taillight assy. • Remove the tail section. • Undo and remove the screw. Collect the washer. •...

  • Page 290

    SL 750 SHIVER Bodywork • Remove the cover. • Undo and remove the screw. • Remove the side fairing. BODYW - 4...

  • Page 291

    SL 750 SHIVER Bodywork LOWER SIDE FAIRINGS • Remove the side fairing and after- wards remove the saddle. • Undo and remove the two screws. • Slide off the lower fairing See also Seat License plate holder • Remove the saddle.

  • Page 292: Air Box

    SL 750 SHIVER Bodywork • Remove the clamp. • Undo and remove the two screws; col- lect the spacers and the collars. • Slide off the license plate holder towards the back. See also Seat Tail guard Air box •...

  • Page 293

    SL 750 SHIVER Bodywork • Undo and remove the inner screw. • Undo and remove the screw. • Remove the filter support partition. • Slide off the start-up relay. BODYW - 7...

  • Page 294

    SL 750 SHIVER Bodywork • Release the cable harness from the clamps . • Working from the left side, undo and remove the screw to remove the cable guide. • Undo and remove the two screws after loosening the front and rear manifold clamps.

  • Page 295

    SL 750 SHIVER Bodywork • Loosen the clamp to slide off the bleed pipe. • Lift the filter casing and working on both cylinders, loosen and move the clamp and slide off the oil vapour re- covery pipe. • Working on the left side, disconnect the two control unit connectors.

  • Page 296: Fuel Tank

    SL 750 SHIVER Bodywork • Disconnect the two connectors. • Remove the filter casing together with the throttle body, by lifting it up from behind. CAUTION COVER THE COUPLING OPENINGS SO THAT NO FOREIGN BODIES COME IN. Should the throttle body be removed, disconnect either the map sensor pipes or the inlet ducts; it is necessary to check the air system tightness.

  • Page 297: Fuel Tank

    SL 750 SHIVER Bodywork • Working from both sides, undo and re- move the screw. • Remove at least one side air deflector. • Slide off the key lock plate. • Undo and remove the two screws and collect the two collars.

  • Page 298: Front Mudguard

    SL 750 SHIVER Bodywork • Keeping the tank up, disconnect the fuel pump connector. • Working on both sides, disconnect the vapour recovery pipe. • Protecting the vehicle from potential fuel leaks with a cloth, disconnect the quick coupler. •...

  • Page 299

    SL 750 SHIVER Bodywork Instrument cluster support • Undo and remove the two front screws. • Working on both sides, loosen the nut and the screw and remove them. • Working from both sides, tilting the front headlight forward, undo and re- move the screw and collect the nut.

  • Page 300

    SL 750 SHIVER Bodywork • Working on the back of the instrument panel, undo and remove the two screws and collect the two washers. • Remove the instrument panel rear cov- • Disconnect the instrument panel connector. • Remove the clamp and disconnect the air temperature sensor.

  • Page 301

    SL 750 SHIVER Bodywork • Operating from both sides of the vehi- cle, undo and remove the two screws. • Operating from both sides of the vehi- cle, undo and remove the screw. • Undo and remove the 4 screws.

  • Page 302

    SL 750 SHIVER Bodywork • Remove the clamp. • Slide off the auxiliary fuses box. • Remove the helmet compartment. • Remove the two clamps. BODYW - 16...

  • Page 303

    SL 750 SHIVER Bodywork • Disconnect the two connectors. • Operating from both sides, slide the exhaust cover tail upward and off. • Working on the right side, remove the right tail. • Working on the left side, remove the saddle lock and the left tail.

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