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•

Remove the flywheel together with the

freewheel.

•

Remove the start-up transmission

gear.

•

Check dimensions of the supports of

transmission gear on crankcase and

cover: the limit is 12.005 mm (0.4726

in) for both supports

•

In case of malfunction, the start-up

transmission gear cannot be over-

hauled. Therefore, the complete trans-

mission gear should be replaced.

•

Collect the crankshaft woodruff key.

Freewheel removal

•

Remove the flywheel.

•

Remove the freewheel gear.

DORSODURO 1200 ABS - ATC Engine

ENG - 223

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: info@motomatrix.co.uk

Index of Topics5
Characteristics8
Rules8
Safety Rules8
Maintenance Rules9
Running-In11
Chassis Number12
Dimensions and Mass12
Engine Number12
Vehicle Identification12
Capacities13
Engine13
Transmission13
Drive Chain14
Electrical System14
Frame and Suspensions14
Brakes15
Wheels and Tyres15
Chassis16
Front Side16
Supply16
Tightening Torques16
Oil Cooling Radiator17
Front Fork18
Steering18
Instrument Panel19
Front Mudguard20
Handlebar20
Clutch Pump21
Front Brake Pump22
Headlamp23
Front Bodywork24
Front Wheel25
Central Part26
Description26
- Front Brake26
- Front Chassis26
M8X2026
- Nm (59 Lbf Ft)26
Loctite 51829
- Air Filter Box30
- Fuel Pump30
- Locks33
- Saddle Mounting34
- Throttle Body34
- Swingarm35
- Rear Suspension36
- Exhaust System37
- Rear Wheel37
- Rear Brake38
- Tail Light39
- Rear Bodywork40
- ABS System42
- Head43
- Head Cover43
- Cylinder44
- Timing System45
- Crankshaft46
- Oil Pump47
- Gear Selector48
- Clutch Cover49
- Clutch50
- Water Pump50
- Ignition51
- Crankcase52
- Assembly Clearances53
- Crankcase - Crankshaft - Connecting Rod53
- Cylinder - Piston Assy53
- Overhaul Data53
- Crankcase Classes54
- Internal Marking on Second Generation Crankcases54
- Crankshaft Classes55
- Main Bushings55
- Bushings57
- Connecting Rods57
- Shaft Category57
- Recommended Products Chart58
- Special Tools60
- Maintenance Chart67
- Routine Maintenance Table67
- Front Spark Plug68
- Rear Spark Plug69
- Check70
- Engine Oil70
- Replacement71
- Engine Oil Filter72
- Air Filter73
- Checking the Valve Clearance74
- Troubleshooting78
- RUN/STOP Switch81
- Check Fuel Pump82
- Diagnosis Instrument Connection Check82
- Electrical System Installation82
- Auxiliary Injection Relay 31 Check83
- Main Injection Relay 17 Check84
- Starter Button Check84
- Components Arrangement88
- Auxiliary Injection Relay89
- Light Logic Relay89
- Main Injection Relay89
- Start-Up Relay89
- Fan Control Relay90
- High Beam Lights Relay90
- Recovery Logic Relay90
- Motorcycle Division91
- Special Checks for the Correct Connection and Laying of Cables91
- Back Side110
- General Wiring Diagram114
- Checks and Inspections117
- Conceptual Diagrams117
- Connector Check Procedure117
- Continuity Check117
- Ground Conection Check118
- Immobiliser118
- System Components118
- Voltage Check118
- Instrument Panel: Errors119
- Dashboard120
- Diagnosis120
- Installing a New Instrument Panel120
- Instrument Panel Errors121
- Service Warning Light Reset123
- Start-Up System Check123
- Lights List124
- Control Unit125
- Fuses125
- Control Unit- Diagnosis127
- Diagnosis Instrument: Parameters ISO127
- Parameters127
- Activation128
- Statuses128
- Electrical Errors129
- Logic Errors130
- Battery131
- Vehicle Front Speed Sensor133
- Vehicle Rear Speed Sensor134
- Engine Rpm Sensor136
- Engine Speed Sensor136
- Throttle Grip Position Sensor138
- Twistgrip Position Sensor138
- Adjustable Parameters143
- Intake Pressure Sensor144
- Engine Temperature Sensor148
- Air Temperature Sensor151
- Lambda Sensor152
- Injector156
- Coil160
- Front Central Coil161
- Front Side Coil161
- Rear Central Coil161
- Rear Side Coil161
- Engine Oil Pressure Sensor175
- Neutral Sensor176
- Clutch Lever Sensor178
- Side Stand Sensor179
- Bank Angle Sensor180
- Electric Fan Circuit181
- Connectors183
- Ecu184
- Can Line189
- Can Protocol189
- Can System Advantages189
- Engine from Vehicle193
- Vehicle Preparation195
- Removing the Engine from the Vehicle201
- Installing the Engine to the Vehicle206
- Diagram210
- Gearbox210
- Gearbox Shafts Diagram211
- Disassembling the Gearbox212
- Removing the Gear Selector215
- Checking the Gear Selector217
- Pawl217
- Reassembling the Gear Selector217
- Selector Spring217
- Gearbox Selector Shaft218
- Starter Motor218
- Removing the Starter Motor219
- Generator Side220
- Removing the Flywheel Cover220
- Removing the Flywheel Cover Components221
- Magneto Flywheel Removal222
- Freewheel Removal223
- Installing the Flywheel224
- Clutch Side226
- Removing the Clutch Cover227
- Disassembling the Clutch229
- Checking the Clutch Plates232
- Checking the Clutch Housing233
- Mushroom Valve Check233
- Checking the Clutch Hub234
- Checking the Pusher Plate234
- Main Driven Gear Check234
- Assembling the Clutch235
- Checking the Springs235
- Clutch-Side Cover Oil Seal Installation238
- Installing the Clutch Cover238
- Heads239
- Head Cover Removal240
- Front Head241
- Head Cover Fitting241
- Removing Camshafts241
- Camshaft Lobes242
- Camshaft Toothed Wheel Check242
- Inspecting Camshafts242
- Installing Camshafts243
- Front Head Removal244
- Front Head Check247
- Rear Head247
- Rear Head Removal250
- Rear Head Check254
- Valve Removal254
- Valve Check256
- Valve Stem Deviation256
- Spring Check257
- Timing258
- Cam Timing259
- Installing the Chain Tensioner259
- Cylinder-Piston Assembly262
- Removing the Cylinder262
- Disassembling the Piston263
- Checking the Cylinder265
- Checking the Piston265
- Piston Ring End Gap266
- Piston Ring Side Clearance266
- Piston Rings266
- Cylinder-Piston Coupling267
- Selecting the Base Gasket269
- Base Gasket270
- Crankcase - Crankshaft271
- Splitting the Crankcase Halves272
- Removing the Crankshaft275
- Bearings and Oil Seal Check276
- Inspecting the Crankcase Halves276
- Oil Filter and Oil Delivery Pipe Check276
- Lubrication Check277
- Crankshaft Axial Clearance Check278
- Inspecting the Crankshaft Components278
- Removal278
- Assembling the Connecting Rod279
- Installing279
- Installing the Crankshaft279
- Refitting the Crankcase Halves280
- Lubrication284
- Power Supply293
- Injection294
- Operating Logic295
- Ride by Wire295
- Injection/Ignition Control296
- Marelli 7SM Electronic Control Unit296
- Pressure Sensors296
- Ride by Wire System Control296
- System Safety Checks297
- Removing the Throttle Body298
- Using Navigator for Injection System300
- Front302
- Removing the Front Wheel302
- Suspensions302
- Checking the Front Wheel304
- Front Wheel Bearings304
- Radial and Axial Clearances Check304
- Wheel Axle304
- Front Fork Diagram306
- Removing the Fork Legs307
- Disassembling the Fork308
- Checking the Components312
- Stem312
- Reassembling the Fork314
- Filling Oil318
- Adjusting Play319
- Steering Bearing319
- Steering Ring Nut321
- Steering Upper Plate322
- Assembling323
- Rear325
- Removing the Rear Wheel325
- Checking the Rear Wheel327
- Rear Wheel Axle328
- Rear Wheel Gaskets328
- Rear Wheel Rim328
- Removing329
- Shock Absorbers329
- Swinging Arm331
- Adjusting333
- To Check Clearance333
- Checking the Chain, the Pinion and the Sprocket for Wear334
- Cleaning and Lubrication335
- Stand335
- Exhaust336
- Removing the Tail Pipe336
- Removing the Exhaust Manifold338
- Engine Oil Cooler340
- Removing the Lambda Sensor340
- Abs343
- Braking System343
- Interventions Rules343
- ABS ECU Control Unit Pin Configuration344
- Foreword345
- Operating Diagram346
- ABS Operation347
- General Specifications347
- ABS System Description348
- ABS Enable/Disable349
- Riding with an Active ABS System349
- Guide to Diagnosis350
- ABS Faults - Guide to the Diagnosis351
- Abs Screen Pages352
- ECU INFO Screen Page352
- Using Navigator for the Abs352
- PARAMETERS Screen Page353
- ACTIVATION Screen Page354
- ERRORS Screen Page355
- SETTINGS Screen Page356
- Modulator Removal357
- Rear Brake Calliper358
- Front Brake Calliper359
- Front Brake Pads359
- Bleeding the Braking System360
- Rear Brake Pads360
- Bleed System after Brake Pump Replacement361
- Preliminary Operations361
- Regular Bleeding System361
- Brake Bleeding after ABS Control Unit Replacement362
- Brake Bleeding after Calliper Replacement363
- Braking System Bleeding363
- Bleeding System with Navigator364
- Brake Fluid Replacement364
- Changing the Brake Fluid364
- Purging Process to Change the Braking System Fluid364
- Clutch System367
- Circuit Diagram369
- Cooling System369
- Electric Fan369
- Coolant Replacement370
- Cover Removal372
- Pump Rotor Removal372
- Complete H20 Pump Removal373
- Removing the Radiator373
- Thermostatic Valve375
- Headlight Assy.382
- Disassembling the Lock384
- Taillight Assy.385
- Footrest387
- Right Footrest387
- Left Footrest388
- Side Body Panels388
- License Plate Holder389
- Air Box390
- Instrument Cluster Support396
- Tail Guard397
- Aesthetic Inspection400
- Pre-Delivery400
- Tightening Torques Inspection400
- Levels Check401
- Road Test401
- Functional Inspection402
- Specific Operations for the Vehicle402
- Static Test402
- Index405

Brand	APRILIA
Model	DORSODURO 1200 ABS - ATC
Category	Motorcycle
Language	English

APRILIA DORSODURO 1200 ABS - ATC User Manual

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APRILIA DORSODURO 1200 ABS - ATC Specifications

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