Aprilia Shiver 900 E4 Eu Usa 2017 Service Station

SERVICE STATION MANUAL
2Q000335
SHIVER 900
SERVICE STATION
MANUAL
SHIVER 900
THE VALUE OF SERVICE

Due to continuous updates and technical training programmes specific to aprilia products, only Aprilia
Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out
maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, performing maintenance correctly and using only original Aprilia spare parts are essential factors
for the reliability of your vehicle!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting original aprilia spare parts can you be of purchasing products that were developed
and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and images in this publication are given for illustrative purposes only.
While the basic features as described and illustrated in this manual remain unchanged, Piaggio & C.
S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessory supplies which it deems necessary to improve
the product, or which are required for manufacturing or commercial reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
versions/models should be confirmed with the official Aprilia sales network.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2017 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
SHIVER 900
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Piaggio & C. S.p.a. commits itself
to continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Aprilia CUSTOMER DEPARTMENT,
which will be prepared to provide any information on the subject and any further communications on
updates and technical changes related to the vehicle.
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.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee
INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
CLUTCH SYSTEM CLU SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
SHIVER 900 Characteristics
Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY INFLAMMABLE AND CAN BECOME
EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY
OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE EN-
GINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID
ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY
CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
Hot parts
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.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE PARTICULAR CARE NOT TO SPILL COOLANT ONTO HOT PARTS OR THE ENGINE AND
EXHAUST SYSTEM; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN
CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES.
WHILE POISONOUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY AP-
PEALING TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE
REACHED AND DRUNK BY AN ANIMAL.
CHAR - 7
Characteristics SHIVER 900

NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER
PRESSURE AND MAY CAUSE BURNS.
Used engine oil and transmission oil
CAUTION
WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC-

TIVE IMPERMEABLE GLOVES.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS
WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE
SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN
THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-
mendations strictly.
CHAR - 8
BEFORE DISASSEMBLING COMPONENTS
• Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com-
ponents. Wherever required, use the special tools designed for this vehicle.
DISASSEMBLING COMPONENTS
• Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use
the specific wrench.
• Mark the positions on all the connection joints (hoses, cables, etc.) before separating them
and identify them with different distinctive marks.
• Each piece should be clearly marked in order to be identified during the installation phase.
• Carefully clean and wash the disassembled components with detergents with a low flam-
mability grade.
• Keep the coupled parts together because they have "adapted" to one another following
normal wear.
• Some components must be used together or replaced entirely.
• Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
• Only use ORIGINAL Aprilia SPARE PARTS.
• Comply with lubricant and consumables use guidelines.
• Lubricate parts (whenever possible) before reassembling them.
• When tightening nuts and screws, start either from the components with the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
• Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
• When assembling the bearings, make sure to lubricate them well.
• Check that each component is assembled correctly.
• After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
• Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand
or batch number facing outward (visible side).
ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
CHAR - 9
• Grip the two connectors and disconnect them by pulling them in opposite directions.
• If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
• Ensure that the cables are correctly fastened to the internal connector terminals.
• Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
IF UNSCREWING A SELF-LOCKING NUT, IT MUST BE REPLACED WITH A NEW ONE.
CAUTION
REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELEMENTS LOCATED ON
WHEELS, BRAKES, WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A FUN-
DAMENTAL ROLE IN GUARANTEEING THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT
THE PRESCRIBED VALUES. REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING
ELEMENTS AND ALWAYS USE A TORQUE WRENCH WHEN REFITTING. IF THESE WARNINGS
ARE NOT OBSERVED, ONE OF THESE COMPONENTS COULD LOOSEN AND COME OFF,
BLOCKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA-
NOEUVRABILITY, LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN
DEATH.
Running-in
Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow these guidelines:
• Do not fully open the throttle grip abruptly at low engine speeds, either during or after the
running in period.
• During the first 100 Km (62.14 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
• It is recommended that during the first 250 km (155.34 mi) not to exceed 6500 rpm and not
to fully open the gas knob for prolonged periods. For the subsequent km, up to approximately
1000 km (621.37 mi), progressively increase rpm and "full gas" periods.
CAUTION
TO PREVENT THE RISK OF INJURY TO YOURSELF OR OTHERS AND/OR DAMAGE TO THE
VEHICLE, HAVE THE CHECKS LISTED IN THE SCHEDULED MAINTENANCE TABLE OF THE
CHAR - 10
MAINTENANCE PROGRAMME SECTION CARRIED OUT AT THE SPECIFIED MILEAGE INTER-

VALS.
Vehicle identification
Write down the chassis and engine number in the specific space in this booklet. The chassis number
is handy when purchasing spare parts.
CAUTION
THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.

HOWEVER, THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE
IDENTIFICATION NUMBER (VIN) HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED.
This number consists of numbers and letters, as in the example shown below.
ZD4RKH000YSXXXXXX
KEY:
ZD4: WMI (World manufacturer identifier) code;
KH: model;
000: RF or RR (Europe);
0: free digit;
Y: year of manufacture;
S: production plant (S= Scorzè);
XXXXXX: serial number (6 digits);
FRAME NUMBER
The chassis number is stamped on the RH side of
the headstock.
Chassis No. ....................
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
CHAR - 11
Dimensions and mass
WEIGHT AND DIMENSIONS

Specification Desc./Quantity
Max. length 2130 mm (83.86 in)
Max. width 810 mm (31.89 in)
Max height (at handlebar) 1110 mm (43.70 in)
Wheelbase 1465 mm (57.68 in)
Kerb weight 218 Kg (481 lb)
Weight fully loaded 435 kg (959 lb)
Engine
ENGINE
Model M55CM
Type Four-stroke longitudinal 90° V twin-cylinder with 4 valves per
cylinder, 2 cam shafts at the big end.
Cylinder number 2
Total engine capacity 896.1 cm³ (54.68 cu in)
Bore / stroke 92 x 67.4 mm (3.62 x 2.65 in)
Compression ratio 11.5: 1
Start-up Electric
Intake valve clearance 0.10 - 0.15 mm (0.0039 - 0.0059 in)
Exhaust valve clearance 0.15 - 0.20 mm (0.0059 - 0.0078 in)
Engine idle speed 1450 +/- 100 rpm
Rpm of the engine at full power 8750 +/- 100 rpm
Clutch Multi plate wet clutch with mechanical control lever on left side
of the handlebar.
Lubrication Wet crankcase. Pressure-fed, controlled by trochoidal pump
Air filter With dry filter cartridge
Cooling Liquid
GEARBOX
Type Mechanical, 6 speeds with foot lever on the left hand side of
the engine
Transmission
DRIVE RATIOS
Drive ratio Primary gear 40/69
Drive ratio, 1st gear 14/36 (secondary)
Drive ratio, 2nd gear 17/32 (secondary)
Drive ratio, 3rd gear 20/30 (secondary)
Drive ratio, 4th gear 22/28 (secondary)
Final drive ratio 16/44
Capacities
CAPACITY
Fuel (reserve included) 14.5 l (3.19 UK gal; 3.83 US gal)
CHAR - 12
Fuel reserve 3 l (0.66 UK gal; 0.79 US gal)
Engine oil 3.0 l (without oil filter change) (0.66 Uk gal; 0.79 US gal)
3.2 l (with oil filter change) (0.70 Uk gal; 0.85 US gal)
Coolant 1.8 l (0.40 UK gal; 0.48 US gal)
Seats 2
Maximum weight limit 215 kg (474 lb) (rider + passenger + luggage)
Drive chain
DRIVE CHAIN
Type Endless (without chain hammerlocks) and with sealed links.
No. of links 108
Model 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Battery 12 V - 10 Ah YTX 12 - BS
Alternative solution:
12 V - 12 Ah YTX 14 - BS
Main fuses 30 A, 5 A
Secondary fuses 7,5 A (2), 10 A, 15 A (3)
ABS fuses 20 A
Alternator (permanent magnet) 13.5 V - 450 W at 6000 rpm
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit.
SPARK PLUGS
BRAND TYPE RESISTANCE ELECTRODE GAP
NGK-R CR8EKB 5 kOhm 0.6 - 0.7 mm (0.024 - 0.028 in)
(*) NGK-R CR7EKB 5 kOhm 0.6 - 0.7 mm (0.024 - 0.028 in)
(*) NGK IR MR8BI-8 7.5 KOhm (MAX) / 3KOhm (MIN) 0.8 mm (0.031 in)
(*) Alternative solution
BULBS
Low beam light 12 V - 55 W H7
High beam light 12 V - 55 W H7
Front DRL 12V- 5W x 2
Turn indicators 12V - 10W
Licence plate light 12 V - 5 W
Rear daylight running light /stop light 12V- 5/21W x 2
INDICATOR LAMPS
ABS LED
High beam light LED
Fuel reserve LED
Turn indicators LED
Overspeed threshold/shift light LED
Immobilizer LED
MI LED
General warning LED
Side stand LED
ATC LED
CHAR - 13
Frame and suspensions
FRAME
Type Die-cast aluminium plates and high-yield strength steel frame.
Steering inclination angle (with extended suspensions) 26°
Trail 114 mm (4.49 in)
SUSPENSIONS
Front Telescopic upside-down hydraulic fork, stems diam 41 mm
(1.61 in)
Travel 127 mm (5.00 in)
Rear Swingarm and adjustable hydraulic monoshock
Travel 43 +/- 1 mm (1.69 +/- 0.039 in)
SIZES A AND B
Size A ... mm (... in)
Size B ... mm (... in)
Brakes
BRAKES
Front Double floating disc - Ø 320 mm (12.60 in), radially-mounted
calliper with 2 Ø 27 mm (1.06 in) pistons; 2 diam. 32.03 mm
(1.26 in) and 4 pads
Rear Disc brake - diam. 240 mm (9.45 in), single piston calliper -
diam. 35 mm (1.38 in)
Wheels and tyres
WHEELS
Type In light alloy with extractable pin
Front 3.50 x 17"
Rear 6.00 x 17"
CHAR - 14
TYRES
Front 120/70 ZR17" (58W)
Inflation pressure 1 passenger: 2.3 bar (230 KPa) (33.36 PSI)
2 passengers: 2.5 bar (250 KPa) (36.26 PSI)
Rear 180/55 ZR17" (73W)
Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SUPPLY SYSTEM

Type Electronic injection (Multipoint)
Throttle valve diameter Diam. 52 mm (2.05 in)
Fuel Unleaded petrol max E10 (95 RON).
Tightening Torques
If the following tables do not expressly indicate the tightening torque values, refer to the table with the
generic torque values indicated below.
GENERAL TIGHTENING TORQUES

M4 M5 M6 M8 M10 M12
Metric tightening torque: TE - TEFL - SHC - TBEI 3 Nm (2.21 6 Nm (4.43 10 Nm 25 Nm 50 Nm 80 Nm
- TCC - TS lb ft) lb ft) (7.38 lb ft) (18.44 lb ft) (36.88 lb ft) (59.00 lb ft)
GENERAL TIGHTENING TORQUES FOR SELF TAPPING SCREWS FOR PLASTIC

2.9 mm 3.9 mm 4.2 mm 5 mm
Tightening torque 2 Nm (1.48 lb ft) 2 Nm (1.48 lb ft) 3 Nm (2.21 lb ft) 3 Nm (2.21 lb ft)
Chassis
CHAR - 15
Front side
HEADLAMP
Pos. Description Type Quantity Torque Notes
1 Button head, hex. socket screws M6x15 2 10 Nm (7.38 lb ft) -
used to fasten the headlight bracket
to the bottom yoke
used to fasten the direction indica-
tors
3 Self-locking, flanged direction indica- M5 2 2 Nm (1.48 lb ft) -
tor fastening nuts
4 Flanged, self-locking upper headlight M6 2 10 Nm (7.38 lb ft) -
fastening nuts
5 Flanged, self-locking lower headlight M6 1 10 Nm (7.38 lb ft) -
fastening nut
CHAR - 16
INSTRUMENTS
1 Button head, hex. socket instrument M5x12 4 3 Nm (2.21 lb ft) -
panel adapter fastening screws
2 Self-tapping, SWP screws used to 5x14 3 3 Nm (2.21 lb ft) -
fasten the instrument cluster and
cover to the support plate
3 Button head, hex. socket screws for M6x16 2 10 Nm (7.38 lb ft) -
fastening the steering plate to the in-
strument panel plate
4 Special screws for fastening the M6 2 10 Nm (7.38 lb ft) -
steering plate to the instrument panel
support plate
fastening nuts
CHAR - 17
HANDLEBAR-CONTROLS
1 Stainless steel, cyl. head Pozidriv M8x25 4 25 Nm (18.44 lb ft) -
screws used for fastening the upper
U-bolt to the lower U-bolt
2 Electronic accelerator control fasten- - 1 4 Nm (2.95 lb ft) -
ing screws
3 Light switch fastening screws - 2 1.5 Nm (1.11 lb ft) -
4 Cyl. head, hex. socket anti-vibration M6x45 2 10 Nm (7.38 lb ft) -
counterweight fastener screws
CHAR - 18
CLUTCH CONTROL
1 Clutch pump U-bolt fastening screws - 2 10 Nm (7.38 lb ft) -
2 Special screw for fastening the pipe M10 1 25 Nm (18.44 lb ft) -
to the clutch cylinder
to the clutch pump
4 Countersunk, hex. socket screws M6x75 1 8 Nm (5.90 lb ft) Perform two tight-
used for fastening the clutch actuator ening cycles
cylinder
cylinder
FRONT BRAKE MASTER CYLINDER

1 Brake pump U-bolt fixing screws - 2 10 Nm (7.38 lb ft) -
to the brake pump
CHAR - 19
STEERING
1 Headstock ferrule (pre-tightening) M25 1 50 Nm (36.88 lb ft) Steering assembly
settling
1 Headstock ferrule (tightening) M25 1 15 Nm (11.06 lb ft) -
2 Flanged upper steering plate fasten- M22 1 25 Nm (18.44 lb ft) -
ing nut (stop)
2 Flanged upper steering plate fasten- M22 1 25 Nm (18.44 lb ft) Loct. 243
ing nut (pre-tightening)
ing nut (tightening)
3 Cyl. head, hex. socket screws used M8x30 2 25 Nm (18.44 lb ft) -
for fastening the fork stanchions to
the upper plate
4 Low profile, cyl. head, hex. socket M8x30 1 25 Nm (18.44 lb ft) -
screw used for fastening the steering
headstock to the upper plate
the lower plate
6 Cyl. head, hex. socket screws for fas- M10x60 2 50 Nm (36.88 lb ft) Loct. 243
tening the lower U-bolt to the upper
steering plate
CHAR - 20
FRONT FORK
1 Flanged, hex. head screws used for M6x40 4 10 Nm (7.38 lb ft) -
closing the fork feet
used for fastening the sensor to the
right hand fork foot
CHAR - 21
FRONT MUDGUARD - ENGINE FAIRING

1 Button head hex. socket screws M5x9 4 4 Nm (2.95 lb ft) Loct. 243
used to fasten the mudguard to the
calliper mounting bracket
2 Button head hex. socket screws for M6x20 4 10 Nm (7.38 lb ft) -
fastening the engine fairing to the
support
FRONT WHEEL
1 Wheel axle nut - 1 80 Nm (59.00 lb ft) -
2 Flanged, hex. head phonic wheel M8x20 12 30 Nm (22.13 lb ft) Pre-impregnated
and brake discs fixing screws screws
CHAR - 22
FRONT BRAKE CALLIPERS

1 Flanged, hex. head screws for fas- M10x1.25 4 50 Nm (36.88 lb ft) -
tening the brake callipers to the fork
stanchions
brake pipe to the callipers
CHAR - 23
FRONT ELECTRICAL SYSTEM

1 Flanged, hex. head screws for fas- M6x20 2 10 Nm (7.38 lb ft) -
tening the voltage regulator to the
frame
2 Flanged SWP screws for fastening M5x20 4 2.5 Nm (1.84 lb ft) -
the control unit to the base of the filter
box
3 Screws used for fastening the coils to M6 2 5 Nm (3.69 lb ft) -
the heads
4 Nut used for fastening the power M6 1 10 Nm (7.38 lb ft) -
supply cable to the starter motor
5 Horn fixing screw M6x25 1 10 Nm (7.38 lb ft) -
Central part
CHASSIS
for fastening the side fairings to the
engine
2 TORX cyl. head screws used for fas- M12x53 4 80 Nm (59.00 lb ft) -
tening the trellis to the frame side
fairings
3 Cyl. head, hex. socket screw used for M10x30 1 50 Nm (36.88 lb ft) Pre-impregnated
fastening the shock absorber coun- screw
ter-plate to the right hand frame side
fairing
4 Cyl. head, hex. socket screws used M8x35 4 35 Nm (25.81 lb ft) Pre-impregnated
for fastening the saddle support to screws
the frame
fastening the silencer support brack-
et to the saddle support
CHAR - 24
FOOTRESTS
fastening the rider/passenger rubber
footrests
2 Cyl. head, hex. socket screws used M8x25 4 18 Nm (13.28 lb ft) Loct. 243
for fastening the rider's footrest sup-
port to the frame plates
used for fastening the luggage rack
to the rider's footrest support
for fastening the passenger footrest
supports to the saddle support
CHAR - 25
STAND
fastening the stand plate to the en-
gine
2 Screw for fastening the stand to the M10x1.25 1 10 Nm (7.38 lb ft) -
plate
3 Low profile nut used for fastening the M10x1.25 1 30 Nm (22.13 lb ft) -
stand to the plate
for fastening the stand switch
5 Self-locking, low profile nut used for M5x16 2 7 Nm (5.16 lb ft) -
fastening the stand switch
CHAR - 26
LOCKS
1 Button head, hex. socket ignition lock M8x40 1 25 Nm (18.44 lb ft) -
fastening screw
2 Ignition lock fastening shear head - 1 Manual -
screw
3 Flanged, hex. head screws used to M6x25 2 10 Nm (7.38 lb ft) -
fasten the saddle lock to the saddle
to fasten the filler cap to the fuel tank
6 Cyl. head, hex. socket for fastening M5x16 4 4 Nm (2.95 lb ft) -
the saddle to the tail fairing
CHAR - 27
FUEL TANK COVER

used to fasten the radiator guard to
the radiator
2 Button head, hex. socket block lid/ M5x9 2 10 Nm (7.38 lb ft) -
fuel tank cover fastening screws
3 Button head, hex. socket fuel tank M5x9 8 4 Nm (2.95 lb ft) -
cover fastening screws
4 Cyl. head, hex. socket rear fuel tank M6x90 1 12 Nm (8.85 lb ft) -
cover fastening screw
5 Self-locking rear fuel tank cover fas- M6 1 12 Nm (8.85 lb ft) -
tening nut
CHAR - 28
TANK
pos. Description Type Quantity Torque Notes
1 Flanged, hex. head front fuel tank M6x30 2 6 Nm (4.43 lb ft) -
fastening screws
2 Fuel pump fastening nuts M5 6 6 Nm (4.43 lb ft) -
CHAR - 29
AIR FILTER CASING

1 Self-tapping, SWP air pressure sen- 5x20 2 2 Nm (1.48 lb ft) -
sor fastening screws
2 Self-tapping air temperature sensor 2.9x12 2 2 Nm (1.48 lb ft) -
fastening screws
3 SWP filter box lid fastening screws 5x20 8 2 Nm (1.48 lb ft) -
4 SWP screws used to fasten the up- 5x20 10 2 Nm (1.48 lb ft) -
per part of the filter box
5 SWP screws used to fasten the filter 5x20 3 2 Nm (1.48 lb ft) -
box side cover
6 SWP wiring harness support bracket 5x20 3 2 Nm (1.48 lb ft) -
fastening screws
7 SWP control unit cover fastening 3.9x14 2 2 Nm (1.48 lb ft) -
screws
8 SWP control unit support fastening 5x14 2 2 Nm (1.48 lb ft) -
screws
THROTTLE BODY
1 Flanged, hex. head screws used for M6x60 8 12 Nm (8.85 lb ft) Loct. 242
fastening the inlet coupling
2 Button head, hex. socket screws M6 8 12 Nm (8.85 lb ft) Loct. 242
used for fastening the throttle body to
the bracket
3 Flanged, hex. head screws used for M6 2 12 Nm (8.85 lb ft) Loct. 242
fastening the Injectors
CHAR - 30
SIDE FAIRINGS
1 Self-tapping, cyl. head slot drive 4.2x16 2 3 Nm (2.21 lb ft) -
screws used for fastening the grilles
to the duct covers
screws used for fastening the duct
covers to the ducts
used to fasten the duct covers to the
radiator
fastening the conveyors to the tank
fastening the conveyors to the brack-
et
6 Self-tapping screws used for fasten- 2.9x20 2 2 Nm (1.48 lb ft) -
ing the tank/fuel tank cover/ducts
7 Self-tapping, cyl. head, slot drive 2.9x20 4 2 Nm (1.48 lb ft) -
screws used for fastening the side/
tail fairings
CHAR - 31
COOLING SYSTEM
1 Flanged, hex. head used for fasten- M6x20 1 10 Nm (7.38 lb ft) -
ing the trellis expansion tank
2 Flanged, hex. head screw used for M6x25 1 10 Nm (7.38 lb ft) -
fastening the trellis radiator
3 Button cyl. head screw used for fas- 4.2x20 3 3 Nm (2.21 lb ft) -
tening the electric fan to the radiator
fastening the radiator bracket
CHAR - 32
ABS BRAKING SYSTEM

fastening the ABS control unit on the
support
2 Front fastening, flanged self-locking M6 1 10 Nm (7.38 lb ft) -
nut
3 Flanged, hex. head screw used for M6x25 2 10 Nm (7.38 lb ft) Loct. 270
support
fastening the spacers on the ABS
support
fastening the ABS support on the en-
gine
6 Flanged, hex. head screws for fas- M8x25 1 25 Nm (18.44 lb ft) Loct. 243
tening the spacer plate on the frame
plate
for fastening the pipes under the
steering headstock
ENGINE - ACCESSORIES - LEVER MECHANISMS

1 Flanged, hex. head screw used for M10x1.25x26 1 50 Nm (36.88 lb ft) Pre-impregnated
fastening the pinion screw
2 Cyl. head, hex. socket screw used for M6x20 1 10 Nm (7.38 lb ft) -
fastening the gear lever to the gear-
box output shaft
3 TORX screw used for fastening the M6x22 1 8 Nm (5.90 lb ft) Loct. 270
gear lever pedal
fastening the pinion cover guard
CHAR - 33
PETROL VAPOUR RECOVERY SYSTEM

for fastening the pinion cover guard
Back side
CHAR - 34
SWINGARM
1 Swingarm pivot bolt fastening nut - 1 90 Nm (66.38 lb ft) -
swingarm bolt regulator bushing
3 Swingarm pivot bolt fastening swing- - 1 60 Nm (44.25 lb ft) -
arm bolt ferrule
4 Button head, hex. socket shoe cap M5x12 3 6 Nm (4.43 lb ft) -
fastening screws
used for fastening the chain guard on
the chain guide shoe
6 Wheel axle nut M25x1.5 1 120 Nm (88.51 lb ft) -
7 Chain tensioner adjustment screws - 2 Manual -
8 Flanged, self-locking nut on the M8 2 Manual -
chain tensioner shoe regulator screw
SHOCK ABSORBER
1 Cyl head, hex. socket upper shock M10x50 1 50 Nm (36.88 lb ft) Pre-impregnated
absorber fastening screw screw
2 Cyl head, hex. socket lower shock M10x59 1 50 Nm (36.88 lb ft) -
absorber fastening screw
CHAR - 35
REAR WHEEL
2 Button head, hex. socket screw used M5x16 1 6 Nm (4.43 lb ft) -
for fastening the sensor to the brake
calliper support
3 DAX nut for fastening the crown gear M10x1.25 5 50 Nm (36.88 lb ft) -
on the hub
for fastening the cush to the wheel screws
5 Flanged, hex. head screws used for M8x18 5 30 Nm (22.13 lb ft) Pre-impregnated
fastening the brake disc to the wheel screws
CHAR - 36
REAR BRAKE MASTER CYLINDER

fastening the peg to the gearshift lev-
er
2 Pin used to fasten the lever to the - 1 25 Nm (18.44 lb ft) -
footrest support
3 Lock-nut for pump shaft fork M6 1 10 Nm (7.38 lb ft) -
for fastening the pump to the footrest
support
5 Special brake pipe coupling fasten- M10x1 1 10 Nm (7.38 lb ft) -
ing screw
fastening the brake fluid tank to the
saddle support
7 Flanged, self-locking nut used for M6 1 10 Nm (7.38 lb ft) -
fastening the brake fluid tank to the
saddle support
CHAR - 37
REAR BRAKE CALLIPER

ing screw
used for fastening the brake pipe pro-
tection
CHAR - 38
REAR BODYWORK
used for fastening the covers to the
terminal
2 Self-tapping screws used for fasten- M5x19 4 4 Nm (2.95 lb ft) -
ing the tail fairings to the battery com-
partment
3 Self-tapping, cyl. head Pozidriv 4.2x16 2 3 Nm (2.21 lb ft) -
screws used for fastening the grab-
bar to the tail fairings
used for fastening the number plate
holder to the number plate holder
support
fastening the grab-bar support to the
grab bar and the saddle support
UNDER-SADDLE COMPARTMENT
1 Button cyl. head screws used for fas- M4x16 2 3 Nm (2.21 lb ft) -
tening the battery cover
2 Flanged button head, hex. socket M5 3 5 Nm (3.69 lb ft) -
screws used for fastening the num-
ber plate holder support to the saddle
support
CHAR - 39
SILENCER
1 Lambda probes - 2 40 Nm (29.50 lb ft) -
2 Flanged, self-locking used for fasten- M8 4 12.5 Nm (9.22 lb ft) -
ing the exhaust flanges to the big
ends
for fastening the shock absorber pro-
tection
4 Manifold fastening clamps M6 2 7 Nm (5.16 lb ft) -
5 Terminal fastening clamp M6 1 7 Nm (5.16 lb ft) -
fastening the terminal front coupling
to the support bracket
CHAR - 40
REAR ELECTRICAL SYSTEM

for fastening the anti-rollover sensor
Engine
CHAR - 41
HEAD COVER
1 Special head cover fastening screw M6 8 9 Nm (6.64 lb ft) -
TIMING SYSTEM
1 Cam shaft gear fastening nut M15x1 4 88 Nm (64.91 lb ft) Thoroughly de-
grease both of the
coupling surfaces
CHAR - 42

(axle cone and gear
cone)
2 Timing lay shaft fastening screw M24x1.5 2 88 Nm (64.91 lb ft) 3M SCOTCH GRIP
2353
3 Special mobile / fixed slider fastening M8 4 18 Nm (13.28 lb ft) 3M SCOTCH GRIP
screw 2353
4 Cam tower / head fastening screws M6x37 16 13 Nm (9.59 lb ft) Follow the number-
ing sequence stam-
ped on the cam tow-
ers
5 Cam tower / plate fastening screws M4x10 8 3 Nm (2.21 lb ft) 3M SCOTCH GRIP
2353
6 Decompressor fastening screws M8 2 28 Nm (20.65 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
7 Decompressor fastening screw M5x12.9 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
HEAD
1 Water Temperature Sensor M12x1.5 1 20 Nm (14.75 lb ft) -
2 Threaded plug M12x1.5 1 10 Nm (7.38 lb ft) Loct. drise AL 506
3 Nut for fastening the stud bolts to the M10x1.25 8 13 Nm (9.59 lb ft) Lubricate the
head - Pre-tightening threads before tight-
ening
3 Nut for fastening the stud bolts to the M10x1.25 8 135° + 135° -
head - Tightening
4 Head / Cylinder / Crankcase fasten- M6x75 2 13 Nm (9.59 lb ft) -
ing outside
ing inside
6 Nut for fastening the Stud bolts to the M6 4 12 Nm (8.85 lb ft) -
Head
7 Nut for fastening the Stud bolts to the M8x1.25 2 25 Nm (18.44 lb ft) -
Head
8 Screw for fastening the connector to M5 4 6 Nm (4.43 lb ft) Loct. dry loc 2040
the discharge
CHAR - 43

9 Water vent connector M6 1 3 Nm (2.21 lb ft) Loct. 262
CYLINDER
1 Chain tensioner fastener screw M6x30 4 13 Nm (9.59 lb ft) -
2 Cylinder plate fastening screw M6x16 4 9 Nm (6.64 lb ft) -
3 Chain tensioner adjustment screw M6 2 5 Nm (3.69 lb ft) -
CHAR - 44
CLUTCH COVER
1 Clutch cover / Clutch side cover fas- M6 6 13 Nm (9.59 lb ft) -
tening screw
2 Clutch fastening nut M24x1.5 1 177 Nm (130.55 lb ft) Chamfer
3 Oil filler cap on clutch cover M25x1.25 1 2 Nm (1.48 lb ft) -
4 Clutch Control Plate / Support coun- M5x12 3 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
tersunk hex head fastening screw 2353
5 Flywheel side clutch control support / M6 2 13 Nm (9.59 lb ft) -
half-crankcase fastening screw
CLUTCH
1 Clutch spring fastening screw M6 6 12 Nm (8.85 lb ft) -
CHAR - 45
WATER PUMP
1 Clutch side cover fixing screw M6x40 13 13 Nm (9.59 lb ft) -
2 Pump cover / Clutch side cover fas- M6x25 3 13 Nm (9.59 lb ft) -
tening screw
3 Pump cover / Clutch cover / clutch M6x60 2 13 Nm (9.59 lb ft) -
side half-crankcase fastening screw
4 Water pump control crown fastening M6 1 12 Nm (8.85 lb ft) Loct. 244
nut
5 Water pump impeller (brass insert) M6 1 4 Nm (2.95 lb ft) -
6 Flanged hex head screw for fasten- M6x12 1 9 Nm (6.64 lb ft) Loct. 242
ing the chain tensioner slider
7 Pump support fastening screw M6x30 3 12 Nm (8.85 lb ft) -
CHAR - 46
IGNITION
1 Spark plug - 2 13 Nm (9.59 lb ft) -
2 Free wheel ring fastening screw M6x18 6 14 Nm (10.33 lb ft) 3M SCOTCH GRIP
2353
3 Rotor fastening screw - Crankshaft M14x1.5 1 191 Nm (140.87 lb ft) Thoroughly de-
grease both of the
coupling surfaces
4 Stator fastening screw / Flywheel M6x30 3 9 Nm (6.64 lb ft) -
cover
5 Pick-up fastening screw / Flywheel M5x14 2 3 Nm (2.21 lb ft) Loct. 270
cover
6 Flywheel cover fastening screw M6x30 10 13 Nm (9.59 lb ft) -
7 Crankshaft access plug - 1 4 Nm (2.95 lb ft) -
8 Crown containment plate fastening M6x12 1 8 Nm (5.90 lb ft) -
screw
9 Bracket to starter motor fastening M6x14 2 7 Nm (5.16 lb ft) Loct. 242
screw
10 Starter motor bracket to crankcase M6x16 2 13 Nm (9.59 lb ft) -
fastening screw
CHAR - 47
CRANKCASE II
1 Half-crankcase coupling screw M8x80 9 28 Nm (20.65 lb ft) -
3 Special oil calibration screw M10x1 1 14 Nm (10.33 lb ft) -
CHAR - 48
CRANKCASE I
1 Crankcase-cylinder-head fastening M10x1.25x166 8 Distance-based tighten- SCOTCH GRIP
stud bolts ing 2510 GREEN
2 Bearing retainer fastening screws M6x12 3 10 Nm (7.38 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
3 Threaded plug M8x1 5 15 Nm (11.06 lb ft) 3M SCOTCH GRIP
2353
4 Piston oil jet fastening screw M5x16 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
LUBRICATION
1 Oil drainage plug M16x1.5 1 17 Nm (12.54 lb ft) +/- -
15%
2 Oil pressure sensor M10x1 1 13 Nm (9.59 lb ft) -
3 Fitting fixing of the oil filter - 1 20 Nm (14.75 lb ft) -
4 Oil filter - 1 14 Nm (10.33 lb ft) -
5 Oil pressure regulation valve M16x1.5 1 41 Nm (30.24 lb ft) -
6 Oil pump / bulkhead fastening M6x45 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
screws 2353
7 Strainer fastening screws - 2 12 Nm (8.85 lb ft) -
8 Oil pump gear fastener nut M6 1 11 Nm (8.11 lb ft) -
9 Gear sensor fastening screws M5x16 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353
10 Oil temperature sensor M10x1 1 13 Nm (9.59 lb ft) -
CHAR - 49
GEAR SELECTOR
1 Gear sensor fastening screw M5 2 6 Nm (4.43 lb ft) Loct. 270
2 Selector plate fastening screw M5x12 3 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353
3 Desmodromic drum/sprocket fasten- M8x1.25x17 1 15 Nm (11.06 lb ft) 3M SCOTCH GRIP
ing screw 2353
4 Selector pin fastening screw M10x1.5 1 16 Nm (11.80 lb ft) Loct. 242
5 Ratchet pin fastening screw M6 1 12 Nm (8.85 lb ft) Loct. dry loc 2040
CHAR - 50
CRANKSHAFT
1 Primary crankshaft fastening net M24x1.5 1 294 Nm (216.84 lb ft) Thoroughly de-
grease both of the
coupling surfaces
(shaft cone and
gear cone)
2 Connecting rod fastening screws - M10x1x40 4 15 Nm (11.06 lb ft) Lubricate the
Pre-torque threads before tight-
ening
2 Connecting rod fastening screws - M10x1x40 4 30 Nm (22.13 lb ft) + 50° -
Torque +/- 2°
2 Connecting rod fastening screws - M10x1x40 4 70 Nm (51.63 lb ft) -
Control
Overhaul data
Assembly clearances
Cylinder - piston assy.
The pistons are available in four size types (A, B,

C, D) to be coupled to the four cylinder types (A,
B, C, D).
Only one type of piston ring is available.
PISTON - CYLINDER COUPLING

Cylinder-piston class A coupling Cylinder: 91.990 - 91.997 mm (3.6216 - 3.6219 in)
Piston: 91.933 - 91.940 mm (3.6217 - 3.6197 in)
Cylinder-piston class B coupling Cylinder: 91.997 - 92.004 mm (3.6219 - 3.6222 in)
Piston: 91.940 - 91.947 mm (3.6197 - 3.6199 in)
Cylinder-piston class C coupling Cylinder: 92.004 - 92.011 mm (3.6222 - 3.6225 in)
Piston: 91.947 - 91.954 mm (3.6199 - 3.6202 in)
Cylinder-piston class D coupling Cylinder: 92.011 - 92.018 mm (3.6225 - 3.6227 in)
Piston: 91.954 - 91.961 mm (3.6202 - 3.6205 in)
CHAR - 51
Fitting clearance 0.050 - 0.064 mm (0.00197 - 0.00252 in)
Crankcase - crankshaft - connecting rod
MARKINGS ON THE INSIDE OF THE CRANKCASES

Crankcases selectable in two classes (1 or 2), based on the diameter of the main housing.
The categories are indicated on both half-crankcases:
• In the area of the starter gears on the flywheel side crankcase.

• In the area of the gearshift control devices on the clutch side crankcase.
CRANKCASE SELECTION CLASSES

Crankcase class 1 Bearing housing diameter: 53.954 - 53.960 mm (2.1241 -
2.1244 in)
Crankcase class 2 Bearing housing diameter: 53.960 - 53.966 mm (2.1244 -
2.1246 in)
CRANKSHAFT
There are three crankshaft selection classes for
each capacity:
• 4 - 5 - 6 for the flywheel side;

• 7 - 8 - 9 for the clutch side;
The category type is stamped on the outside of the

crankshaft's counterweight.
NOTE
THE SHAFT CAN HAVE TWO DIFFERENT CLASSES FOR
THE TWO CAPACITIES.
CRANKSHAFT SELECTION CLASSES

Crankshaft class 4 - 7 Main journals - diameter: 49.978 - 49.984 mm (1.9676 - 1.9679
in)
in)
in)
After having determined the categories of:
CHAR - 52
• crankcase
• flywheel side block journal
• clutch side block journal
the bearings to be used for their coupling can be selected based on the following table.
MAIN BEARINGS
Block journal Crankcase class 1 Crankcase class 2
Block journal class 4 (l.v.) Half bearings A (red) Half bearings B (blue)
Block journal class 5 (l.v.) Half bearings B (blue) Half bearings C (yellow)
Block journal class 6 (l.v.) Half bearings E (green) Half bearings A (red)
Block journal class 7 (l.f.) Half bearings A (red) Half bearings B (blue)
Block journal class 8 (l.f.) Half bearings B (blue) Half bearings C (yellow)
Block journal class 9 (l.f.) Half bearings E (green) Half bearings A (red)
See also
Removing the flywheel cover
PRIMARY GEAR CATEGORY

Crankcase selectable in two classes (A or B)
based on the centre distance between the primary
reduction gears.
The categories are indicated on the clutch side
half-crankcase, in the area of the gearshift control
devices.
NOTE
IF THE CRANKCASE IS REPLACED, IT WILL BE SUPPLIED
WITH THE PRIMARY REDUCTION GEAR ALREADY COU-
PLED.
CRANKCASE-PRIMARY GEAR SELECTION CLASSES

Crankcase class A Centre distance: 110.50 - 110.54 mm (4.3504 - 4.3519 in)
Crankcase class B Centre distance: 110.46 - 110.50 mm (4.3488 - 4.3504 in)
PRIMARY CATEGORY
Pinion selectable in two classes (A or B) based on
the centre distance between the primary reduction
gears.
The categories of the class B pinions are indicated
on the pinions themselves.
CRANKSHAFT CATEGORY (CRANK PIN)

Shaft selectable in four classes (4, 5, 6, 7) based on the diameter of the crank pin.
Shaft selectable in seven classes (E1, E2, ...) based on the weight of the connecting rods.
Key:
* Connecting rod selection class.
CHAR - 53
** Crank pin selection class.

*** Progressive traceability number and date.
SHAFT CATEGORY
Class Crank pin diameter (mm)
0 42.000 - 42.006 mm (1.65354 - 1.65377 in)
1 41.994 - 42.000 mm (1.65330 - 1.65354 in)
2 41.988 - 41.994 mm (1.65307 - 1.65330 in)
3 41.982 - 41.988 mm (1.65283 - 1.65307 in)
See also
BEARINGS
Since the connecting rod has only one size category, the bearing must be selected based exclusively
on the crank pin's size class.
BEARINGS
Crank pin diameter Connecting rod class 1
Shaft class 0 Half bearings E (green)
Shaft class 1 Half bearings A (red)
Shaft class 2 Half bearings B (blue)
Shaft class 3 Half bearings C (yellow)
CONNECTING RODS
Spare parts are not available for all the weight classes, but only the four most significant; for the se-
lection, please refer to the following table:
CONNECTING RODS
Class by shaft weight Weight range (g)
E1 450-455
E2 455-460
E3 460-465
E4 465-470
E5 470-475
E6 475-480
E7 480-485
CAUTION
THE CONNECTING RODS FOR THE SAME CRANKSHAFT MUST BE OF THE SAME WEIGHT
CLASS AND MUST HAVE THE SAME TYPE OF CRANKSHAFT COUPLING.
DURING RE-ASSEMBLY, ALSO MAKE SURE THAT THE HALF BEARINGS ARE OF THE SAME
CLASS.
See also
CHAR - 54
INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS

Special tools SHIVER 900
SPECIAL TOOLS
Stores code Description
020709Y Engine support
020710Y Engine plate
AP8140187 U-bolt for motor support
020850Y Primary gear lock
020712Y Handle for removing the flywheel cover
020713Y Flywheel extractor
S-TOOLS - 56
SHIVER 900 Special tools

020714Y Dial gauge mount
9100896 Clutch bell stopper
020716Y Connecting stem lock
020470Y Pin snap ring fitting tool
AP8140302 tool for installing seal rings
020718Y Camshaft gearwheel alignment pin
S-TOOLS - 57

020719Y Timing pin
020720Y Timing tool
AP8140179 Valve springs compressor
020721Y Valve removal adaptor
020376Y Adaptor handle
020629Y 8 mm guide (0.31 in)
020412Y 15mm oil seal guide
S-TOOLS - 58

020439Y 17mm oil seal guide
020263Y Driven pulley assembly sheath
020365Y 22 mm guide (0.87 in)
020364Y 25-mm guide
020483Y 30-mm guide
020441Y Oil seals punch
S-TOOLS - 59

020358Y 37 x 40 mm Adaptor
020357Y 32 x 35-mm Adaptor
020359Y 42 x 47 mm Adaptor
020360Y 52 x 55-mm Adaptor
020724Y Punch cage with rollers gearbox control

stem
020726Y Bushing extractor
020727Y Bushing punch
S-TOOLS - 60

020884Y 46 mm wrench for steering ferrule
AP8140180 Bearing extractor
AP8140199 Tool storage panel
8140426 Hooks for panel
FORK
AP8140149 Guard for assembly operations
020888Y Pre-load pipe clamp
S-TOOLS - 61

AP8140148 Plunger-spacer separator plate
AP8140189 Tool for fitting oil seal for 43 mm (1.69 in)

diameter hole
AP8140146 Weight
AP8140150 Bored shaft for bleeding plunger air
CAUTION
BEFORE USING THE "PRIMARY GEARWHEEL LOCK TOOL - 020850Y", IT IS NECESSARY TO
MAKE THREE HOLES SO THAT IT MAY BE POSITIONED CORRECTLY ON THE ENGINE GUARD.
THE HOLES ARE ILLUSTRATED IN THE FOLLOWING IMAGE.
S-TOOLS - 62
S-TOOLS - 63
INDEX OF TOPICS
MAINTENANCE MAIN
SHIVER 900 Maintenance
Scheduled maintenance table

NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-
HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Check and clean, adjust or replace, if necessary, every 1,000 Km (621 mi)
(2) Replace every 4 years
(3) At each engine start
(4) Check every month
(5) Check at every change of the rear tyre
(6) Replace at whichever of the following occurs first: 40,000 km (24,854 mi) or 4 years
(7) Check before each trip.
SCHEDULED MAINTENANCE TABLE

Km x 1,000 (mi x 1,000) 1 (0.6) 10 20 30 40 EVERY EVERY
(6.2) (12.4) (18.6) (24.9) 12 24
MONTH MONTH
S S
Rear shock absorber (bearings) I I I I
Spark plug R R
Drive chain (1) I I I I I
Steering bearings and steering clearance I I I I I
Wheel bearings - Wheels I I I I
Diagnosis by tool I I I I I I I
Brake discs - Brake pads wear (7) I I I I I
Air filter I R I R
Engine oil filter R R R R R
Fork I I I I
General operation of the vehicle I I I I I
Valve clearance A A
Cooling system I I
Braking systems I I I I I
Light circuit I I I I I
Safety switches (stand, stop, clutch, extra negative stroke, I I I I I I I
gas control)
Clutch control fluid I I I I R
Brake fluid I I I I R
Coolant I I I I R
Fork oil (6) R
Engine oil R I R I R R R
Headlight aiming I I
Fork oil seals I
Flexible couplings (5) I I
Tyres - pressure / wear (4) I I I I I I I
Bolts and nuts tightening I I I
Suspension and setting I I I
Fault indicator light on dashboard (3)
Fuel lines (2) I I I I
Clutch wear I I
Labour time (minutes) 80 70 230 70 320 70 100
MAIN - 65
Maintenance SHIVER 900
SCHEDULED MAINTENANCE TABLE RESERVED FOR THE USA-LATAM MARKET
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY

C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Check and clean, adjust or replace, if necessary, every 1000 Km (621 mi)
(4) At each engine start
(5) Check every month
(6) Check at every change of the rear tyre
(7) Replace at whichever of the following occurs first: 40,000 km (24,854 mi) or 4 years
(8) Check before each trip.
SCHEDULED MAINTENANCE TABLE

km x 1,000 (mi x 1,000) 1 (0.6) 10 (6.2) 20 (12.4) 30 (18.6) 40 (24.9)
Rear shock absorber (bearings) I I
Spark plug R R
Drive chain (1) I I I
Steering bearings and steering clearance I I I
Wheel bearings - Wheels I I
Diagnosis by tool I I I I I
Brake discs - Brake pads wear (8) I I I
Air filter I R I R
Engine oil filter R R R
Fork I I
General operation of the vehicle I I I
Valve clearance A A
Cooling system I I
Braking systems I I I
Light circuit I I I
Safety switches (stand, stop, clutch, extra negative stroke, gas I I I I I
control)
Clutch control fluid (2) I I I
Brake fluid (2) I I I
Coolant (2) I I I
Fork oil (7) R
Engine oil R I R I R
Headlight aiming I I
Fork oil seals I
Flexible couplings (6) I I
Tyres - pressure/wear (5) I I I I I
Bolts and nuts tightening I I I
Suspension and setting I I I
Fault indicator light on dashboard (4)
Fuel lines (3) I I
Clutch wear I I
Labour time (minutes) 80 70 230 70 320
NOTE
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
MAIN - 66
Recommended products
Piaggio Group recommends the products of its

"Castrol Official Partner" for the scheduled
maintenance of its vehicles.
Use lubricants and liquids having specifications
that are equivalent, or superior, to the recommen-
ded products. These indications also apply when
topping up fluid levels.
TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
Engine oil 15W-50 Synthetic-based lubricant for four-stroke SAE 15W-50, JASO MA, MA2; API SJ;
engines. ACEA A3
Fork oil 10W Fork oil. SAE 10W
Brake fluid DOT 4 Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
Anti-freeze liquid, ready to use, colour red Ethylene glycol antifreeze liquid with or- ASTM D 3306 - ASTM D 4656 - ASTM D
ganic inhibition additives. Red, ready to 4985 - CUNA NC 956-16
use.
Lithium-based grease Lithium-calcium soap based grease colour - black, contains EP (Extreme
Pressure) additives, excellent water-re-
pellent properties
Spark plug
Periodically remove the spark plugs, clean them of carbon deposits and, if necessary, replace them.
CAUTION
EVEN IF A SINGLE SPARK PLUG REQUIRES REPLACING, ALWAYS REPLACE BOTH SPARK
PLUGS.
• Remove the saddle, tank, side panels and the radiator.
• Disconnect the ignition coil connectors

and remove the screw fixing the plugs
to the big end covers.
MAIN - 67
• Remove the ignition coils.

• Remove the spark plugs using a spe-
cial key.
• Check the distance between the elec-

trodes using a thread thickness gauge.
CAUTION
DO NOT ATTEMPT IN ANY WAY TO CHANGE THE DIS-

TANCE BETWEEN THE ELECTRODES.
Characteristic
Spark plug electrode gap
0.6 ÷ 0.7 mm (0.024 ÷ 0.028 in)
If the distance between the electrodes is different, replace the spark plug.
• Make sure the washer is in good conditions.
For installation:
• With the washer mounted, manually screw the spark plug completely with caution to avoid
damaging the thread.
• With a suitable key, tighten by performing a 1/2 turn to each spark plug to compress the
washer.
• Loosen and tighten again the spark plug to the specified torque.
CAUTION
TIGHTEN THE SPARK PLUG CORRECTLY. OTHERWISE, THE ENGINE MAY OVERHEAT AND
GET IRRETRIEVABLE DAMAGED.
USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG, OTHERWISE, ENGINE DURATION
AND PERFORMANCE COULD BE COMPROMISED.
If the distance between the electrodes is different, replace the spark plug.
• Make sure the washer is in good conditions.
For installation:
• With the washer mounted, manually screw the spark plug completely with caution to avoid
damaging the thread.
• With a suitable key, tighten by performing a 1/2 turn to each spark plug to compress the
washer.
MAIN - 68
• Loosen and tighten again the spark plug to the specified torque.
CAUTION
TIGHTEN THE SPARK PLUG CORRECTLY. OTHERWISE, THE ENGINE MAY OVERHEAT AND
GET IRRETRIEVABLE DAMAGED.
USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG, OTHERWISE, ENGINE DURATION
AND PERFORMANCE COULD BE COMPROMISED.
Engine oil
Check
Check the engine oil level frequently.

NOTE
USE.
THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.

CAUTION
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE
ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY
15 Km (10 miles) IN EXTRA-URBAN CONDITIONS (ENOUGH TO WARM UP THE ENGINE OIL TO
OPERATING TEMPERATURE).
• Shut off the engine.
• Keep the vehicle upright with both
wheels on the earth.
• Using the relative opening on the en-
gine casing, check the oil level.
MAX (top notch) = maximum level.

MIN (bottom notch) = minimum level
• The level is correct if it reaches the

"MAX" level.
MAIN - 69
Replacement
Check the engine oil level frequently.

To change:
CAUTION
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE
EASILY AND COMPLETELY; IDEAL TEMPERATURE IS
REACHED AFTER THE ENGINE HAS RUN FOR ABOUT
TWENTY MINUTES.
OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT; BE

CAREFUL NOT TO GET BURNED WHEN CARRYING OUT
THE OPERATIONS DESCRIBED BELOW.
• Using a cloth, carefully clean the area of any dirt deposits around the filling cap (1).
• Place a container with a capacity of more than 4000 cm³ (244 cu in) under the drainage plug
(2).
• Unscrew and remove the drainage plug (2).
• Unscrew and remove the filler plug (1).
• Drain the oil into the container; allow several minutes for oil to drain out completely.
• Replace the drainage plug sealing washer (2).
• Remove any metal scrap attached to the drainage plug (2) magnet.
• Screw and tighten the drainage plug (2).
• Replace the oil filter.

• Restore the correct engine oil level, using the recommended engine oil.
Engine oil filter
• Move the ABS control unit.

• Drain the motor oil.
• Remove the oil filter.
• Screw a new engine oil filter.
• Restore the correct engine oil level.
CAUTION
NEVER REUSE AN OLD FILTER.
See also
Replacement
MAIN - 70
Air filter
• Remove the fuel tank.

• Disconnect the vapour recovery tube.
• Disconnect the air temperature sensor.
• Remove the eight screws fixing the air

filter cover.
• Remove the filter case cover.
MAIN - 71
• Operating from both ducts, turn the up-

per part of the intake duct anticlock-
wise and remove it.
• Remove the filter element.
COVER THE INTAKE DUCTS WITH A CLEAN CLOTH TO

PREVENT FOREIGN BODIES FROM ENTERING THE IN-
TAKE DUCTS. UPON REFITTING, BEFORE REPLACING
THE FILTER CASE COVER , MAKE SURE THAT THE
CLOTH OR OTHER OBJECTS ARE NOT LEFT INSIDE.
MAKE SURE THAT THE FILTER ELEMENT IS CORRECTLY
POSITIONED, SO NO UNFILTERED AIR CAN PASS. DO
NOT FORGET THAT THE EARLY USE OF THE PISTON AND
CYLINDER SEGMENTS CAN BE CAUSED BY A FAULTY
OR MISPLACED FILTER ELEMENT.
REFITTING
• When replacing, pay attention to the introduction of the intake ducts, making sure that the
bayonet plug is snapped after each duct is inserted and rotated.
• Check the correct positioning of the fil-
ter, making sure that the arrow printed
on it is directed toward the steering
clutch.
Checking the valve clearance

• Remove the fuel tank and the radiator.
• Disconnect the coils and remove the spark plugs.
• Remove the covers from the heads and measure the distance between the camshaft nose
cone and the valve tappets using a feeler gauge.
• make a note of the measurement
Characteristic
Intake valve clearance
0.10 - 0.15 mm (0.0039 - 0.0059 in)
MAIN - 72
Exhaust valve clearance

0.15 - 0.20 mm (0.0059 - 0.0078 in)
If the valve clearance is out of tolerance, carry

out the adjustment procedure, as follows:
• Position the front cylinder at TDC.

• Remove the cam tower by unscrewing
and removing the 8 fastening screws in
the order indicated on the cam tower
itself.
• Secure the cam shafts in position using

the dedicated timing pins.
Specific tooling
020719Y Timing pin
• Remove one cam shaft at a time

• leave the other camshaft in position
and secured by the timing pin.
CAUTION
IF BOTH CAMSHAFTS ARE REMOVED AT THE SAME
TIME, THE ENGINE COULD ROTATE, RENDERING IT NEC-
ESSARY TO RETIME IT.
MAIN - 73
• Extract the bucket tappets.

NOTE
EACH TIME THE BUCKET TAPPETS ARE EXTRACTED,
ENSURE THE COMPONENT IS ADEQUATELY GREASED.
• Replace the calibrated pad with a pad

having suitable thickness to compen-
sate for the valve clearance measured
earlier.
• List of calibrated pads:
1. Calibrated pad 2.50

10.Calibrated pad 2.95
• if it is necessary to adjust the valve clearance on the rear big end, repeat the procedure
described above.
CAUTION
BEFORE REMOVING THE BIG END COVERS, CAREFULLY CLEAN THE SURFACES OF THE BIG
END AND THE COVER.
CAUTION
MAIN - 74
REPLACE THE FOUR RUBBER INSERTS AND THE GASKET EACH TIME THE BIG END COVER
IS REMOVED.
• Apply THREEBOND around the perim-
eter of the big end cover along the
gasket housings.
• Apply THREEBOND to the head at the

points indicated in figure.
MAIN - 75
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

SHIVER 900 Electrical system
FRONT ELECTRICAL SYSTEM

1 Flanged, hex. head screws for fas- M6x20 2 10 Nm (7.38 lb ft) -
tening the voltage regulator to the
frame
2 Flanged SWP screws for fastening M5x20 4 2.5 Nm (1.84 lb ft) -
the control unit to the base of the filter
box
3 Screws used for fastening the coils to M6 2 5 Nm (3.69 lb ft) -
the heads
4 Nut used for fastening the power M6 1 10 Nm (7.38 lb ft) -
supply cable to the starter motor
5 Horn fixing screw M6x25 1 10 Nm (7.38 lb ft) -
ELE SYS - 77
Electrical system SHIVER 900
REAR ELECTRICAL SYSTEM

for fastening the anti-rollover sensor
ELE SYS - 78
Components arrangement
Key
1. Engine speed sensor

2. intake air pressure sensor
3. Intake air temperature sensor
4. Instrument panel
ELE SYS - 79
5. Air temperature sensor for instrument panel indication

6. Headlamp
7. Starter relay
8. Coils
9. Spark plugs
10.Starter motor
11.Taillight
12.Secondary fuses
13.Main fuses
14.Handle position sensor
15.Gearbox in neutral sensor
16.Rpm sensor - pick up
17.Engine temperature sensor
18.Throttle valve management control unit
19.Lambda probe
20.Fall sensor
21.Main injection relay
22.Engine control unit
23.Front speed sensor
24.Rear speed sensor
25.Electronic control unit
THE IDENTIFICATION OF THE RELAY CANNOT BE CARRIED OUT JUST ON THE BASIS OF THE
INDICATIONS BELOW: IN ANY EVENT IT SHOULD OCCUR WITH THE IDENTIFICATION OF THE
COLOUR OF THE RELAY CABLES.
RELAY LAYOUT
Location of the Component name Position on the vehicle:
component in the
electrical circuit
diagram
7 High beam lights relay Right front side of the filter housing
8 Light relay Right front side of the filter housing
17 Main injection relay Left front side of the filter housing
31 Start-up relay Left front side of the filter housing
35 Secondary injection relay Right front side of the filter housing
38 Fan control relay Left front side of the filter housing
Electrical system installation

INTRODUCTION
Scope and applicability
The position of the wiring harnesses, how they are fixed to the motorcycle and potential problems are
defined on the following sections in order to reach the objectives of vehicle reliability.
ELE SYS - 80
Motorcycle division
The wiring timing is subdivided in three essential
sections, as indicated in the figure.
1. Front section
2. Central section
3. Rear section
SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES

Once the electrical system has been replaced, the connectors have been reconnected and the
various clamps and fasteners have been repositioned, carry out the checks described below.
• Check that the following connectors have been connected correctly and that appropriate
tightening torque has been applied when securing them to the connector block.
1. Instrument panel connector: FRONT SECTION - TABLE B4.

2. Ride By Wire Connector: CENTRAL SECTION - TABLE A4.
3. Timing sensor connector: CENTRAL SECTION - TABLE M2.
4. Side stand switch connector: CENTRAL SECTION - TABLE O2
5. Voltage regulator connector: CENTRAL SECTION - TABLE M2-M3.
6. Front cylinder coil and rear cylinder coil connectors: ENGINE, TABLE A12.
7. Main wiring harness connector: CENTRAL SECTION - TABLE A1.
8. Control unit connector: ENGINE, TABLE A14.
9. Earth: CENTRAL SECTION, TABLE B
10.Fuel pump connector: CENTRAL SECTION, TABLE B.
11.Key Connector - RH Column light switch connectors - LH Column light switch connectors: Con-
nectors housed inside the hood behind the radiator: FRONT SECTION - TABLE A3
12.ABS control unit connector.
13.Front and rear speed sensor connectors: FRONT SECTION, TABLE C3 and REAR SECTION,
TABLE A3
14.Secondary fuses (correct position)
• THE LISTED CONNECTORS ARE CONSIDERED TO BE THE MOST CRITICAL IN COM-

PARISON WITH ANY OTHER BECAUSE THE VEHICLE WILL STOP IF THEY ARE
ACCIDENTALLY DISCONNECTED.
• Undoubtedly the connection of the rest of connectors is also important and essential for the
correct operation of the vehicle.
ELE SYS - 81
Front side
TABLE A - COLUMN LIGHT SWITCH / RIDE BY

WIRE
• Route the right hand column switch (1)

and Ride by Wire gas control grip (2)
wiring harness behind the front brake
pipe (3).
• Route the left hand column switch wir-
ing (4) behind the clutch pipe (5).
TABLE A1 - COLUMN LIGHT SWITCH / RIDE BY

WIRE
• The wiring harnesses must be routed

to the left of the steering headstocks, in
particular column switch wiring har-
nesses must subsequently be routed
underneath the headstock so that are
fed out of the right hand side of the mo-
torcycle.
1) RH column light switch wiring harness.

2) GAS control grip wiring harness.
4) LH column light switch wiring harness.
6) Immobilizer antenna wiring harness.
ELE SYS - 82

WIRE
• Secure the various wiring harnesses

using a rubber clamp (7).

WIRE
• Connect the connectors and insert

them in the safety cap (8).
• Using a clamp (9), secure the various
wiring harnesses as indicated, and
then position the connectors assembly
under the steering headstock, inside
the frame.

WIRE
• The Ride By Wire gas control connec-

tor must be connected correctly and
fastened to the edges support (10),
while the wiring harness must be fas-
tened to the edges support (12) using
a clamp (11).
ELE SYS - 83
TABLE B - INSTRUMENT PANEL
• The clutch switch wiring harness (1),

which may be identified by the grey
tape, and the front stop switch wiring
harness (2) must be routed over the
column switch wiring harness and the
brake/clutch pipes.
TABLE B1 - INSTRUMENT PANEL
• The front indicator cables (3) must be

routed as shown in the photo in order
to avoid pinching when the front head
light is fastened to the steering plate.
ELE SYS - 84
• After fastening the ambient air temper-

ature sensor (4) and securing the re-
spective wiring harness (5), route the
wiring harness behind the instrument
panel support (7) using a clamp (6).
• Position a clamp (8) on the instrument

panel in order to fasten the various wir-
ing harnesses.
• After connecting the ambient air tem-

perature sensor, the USB option con-
nector (9), the instrument panel con-
nector (10), the indicator connectors
(11) and the immobilizer antenna con-
nector (12), close the clamp that was
positioned on the support earlier.
ELE SYS - 85
TABLE C - FRONT ABS SENSOR
• using the cable clamp (1) fasten the

ABS sensor (3) wiring harness (2) and
route it through the hole on the right
hand fork foot.
TABLE C1 - FRONT ABS SENSOR
• Fasten the ABS sensor wiring harness

at the rear mudguard fastening point,
using a clamp (4).
ELE SYS - 86
• Fasten the ABS sensor wiring harness

to the brake pipe using the cable
clamps (5) and two clamps (6), under
the lower steering plate and in align-
ment with the brake pipe fastening
plate, under the steering headstock.
• Check that the front ABS sensor con-

nector is inserted correctly and cou-
pled to the respective support posi-
tioned under the filter box.
Central part
CAUTION
THE FOLLOWING IMAGES ILLUSTRATE THE MAIN/ENGINE WIRING HARNESS INSTALLED ON
THE ENGINE, COMPLETE WITH THE FILTER BOX. IF NECESSARY, WHEN CARRYING OUT
MAINTENANCE WORK, THE WIRING HARNESS MUST BE INSTALLED AFTER POSITIONING
THE ENGINE ON THE FRAME.
ELE SYS - 87
TABLE A - MAIN WIRING HARNESS - ENGINE

WIRING HARNESS
• The main wiring harness (1) must be

positioned on the right hand side of the
motorcycle/engine, as indicated
TABLE A1 - MAIN WIRING HARNESS - ENGINE

WIRING HARNESS
• The connector that units main wiring

harness (1) with the engine wiring har-
ness (2) must be inserted correctly,
making sure that the purple shoe is
pushed in as far as it will go.
ELE SYS - 88

WIRING HARNESS
• Connect the main wiring harness (1) to

the engine wiring harness (2) using a
clamp (3) at the point indicated by the
grey tape.

WIRING HARNESS
• Secure the main wiring harness (1) us-

ing two clamps (4) on the cannister
support, at the point indicated by the
grey tape.
ELE SYS - 89
TABLE B - ENGINE EARTH
• It is important to respect the output di-

rection of the battery earth (1), main
wiring harness earth (2) and engine
wiring harness earth (3) cables.
• After fitting an elastic washer and the
appropriate screw, tighten the latter,
applying the pre-defined torque.
CAUTION
IF THE SCREW IS NOT FASTENED CORRECTLY IT MAY

CAUSE THE VEHICLE TO CATCH FIRE
TABLE C - RELAYS ON FILTER BOX
• Arrange the relays on the right hand

side of the filter box, in accordance with
the coloured reference indicators.
• The highbeam headlight relay (1),
identified by the white tape, must be
secured to the respective fastening
point using the rubber support.
• The headlight relay (2), identified by
the red tape, must be secured to the
respective fastening point using the
rubber support.
• The secondary injection relay (3), iden-
tified by the blue tape, must be secured
to the respective fastening point using
the rubber support. The wiring harness
must be routed behind the blow-bay
vapour recovery pipe.
TABLE C1 - RELAYS ON FILTER BOX
ELE SYS - 90
• The main injection relay (4), fan control relay (5) and starter relay (6), which are located on
the left hand side of the filter box, must be secured to their respective fastening points using
the rubber supports.
TABLE D - STARTER MOTOR CABLE
• The starter motor power supply cable

lug (1) must be fastened to the starter
motor using two electric washers (2)
and secured using serrated washer,
TABLE D1 - STARTER MOTOR CABLE
• Cover the starter motor nut and the

square terminal using water-repellent,
dielectric grease.
• If the starter motor cable is not routed
or fastened correctly, it may cause the
vehicle to catch fire.
TABLE E - OIL PRESSURE BULB
• Check that the terminal is connected

and that the hood is inserted in the bulb
correctly, and apply a clamp so that
cap leg is bent by 180°, as illustrated.
ELE SYS - 91
TABLE F - PRE-ASSEMBLING THE ABS SUP-

PORT BRACKET
• Pre-assemble the supports (1) for the

connectors on the ABS support brack-
et (2) and the seal (3).
TABLE G - PROCEDURE FITTING THE ABS CONTROL UNIT CONNECTOR CORRECTLY
• The initial position of the connector coupling lever must be as indicated in the figures.
TABLE G1 - PROCEDURE FITTING THE ABS

CONTROL UNIT CONNECTOR CORRECTLY
• Place the connector on the opposite

side of the control unit and lower the
driving lever until the "click" that signals
the end of the stroke is heard.

• When the connector has been inserted

fully, the distance measured between
it and the ABS control unit must be 7.5
mm
ELE SYS - 92

• If the initial position of the lever is not

as indicated in the "TABLE G", the con-
nector will not couple correctly and the
distance measurement will be greater
(approx. 12 mm).
• In this case, repeat the operation de-
scribed in "TABLES G1/G2"
• We recommend creating a template in
order to ensure that the connector is
inserted correctly.
TABLE H - ABS CONTROL UNIT
• After making sure that the ABS control

unit (2) connector (1) has been inser-
ted correctly, fasten the wiring harness
(3) to the brake pipes using two clamps
(4).
ELE SYS - 93
TABLE H1 - ABS CONTROL UNIT
• The wiring harness (3) must be routed

behind the brake pipes, as indicated.
TABLE I - OIL TEMPERATURE SENSOR
• Connect the oil temperature sensor

connector (1) to the corresponding
connector on the intermediate wiring
harness (2) and attach it to the dedica-
ted support mounted on the ABS sup-
port bracket.
ELE SYS - 94
TABLE I1 - OIL TEMPERATURE SENSOR
• Connect the intermediate wiring har-

ness connector (2) to the correspond-
ing connector on the main wiring
harness (3), which must be attached to
the dedicated support mounted on the
base of the filter box.
TABLE L - FAN
• Connect the fan connector to the water

radiator using a large clamp.
TABLE M - VOLTAGE REGULATOR/TIMING

SENSOR
• After fastening the voltage regulator (1)

to the frame, secure the "timing sensor
regulator" wiring harness (2) and the
"main wiring harness regulator" wiring
harness (3) using a clamp (4).
ELE SYS - 95
TABLE M1 - VOLTAGE REGULATOR/TIMING

SENSOR
• The voltage regulator wiring harnesses

must be routed internally through the
frame, as indicated.

SENSOR
• The timing sensor regulator connector

must be connected correctly and fas-
tened to the support (5) inserted on the
control unit cover.
ELE SYS - 96

SENSOR
• The main wiring cabinet regulator con-

nector must be connected correctly
and positioned above the timing sen-
sor regulator connector.
TABLE N - HORN
• The horn must be fastened to its sup-

port bracket and, once its connectors
have been inserted, must not be in con-
tact with any other component.
TABLE O - SIDE STAND
• After fastening the side support strut to

the stand support, secure the sensor
(1) wiring harness using a clamp (2).
ELE SYS - 97
TABLE O1 - SIDE STAND
• Install the side stand and route the side

strut sensor wiring harness (1) as indi-
cated, fastening it to the gear sensor
(4) wiring harness using a clamp (3).
• Check that the side stand connector (5)

is connected correctly and fasten the
wiring harness to the flywheel wiring
harness cable clamp using a clamp (6).
• After twisting the wiring harness, feed

it into the cavity inside the frame.
ELE SYS - 98
TABLE P - FRONT LAMBDA PROBE
• Connect the front lambda probe con-

nector (1) correctly, then fasten it to the
cable clamp pre-installed on the ABS
control unit support .
TABLE P1 - FRONT LAMBDA PROBE
• Using a clip (2), fasten the lambda

probe wiring harness to the ABS con-
trol unit support.
TABLE P2 - FRONT LAMBDA PROBE
• Using a clip (3), fasten the lambda

probe wiring harness (4) to the ABS
control unit support.
ELE SYS - 99
TABLE Q - REAR LAMBDA PROBE
• Connect the rear lambda probe con-

nector correctly, then secure the probe
wiring harness (2) using a clip (1).
TABLE Q1 - REAR LAMBDA PROBE
• Using a clip (3), fasten the rear lambda

probe wiring harness (2) to the saddle
support frame.
Back side
TABLE A - REAR BRAKE SWITCH-REAR ABS
SENSOR
• Secure the rear ABS sensor wiring har-

ness (1) using the cable clamp (2)
mounted on the brake calliper support.
TABLE A1 - REAR BRAKE SWITCH-REAR ABS SENSOR

• Secure the ABS sensor wiring harness (1) to the rear brake pipe (3) using the cable clamp
(4), and then route it through the plastic cable clamp (5) mounted on the swingarm.
ELE SYS - 100

TABLE A2 - REAR BRAKE SWITCH-REAR ABS

SENSOR
• Secure the rear ABS sensor (1) and

rear brake switch (7) wiring harness to
the rear brake pipes (3) using the
clamps (6).
TABLE A3 - REAR BRAKE SWITCH-REAR ABS

SENSOR
• Check that the rear ABS sensor con-

nector is connected securely and posi-
tioned underneath the main wiring
harness.
TABLE B - MAIN SADDLE SUPPORT WIRING

HARNESS
• Fasten the main wiring harness (1) to

the saddle support frame using two
clamps (2).
ELE SYS - 101

TABLE B1 - MAIN SADDLE SUPPORT WIRING

HARNESS
• The main wiring harness (1) must be

routed under saddle support frame
crossbar.
TABLE C - STARTER RELAY
• Check that the two screws used for

fastening the cables are secured cor-
rectly. Failure to secure them correctly
may result in fires and vehicle malfunc-
tions.
TABLE D - SADDLE SUPPORT ZONE
• Position a large clamp (1), and then,

after connecting the read light assem-
bly connector (2), position it as indica-
ted.
ELE SYS - 102

TABLE D1 - SADDLE SUPPORT ZONE
• After connecting the license plate light

connector (3) and positioning it above
the rear light assembly connector (2),
fasten the wiring harnesses to the rear
grab bar using a clamp (4).
• Position the fall sensor (5) and after

connecting the connector, close all the
connectors that were positioned earli-
er.
• Insert the AMP (Aprilia Multimedia

Platform) connector (6) in the dedica-
ted space and the main fuse (7), con-
necting it to the support saddle sup-
port.
ELE SYS - 103

• Position the secondary fuses (8), cou-

pling the rubber support to the tabs
present on the saddle support.
• fasten the branch of the main wiring
harness (9) using two clamps (10). Po-
sition the ABS fuse (11) and the re-
programming connector (12) in the
respective housings.
• After positioning the relay on its base

and connecting it, bend the cables that
leave the connector by 90° in order to
create an "S", as illustrated.
• After fastening the plastic cover that

hides the various connections, check
that the "Red White" starter relay ca-
bles are not in contact with the plastic
at the point indicated.
ELE SYS - 104

TABLE E - NUMBER PLATE HOLDER
• Fasten the direction indicator and li-

cense plate light wiring harnesses to
the number plate holder frame using
two clamps.
TABLE E1 - NUMBER PLATE HOLDER
• Make sure that the anti-vibration foam

is fitted on the number plate light.
Engine
TABLE A - ENGINE WIRING HARNESS ON

THROTTLE BODY AND FILTER BOX
• Fasten the engine wiring harness (1),

centring it under the conduit (2) using
the grey reference points.
ELE SYS - 105

TABLE A1 - ENGINE WIRING HARNESS ON

• Route the branch with the throttle body

connections through the lateral open-
ing.

• Connect the front injector (3 - green)

and rear injector (4 - black) connectors.

• After fastening the throttle body to the

base of the filter box, connect the cyl-
inder pressure sensors (5) and the
throttle body connectors (6).
CAUTION
THE FRONT THROTTLE BODY AND FRONT CYLINDER
PRESSURE SENSOR WIRING HARNESSES ARE MARKED
WITH THE INDICATION "FRONT", WHILE THE REAR
THROTTLE BODY AND REAR CYLINDER PRESSURE
SENSOR WIRING HARNESSES ARE MARKED WITH THE
INDICATION "REAR",
INVERTING THESE CONNECTORS WOULD RESULT IN
MOTORCYCLE MALFUNCTIONS.

• Fasten the wiring harness to the throt-

tle bodies connection bracket inside
the filter box using two clamps (7), at
the points identified by the grey tape.
ELE SYS - 106


• Fit the filter box side cover, position the

engine wiring harness (1) using the
grey reference point that can just be
distinguished from outside the cover.

• Connect the engine wiring harness

connector (8) to its support (9) and
check that it has been coupled correct-
ly to the base of the filter box.

• Connect the coil wiring harnesses to

the filter box, using the clamps (10)
positioned at the points indicated by
the grey tape.
CAUTION
THE CLAMPS POSITIONED ON THE LOWER PART OF THE
FILTER BOX MUST BE MOUNTED SO THAT THE "HEAD"
IS FACING DOWNWARDS AND RESTING AGAINST THE
WALL OF THE FILTER BOX.

• Take care to position the branch from

the wiring harness next to the connec-
tor and not externally.
TABLE A9 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX
• Attach the cable clamp (11) already mounted on the coil wiring harnesses to the base of the
filter box, in correspondence with the holes.
ELE SYS - 107


• Install the air temperature sensor (12)

and connect it to the engine wiring har-
ness.

• After reassembling the filter box, com-

plete with air filter and intake ducts, and
before inserting it, connect the water
temperature sensor connector (13).
TABLE A12 - ENGINE WIRING HARNESS ON THROTTLE BODY AND FILTER BOX
• Connect the coil connectors (14) and attach them to the supports positioned on the base of
the filter box.
ELE SYS - 108


• Route the flywheel wiring harness (15)

under the tab on the control unit sup-
port box.

• Connect control unit connectors (16)

and apply a clamp (17) on the small
connector so that the wiring harness
remains inside the support box.
ELE SYS - 109


• After connecting the gear sensor con-

nector (18), attach it to the support on
the base of the filter box (19).
• Using a clamp (20), fasten the fly-
wheel, gear sensor and side stand
switch wiring harnesses together.
ELE SYS - 110

General wiring diagram
Key:
1. MULTIPLE CONNECTORS
2. FRONT RIGHT TURN INDICATOR
3. COMPLETE HEADLAMP
4. FRONT LEFT TURN INDICATOR
ELE SYS - 111

5. LOW BEAM LIGHT BULB

6. FRONT POSITION LIGHT BULB
7. HIGH BEAM LIGHT RELAY
8. LIGHTS RELAY
9. HORN
10.LEFT LIGHT SWITCH
11.STOP/POSITION BULB
12.INSTRUMENT PANEL
13.FRONT STOP SWITCH
14.REAR STOP SWITCH
15.CLUTCH SWITCH
16.IGNITION SWITCH
17.MAIN INJECTION RELAY
18.IMMOBILIZER ANTENNA
19.REAR LEFT TURN INDICATOR
20.REAR RIGHT TURN INDICATOR
21.LICENCE PLATE LIGHT
22.TAILLIGHT
23.INSTRUMENT PANEL FUSE
24.SECONDARY FUSES
25.ABS CONTROL UNIT
26.FRONT ABS SENSOR
27.REAR ABS SENSOR
28.VOLTAGE REGULATOR
29.ALTERNATOR
30.STARTER MOTOR
31.START-UP RELAY
32.ABS CONTROL UNIT FUSE
33.MAIN FUSE
34.BATTERY
35.SECONDARY INJECTION RELAY
36.OIL PRESSURE SENSOR
37.FAN
38.FAN CONTROL RELAY
39.RIGHT LIGHT SWITCH
40.BLUEDASCH SET-UP (OPTIONAL)
41.FUEL RESERVE SENSOR
42.FUEL PUMP
ELE SYS - 112

43.USB PORT (OPTIONAL)

44.DIAGNOSTICS SOCKET
45.FALL SENSOR
46.SIDE STAND SWITCH
47.GEAR SENSOR
48.REAR CYLINDER PRESSURE SENSOR
49.FRONT CYLINDER PRESSURE SENSOR
50.REAR CYLINDER MOTORISED THROTTLE VALVE
51.FRONT CYLINDER MOTORISED THROTTLE VALVE
52.INTAKE AIR TEMPERATURE SENSOR
53.WATER TEMPERATURE SENSOR
54.7SM ENGINE CONTROL UNIT
55.HANDLE POSITION SENSOR
56.ENGINE SPEED SENSOR
57.FRONT CYLINDER COIL
58.REAR CYLINDER COIL
59.SPARK PLUG
60.FRONT CYLINDER INJECTOR
61.REAR CYLINDER INJECTOR
62.REAR CYLINDER LAMBDA PROBE
63.FRONT CYLINDER LAMBDA PROBE
64.HIGH BEAM LIGHT BULB
65.AIR TEMPERATURE SENSOR
66.OIL TEMPERATURE SENSOR
Colour key:
Ar Orange
Az Light blue
B Blue
Bi White
G Yellow
Gr Grey
M Brown
N Black
R Red
Ro Pink
V Green
Vi Violet
ELE SYS - 113

Conceptual diagrams
Checks and inspections
GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS
THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC-

TORS; NOTE THAT THE DRAWING ALWAYS DEPICT THE CONNECTOR/COMPONENT VIEWED
FROM THE WIRING HARNESS SIDE, I.E. FROM THE SIDE ON WHICH THE CABLES LEADING
FROM THE MAIN WIRING HARNESS ENTER THE CONNECTOR/COMPONENT.
CAUTION
BEFORE STARTING ANY TROUBLESHOOTING PROCEDURES ON THE VEHICLE, CHECK THAT
THE BATTERY VOLTAGE IS ABOVE 12V.
CONNECTOR CHECK PROCEDURE
The procedure includes the following checks:
1. Observation and check of the connector correct
position on the component or on the coupling con-
nector, making sure that the locking catch is re-
leased.
2. Observation of the terminals on the connector:
no rust marks or dirt should be present and it is
important to check terminal correct positioning on
the connector (i.e., all terminals aligned at the
same depth) and terminal integrity (i.e., that termi-
nals are not loose, open/bent, etc.). For connec-
tors whose terminals are not visible (e.g. Marelli
control unit) use a metal cable of suitable diameter
and introduce it carefully in the connector slot at
the same depth as for the other terminals of the
connector.
CAUTION
IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE
THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PER-
FORMING EACH OF THE CHECKS INDICATED FOR TROU-
BLESHOOTING.
3. Pull cables gently from the back of the connector to check that the terminals are fitted correctly on
the connector and that the wires are fastened correctly to the terminals.
Checking electrical CONTINUITY
Purpose of check: the purpose of this check is ensure that there are no interruptions or excess re-
sistance (due to corroded terminals, for example) in the circuit under inspection.
Tester: set the tester selector to the "continuity" symbol and place the probes of the tested at the two
ends of the circuit. Normally, the tester will sound an audible signal to confirm continuity in the section
ELE SYS - 114

of circuit tested. Continuity may also be tested by setting the tester selector to the "Ohm" symbol and
checking that the resistance in the circuit is zero or of a few tenths of an Ohm.
IMPORTANT: THE CIRCUIT MUST BE UNPOWERED DURING THIS TEST. IF THE CIRCUIT IS
POWERED, THE RESULTS OF THIS TEST ARE MEANINGLESS.
Checking GROUND CONNECTION
Purpose of check: the purpose of this check is to verify that a cable or circuit is correctly connected
to the ground (-) of the vehicle.
Tester: set the tester selector to the "continuity" symbol and place one of the tester probes on the vehicle
ground point (or on the battery negative pole) and the other probe on the cable under inspection. Nor-
mally, the tester will sound an audible signal to confirm continuity in the section of circuit tested.
Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the
resistance in the circuit is zero or of a few tenths of an Ohm.
IMPORTANT: WHERE GROUND IS PROVIDED BY THE ECU, CHECK THAT THE ECU IS EFFEC-
TIVELY PROVIDING THE GROUND CONNECTION FOR THE CIRCUIT DURING THE TEST.
Checking VOLTAGE
Purpose of check: the purpose of this check is to determine if a cable is carrying voltage, in other
terms, to verify whether it powered by the battery or ECU.
Tester: set the tester selector to the "DC voltage" symbol and place the red tester probe on the cable
under inspection and the black tester probe on the vehicle ground point (or on the battery negative
pole).
CAUTION
IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS
SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOT-
ING.
Immobiliser
System components
Function
detects the transponder code in the key and sends
it to the instrument panel
Level in electrical circuit diagram:
Immobilizer
Position:
• on the vehicle: in the ignition switch as-

sembly
• connector: two way, grey colour, be-
hind the instrument panel
ELE SYS - 115

Electrical specifications
• 14 Ohm
Pin out
1. Grey colour, from the instrument panel to the
antenna - Section 0.5
2. Grey colour, from the instrument panel to the
antenna - Section 0.5
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
INSTRUMENT PANEL: ERRORS

B0003 Immobilizer fault
• key code read but not recognised
Error cause
• The read code is not stored in the instrument panel memory
Troubleshooting
• Carry out key data storage procedure

• read key code not read (key not present or transponder not working)
Error cause
• Key transponder does not communicate its own code
Troubleshooting
• Replace the key

• Immobilizer fault: aerial not working (open or short-circuited)
Error cause
• An electric interruption or a ground short circuit or voltage to the circuit have been detected
Troubleshooting
• Check the sensor connector on the cable harness and the instrument panel connector. If
not OK, restore; if OK, check electrical characteristics and aerial circuit continuity from the
instrument panel connector on PIN 2 and 3: if not OK, restore cable harness; if OK, check
circuit ground insulation: if not ground insulated, restore cable harness; if insulated, with key
ON, with instrument panel connector disconnected, check that there is not voltage at the
circuit ends: if there is voltage, restore the cable harness
B0006 Internal controller fault
ELE SYS - 116

Error cause
• There is a fault in the instrument panel
Troubleshooting
• Replace the instrument panel
System not programmed
Storing new keys

NOTE
REGARDLESS OF THE LANGUAGE SET IN THE DASHBOARD FUNCTIONS, THE KEY PRO-
GRAMMING PROCEDURE CAN ONLY BE VIEWED IN ENGLISH.
• To carry out the one or more key pro-
gramming procedures, up to a maxi-
mum of four, you must connect the
motorcycle to the diagnostic tool.
• Turn key to "ON" and insert the USER
CODE where required.
• Carry out the self-diagnosis of the
dashboard and enter the "SETTINGS"
section by clicking on "RESET KEYS".
• At this point, a screen with a warning

message will be visible. Press "OK"
and start programming the keys.
NOTE
IF THE IMMOBILIZER ANTENNA IS DISCONNECTED, YOU
WILL NOT BE ABLE TO START KEY PROGRAMMING.
• Enter the USER CODE to continue.

• If the code entered is correct, the first
key is stored.
ELE SYS - 117

• At this point, on the digital display of the

motorcycle, after the automatic restart
of the dynamic presentation screen, a
message will appear with a countdown
of 20 seconds to insert the second key
to be programmed.
• Set key to "OFF", insert the second key
and set to "ON".
CAUTION
IF YOU DO NOT HAVE A SECOND KEY OR YOU DON'T
WANT TO STORE ONE, THE DIAGNOSTIC TOOL WILL
SHOW AN ERROR SAYING "1 KEY STORED"
• The second key is stored and you will

be asked to enter the third key (if you
have one). The same operation will be
repeated to store the fourth key.
• To complete AND end the memorisa-
tion procedure, set key to "OFF".
• You should then test the correct func-
tioning of all keys stored.
Diagnosis
• In case of malfunction of certain or-

gans, the digital display of the instru-
ment panel may display errors. To
check and diagnose the specific com-
ponent, check the dedicated section.
ELE SYS - 118

Azzeramento icona manutenzione
The system displays the function as follows:
• After the maintenance interval thresh-

olds are exceeded (excepting the first),
an icon with the adjustable wrench is
shown on the digital display.
To reset Service proceed as follows:
• Connect the diagnostic tool;

• Select the concerned model;
• Enter in the "INSTRUMENT PANEL"
section;
• Select "SELF-DIAGNOSIS";
• Select "ACTIVATIONS";
• Enable the command "SERVICE RE-
SET".
Battery recharge circuit
RECHARGING SYSTEM
• Remove the tank and the filter casing;

• Disconnect the three-way connector
(1) (white).
NOTE
THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A"
Measurement of resistance (with engine off)
• For a correct detection of the alternator

resistance, an ambient temperature
measurement must be carried out and
afterwards a heat stabilisation (after
turning fan on) by using a tester, using
alternatively the 3 connector pins:
stage "1" (pin 1-2), stage "2" (pin 1-3),
stage "3" (pin 2-3).
ELE SYS - 119

• Take the measurement; The correct value is determined by the value measured for each
stage in which from time to time the resistance of the tester wires is subtracted, obtained by
touching the two lugs.
Example:
• Resistance of stage 1 read on the display = 0.65 Ohm
• Resistance of the wires read on the display = 0.47 Ohm
• Effective resistance stage 1 = 0.65-0.47 = 0.18 Ohm
• If there is a significant difference between one stage and another (other than 0.15 Ohm),
this means that the alternator is defective and must be replaced.
ELE SYS - 120

RESISTANCE MEASUREMENT
Winding stage Ambient temperature (ohm) Afterwards heat stabilisation (ohm)
Stage 1 0.15 - 0.20 0.18 - 0.23
Stage 2 0.15 - 0.20 0.18 - 0.23
Stage 3 0.15 - 0.20 0.18 - 0.23
Zero load voltage
• Disconnect the three-way connector (1);

• For a correct detection of the alternator voltage, a measurement must be carried out using
alternatively the 3 engine side connector pins: stage "1" (pin 1-2), stage "2" (pin 1-3), stage
"3" (pin 2-3)
• Take the measurements;
• If there is a significant difference between one stage and another (other than 15 V), this
means that the alternator is defective and must be replaced.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE
DETECTED WITH THE ENGINE COLD.
EMPTY VOLTAGE
rpm 2000 6000 8000
Vm linked voltage Reference values (V rms) 20 - 30 75 - 85 95 - 105
Short-circuit current
• For a correct detection of the short-cir-

cuit current, a connector must be pre-
pared that generates a downstream
short circuit between the three alterna-
tor cables;
• Start the engine and with an ammeter
clamp measure each single cable.
• If there is a significant difference be-
tween the measure of the single cables
(other than 10 A), this means that the
alternator is defective and must be re-
placed.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE
ON AVERAGE 2-3 A LESS THAN THOSE DETECTED WITH
THE ENGINE COLD.
WARNING
NEVER KEEP THE ENGINE RUNNING FOR MORE THAN
ONE MINUTE; FAILURE TO DO SO COULD CAUSE SERI-
OUS OVERHEATING DAMAGES TO THE MOTORCYCLE
CIRCUITS.
ELE SYS - 121

COLD SHORT CIRCUIT CURRENT

RPM 2000 4000 6000 8000
RMS DC current (Arms) (average of the 3 stage 26 - 31 26 - 31 26 - 31 26 - 31
currents)
Voltage on battery poles with engine speed always between 3000 - 5000 RPM
• Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM,
then measure with a tester the voltage at the battery poles that must always be between
13V and 15V. Otherwise, if the correct operation of the alternator has already been checked,
replace the regulator.
CAUTION
PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION (START
VOLTAGE ABOUT 13V) MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIR-
CUIT.
Start-up system check
Function
Communicates to the control unit the will to start-
up the engine.
Operation / Operating principle
Press the start-up button to close the specific cir-
cuit taking the PIN 58 of the control unit to a voltage
equal to zero (ground closing).
Start enable switches
Position:
• on the vehicle: Right hand light switch.

• connector: behind the steering head-
stock, inside the protection case (black
colour, 4 way).
Electrical specifications:
• key released: open circuit

• key pressed: closed circuit
Pin out:
1. - Green/pink colour from the RH lights switch to
the clutch switch - Section 0.5
2. Voltage + 5V - Pink/Brown colour from the RH
lights switch to 7SM control unit PIN 58 (engine
start) - Section 0.5
ELE SYS - 122

3. Ground - Green/pink colour from the engine to

the clutch switch - Section 0.5
4. - Yellow/pink colour from the RH lights switch to
the 7SM control unit PIN 78 (engine stop) - Section
0.5
CAUTION
DIAGNOSTIC TOOL: ELECTRICAL ERRORS

P0615 Starter relay
• short circuit to positive / open circuit, short circuit to negative.
Error cause
• Short-circuit to positive: excessive voltage identified at PIN 69, at the command time; If open
circuit, short circuit to negative: a voltage close to zero was identified when there is no
command to the start-up relay.
DIAGNOSTIC TOOL: LOGIC ERRORS

P0512 Starter switch
• signal not plausible.
Error cause
• Fault in the switch (lock) of the engine start-up. A continuous voltage close to 0 was detected
for a certain time (e.g. locked button).
• The instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting
• Check the locking cause and restore.
Lights list
Front headlamp
Characteristic
Front daylight running light
12V - 5W x 2
Low beam light
12 V - 55 W H7
High beam light
12 V - 55 W H7
ELE SYS - 123

Rear light
Characteristic
Rear daylight running light /stop light
12V - 5/21W x 2
Fuses
It is necessary to check the fuses whenever an electrical component fails to operate or malfunctions or
when the engine does not start.
Check the auxiliary 15A fuses first, then the main 30A fuse.
CAUTION
DO NOT ATTEMPT TO REPAIR FAULTY FUSES.

NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES
TO THE ELECTRICAL SYSTEM OR SHORT CIRCUITS, AND THE RISK OF FIRE.
NOTE
A FUSE THAT BLOWS FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD.
SECONDARY FUSES
Before replacing the fuse, find, if possible, the
cause of the problem.
To check the secondary fuses:
• To avoid an accidental short-circuit,

place the power switch to "OFF".
• Remove the rider saddle.
• Open the cover of the secondary fuse
box (1).
• Take out one fuse at a time and check
whether the filament (2) is broken. In
this case change the fuse with one of
the same amperage.
NOTE
IF THE SPARE FUSE IS USED, REPLACE WITH ONE OF
THE SAME TYPE IN THE CORRESPONDING FITTING.
ELE SYS - 124

AUXILIARY FUSES DISTRIBUTION

A) 10A fuse Lights relay/high beam relay, buttons and brake lights/horn,
daylight running lights (front, rear)/license plate
B) 15A fuse ECU live positive lead
F) 7,5A fuse ECU permanent positive lead
D) 15A fuse Coils, injectors, fuel pump, secondary injection relay
E) 15A fuse Low beam/high beam lights
C) 7.5A fuse Fan
G) spare fuses -
Auxiliary fuses are placed in the central part of the motorcycle, under the rider saddle.
MAIN FUSES
To check the main fuse (H)
• Remove the protective cover (3), un-

screwing the two screws (4).
• Remove the protective cover, take out

the fuse (H) and check whether the fil-
ament (2) is broken. In this case
change it with one of the same amper-
age.
CAUTION
REMOVING THE 30A FUSE RESETS THESE FUNCTIONS
ON THE DASHBOARD:
To check the main fuse (L)

the fuse (L) and check whether the fil-
ament (2) is broken. In this case
change it with one of the same amper-
age.
ELE SYS - 125

To check the ABS fuse (I)

the fuse (I) and check whether the fila-
ment (2) is broken. In this case change
it with one of the same amperage.
MAIN FUSES DISTRIBUTION

H) 30A fuse Recharge, "F-D-C positive fuses", key positive, main relay, 5A
positive fuse (dashboard)
I) 20A fuse ECU ABS permanent positive
L) 5A fuse dashboard permanent positive
M) spare fuse -
The main fuses are located in the central part of the motorcycle, under the rider saddle.
Control unit
• To remove the control unit, refer to chapter " Bodywork", "Air filter housing" section.
CONTROL UNIT - Diagnosis

Function
It manages the Ride by wire system, the injection/
ignition, the system safety checks and the self-di-
agnosis function
Each level in which the main component involves
the control unit
Position:
• on the vehicle: to the left of the filter

housing
• connector: on the control unit connec-
tor from 52 PIN ENGINE, connector
from 28 PIN VEHICLE
Pin out:See CONNECTORS paragraph
DIAGNOSTIC TOOL:INFO
(screen page/example values with key ON)
• ISO code / -
• Drawing number / - (identified inserted by the manufacturer)
ELE SYS - 126

• HW number/ - (indicates the Hardware number)

• Approval number / -
• Author of the latest progr. / - (author of the latest programming)
• Mapping / - (indicates the mapping number)
• Programming date / - (control unit programming date)
• NIP code / - (internal code identifying the control unit)
• VIN / - (vehicle identification number
DIAGNOSTIC TOOL:PARAMETERS AND STATUSES
PARAMETERS:
• Engine rpm / - (engine rpm)

• Air temperature / - (indicates the air temperature)
• Water temperature/ - (indicates the water temperature)
• Throttle valve angle / - (throttle vale opening angle)
• Actuated advance / - (value of the real advance, seen from the control unit)
• Injection time / - (indicates the electric injector opening time)
• Battery voltage / - (indicates the battery voltage)
• Lambda probe control / - (indicates the lambda probe correction percent)
• Lambda probe voltage / - (indicates the value of the lambda probe voltage)
• Atmospheric pressure / - (indicates the atmospheric pressure)
• Objective minimum speed / - (minimum rpm required by the control unit)
• Stepper CI.Loop Opening / - (Stepper Closed Loop opening)
• Intake manifold pressure / - ( measure at the intake manifold)
• Scheduled advance / - (value of the desire advance for the control unit)
• Vehicle speed / - (indicates the actual speed of the vehicle)
• Lambda adaptive gain / - (lambda adaptive gain)
• Stepper equiv. throttle valve / - (stepper equivalent throttle valve angle)
• Base Stepper opening / - (base stepper opening)
• Stepper regulat. opening / - (stepper regulator opening)
• KON count / - (key ON count)
• Coil Dwell / -
• Injector bleed / -
STATUSES:
• Engine status / - (indicates the engine status)

• Throttle valve status / - (indicates if the throttle valve is open or closed)
• RUN - OFF switch / -
• Start enable / - (indicates if the control unit allows the start up)
• Ratio control status / -
ELE SYS - 127

• Lambda probe / - (indicates if the lambda probe is operating)

• Engine mode / -
• Tone wheel / - (tone wheel status)
• Ign. Activ. rec. status / - (ignition activation recognition status)
• Fan relay / - (status of the cooling fan relay)
• Engine stepper status / - (engine stepper status)
• Start-up request / -
• Clutch / -
• Gearbox in neutral / -
DIAGNOSTIC TOOL:ACTIVATIONS
• Coil / (coil actuator)

• Fuel pump / (fuel pump activation)
• Injector activation / (injector activation)
• Warning light / (warning light activation)
• Stepper circuit / (stepper circuit electric test)
• Fan activation / (fan connection activation)
• Headlights relay / (activates the headlight relay)
DIAGNOSTIC TOOL: ADJUSTMENTS

• Self-adaptive param. reset / (self-adaptive parameter reset)
• Saved data download / (save data files download)
• TPS reset
P0601 EEPROM error

Electrical diagnosis:
• Circuit not functioning
Error cause:
• Replace the injection control unit.
The instrument cluster indicates the presence of this error with the MI warning light on fixed.
NOTE
THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN.
P0604 RAM Error
Error cause:
ELE SYS - 128

NOTE
P0605 ROM Error
Error cause:
NOTE
P060B A/D converter
Error cause:
The instrument panel indicates this error by lighting up in a fixed manner the MI warning light and by
flashing the general warning light.
NOTE
P160C Level 2 safety reset

Error cause:
• Due to the fact that the level 2 safety system (comparison between requested torque and
calculated torque) detected a fault, the control unit reset the engine (severity C).
The instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting:
• Perform the troubleshooting for the other detected errors
P060C Safety Engine Stop

Error cause:
• Due to the fact that the safety system detected a serious fault, the control unit has stopped
the engine.
The instrument panel indicates this error by lighting up in a fixed manner the MI warning light and the
general warning light.
Troubleshooting:
• Perform the troubleshooting for the other detected errors.
NOTE
ELE SYS - 129

P1606 Hardware and software incompatibility

Error cause
• Incorrect engine control unit mapping
This error is indicated by lighting up in a fixed manner the general warning light.
Troubleshooting
• Call the Help Desk
NOTE
THIS ERROR DETERMINES THE ENGINE STOP AN THE DEACTIVATION OF THE STARTER MO-
TOR.
P1607 Saved data file (for safety reasons)
• Filled
Error cause
• This indication appears only if the Level 2 safety has reset the engine (C gravity).
The instrument panel does not indicate the presence of this error even in the ATT status
Troubleshooting
• Perform the troubleshooting for the other detected errors.
P1650 Engine events configuration Checksum calculation error

Error cause:
• Corrupt Flash-eeprom (hardware problem).
• Upload (e.g. in service) of an incompatible software version, therefore missing the reference
check-sum.
Troubleshooting:
• Call the Help Desk.
Errori di errata configurazione
P1901 Ax acceleration sensor plausibility

Functional diagnosis:
• Incorrect control unit set up
Error cause:
Probably there is an attempt to set up the control unit with an inadequate map.
NOTE: The instrument panel does not indicate the presence of this error even in the ATT status.
NOTE
THIS ERROR DISABLES THE TRACTION CONTROL.
P1902 Az acceleration sensor plausibility
ELE SYS - 130

• Incorrect control unit set up

Error cause:
Probably there is an attempt to set up the control unit with an inadequate map.
NOTE: The instrument panel does not indicate the presence of this error even in the ATT status.
NOTE
Battery
Function
Provides electrical power to vehicle: the YTZ 12
BS battery is already activated, charged and
sealed;
Battery charge
Position:
• on the vehicle: under the saddle

• connector: on the battery
Electrical specifications:12 V / 10 Ah
Pin out:
1. Positive pole (red): approx. 12,6 V

2. negative pole (black): ground lead
DIAGNOSTIC TOOL:PARAMETERS
Battery voltage
• Example value with key ON: 12.0 V

• Example value with engine on: 14.2 V
This is one of the values set by the ECU in the

event of recovery mode
Battery voltage before prior to Recovery mode
• Example value with key ON: 12.0 V

• Example value with engine on: 14.2 V
Value determined from signal read without taking

considering whether recovery mode is implemen-
ted
CAUTION
ELE SYS - 131

P0560 Battery voltage
• too high/too low
Error cause
• If too high: too high a voltage has been detected at PIN 42. If too low: too low a voltage has
been detected at PIN 42.
Troubleshooting
• If too high: check that the voltage regulator is working correctly.

• If too low: check voltage regulator connectors, engine-vehicle wiring harness connector and
ECU connector (check in particular for oxidation): if not OK, repair. If OK, check that resist-
ance of the Red/White cable from the voltage regulator connector to the ECU connector is
a few tenths of an Ohm; if not OK, repair the wiring harness. If OK, check that the alternator
is working correctly: if not OK, repair. If OK, check that the voltage regulator is working
correctly
P1560 Low battery voltage error - GCC error

• low voltage
Error cause
• The error is enabled if, after 5 seconds from the key to ON, the battery voltage is judged low
by the ECU.
• Low voltage detected to PIN 52 of the Marelli ECU.
The presence of this error is signalled by the fixed lighting of the general warning light.
Troubleshooting
• Try charging / replacing the battery: if NOT OK, carry out the check procedure for the alter-
nator connector and the control unit connector (paying particular attention to any oxidation):
if not OK, restore. If OK, check that cable resistance between the alternator cable and the
control unit is a few tenths of Ohm: if not OK, repair the wiring harness; if OK, check that the
alternator is working correctly: Restore if not OK.
NOTE
THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON-
TROL AND THE CRUISE CONTROL.
ELE SYS - 132

Speed sensor
FRONT VEHICLE ABS SENSOR

Function:
Generates a signal used by the ABS control unit
to determine the speed value of the wheel.
Operation / Operating principle:
Magneto-resistive sensor: generates a square
wave signal with an amplitude of approximately 1V
between PIN13 and PIN14 of the ABS control unit.
Electrical circuit diagram - Level in electrical
circuit diagram:
ABS system
Position on vehicle:
On right-hand stanchion of fork, near the brake
calliper mounting bracket.
Position of connector (if applicable):
On the filter housing, right side.
Pin-out:
• PIN1 - Power feed negative/Signal

negative (white)
• PIN2 - Power feed positive/Signal pos-
itive (white/brown)
DIAGNOSTIC TOOL
Parameters: Speed (km/h) - Vehicle speed.
ELECTRICAL ERRORS
Speed sensor
5D90 electric malfunction: Electrical fault in sensor or wiring harness.
Troubleshooting: Check the sensor connector and the ABS control unit connector. If they are not OK,
restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the
sensor on the wiring harness side and PIN 14 of the ABS control unit connector. If there is no continuity,
restore them. If there is, PIN 2 of the sensor on the wiring harness side, with the sensor disconnected
and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity
with the vehicle ground connection: if it is grounded, restore the wiring harness. If OK, replace the control
unit. If PIN 2 has approx. 12 V, check the continuity of the white cable between PIN 1 of the sensor on
the wiring harness side and PIN 13 of the ABS control unit connector. If there is no continuity, restore
the wiring harness. If there is, replace the logic errors sensor.
P0501 Front wheel speed sensor/signal
ELE SYS - 133

• Connect to the ABS control unit diagnosis.
LOGIC ERRORS
Speed sensor
5D91 the signal changes in intermittent manner
• faulty sensor or signal interference.
Troubleshooting:
• Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is
dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise,
replace the speed sensor.
5D92 the signal becomes weak periodically
• Possible tone wheel fault due to deformations or dirt; the surface of the wheel bearings may
be deteriorated. In very rare cases, abnormal tone wheel vibrations.
Troubleshooting:
• Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not OK,
replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace
the bearings.
5D93 no signal or speed to low compared to the rear wheel
• Faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and
the tone wheel or tone wheel with wrong number of teeth.
Troubleshooting:
• Check that the speed sensor and the tone wheel are installed. If they are not, install them.
If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not
OK, replace the tone wheel and if it is OK, replace the speed sensor.
5D94 no acceleration after pressure reduction
• Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and
the tone wheel.
Troubleshooting:
5D95 excessive measured speed
• Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size.
Troubleshooting:
ELE SYS - 134

OK, replace the tone wheel and if it is OK, check that the tyre size is the correct one. If it is
not OK, replace it. If it is OK, check that the tyre pressure is the correct one. If it is not OK,
restore it; if it is OK, replace the speed sensor.
P2162 Wheel speed plausibility
Error cause:
• ABS system malfunction
Troubleshooting:
REAR ABS VEHICLE SENSOR

Function:
Generates a signal used by the ABS control unit
to determine the speed value of the wheel.
Operation / Operating principle:
Magneto-resistive sensor: generates a square
wave signal with an amplitude of approximately 1V
between PIN11 and PIN12 of the ABS control unit.
Electrical circuit diagram - Level in electrical
circuit diagram:
ABS system
Position on vehicle:
On the rear brake calliper support plate.
Position of connector (if applicable):
Under the saddle, on the left side, between the
battery and the seat supporting frame.
Pin-out:
• PIN1 - Power feed negative/Signal

negative (yellow)
• PIN2 - Power feed positive/Signal pos-
itive (yellow/brown)
DIAGNOSTIC TOOL
Parameters: Speed (km/h) - Vehicle speed.
ELECTRICAL ERRORS
Speed sensor
5DA0 electric malfunction
ELE SYS - 135

• Electrical fault in sensor or wiring harness.
Troubleshooting:
• Check the sensor connector and the ABS control unit connector. If they are not OK, restore
the connectors. If they are OK, check continuity of the yellow/brown cable between PIN 2
of the sensor on the wiring harness side and PIN 11 of the ABS control unit connector. If
there is no continuity, restore them. If there is, PIN 2 of the sensor on the wiring harness
side, with the sensor disconnected and key set to ON, must have 12V voltage approximately:
if there is no voltage, check PIN 2 for continuity with the vehicle ground connection: if it is
grounded, restore the wiring harness. If OK, replace the control unit. If PIN 2 has approx.
12 V, check continuity of the yellow cable between PIN 1 of the sensor on the wiring harness
side and PIN 12 of the ABS control unit connector. If this is not OK, restore the wiring har-
ness. If it is OK, replace the sensor.
P2158 Rear wheel speed sensor/signal
LOGIC ERRORS
Engine speed sensor
5DA1 the signal changes in intermittent manner
• faulty sensor or signal interference.
Troubleshooting:
• Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is
dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise,
replace the speed sensor.
5DA2 the signal becomes weak periodically
• Possible tone wheel fault due to deformations or dirt; the surface of the wheel bearings may
be deteriorated. In very rare cases, abnormal tone wheel vibrations.
Troubleshooting:
• Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not OK,
replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace
the bearings.
5DA3 no signal or speed to low compared to the front wheel
• Faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and
the tone wheel or tone wheel with wrong number of teeth.
Troubleshooting:
ELE SYS - 136

5DA4 no acceleration after pressure reduction
• Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and
the tone wheel.
Troubleshooting:
5DA5 excessive measured speed:
• Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size.
Troubleshooting:
OK, replace the tone wheel and if it is OK, check that the tyre size is the correct one. If it is
not OK, replace it. If it is OK, check that the tyre pressure is the correct one. If it is not OK,
restore it; if it is OK, replace the speed sensor.
P2162 Wheel speed plausibility

Error cause:
• ABS system malfunction
Troubleshooting:
Engine rpm sensor
Function
indicates the position and speed of the crankshaft
at the Marelli control unit
Inductive sensor: sinusoidal-type generated volt-
age; two teeth are missing on the flywheel for the
reference position
Engine speed sensor
ELE SYS - 137

Position:
• on the vehicle: on the flywheel cover

• connector: under the tank, on the left
side, between the filter housing an the
frame (2 way white connector)
0.79 kohm at ambient temperature
Pin out:
1. positive signal
2. negative signal
Engine rpm:rpm
CAUTION
DIAGNOSTIC TOOL: STATUSES

Synchronised panel
• No_in analysis_awaiting_Yes

CAUTION
NO ERROR IS GENERATED IF THE ELECTRICAL CIRCUIT IS INTERRUPTED OR SHORT
CIRCUITED. CARRY OUT THE MARELLI CONTROL UNIT AND RPM SENSOR CONNECTORS
CHECK PROCEDURE: IF THE CONNECTORS ARE NOT OK, REPAIR OR REPLACE THEM AS
NECESSARY, IF THEY ARE OK CHECK THE SENSOR CONFORMS TO THE ELECTRICAL SPEC-
IFICATIONS: IF NECESSARY, REPLACE THE SENSOR, IF IT IS OK, CHECK THE CONTINUITY
ON THE TWO CABLES, VERIFYING THAT THEY ISOLATED FROM THE POWER SUPPLY AND
EARTH. CARRY OUT THE TESTS ON THE CONNECTOR OF THE SENSOR TOWARDS THE SEN-
SOR, IF IT IS NOT OK REPAIR THE WIRING/REPLACE THE SENSOR, IF IT IS OK, CARRY OUT
THE TEST ON PINS 20 TO 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR.
P0336 Engine rpm sensor

• Signal not plausible
Error causes:
• Potential false contact in the electrical circuit detected at PIN 20 - 35 of the marelli control
unit ENGINE connector
Troubleshooting:
ELE SYS - 138

• Check the integrity of the electrical circuit, the cleanliness of the flywheel teeth and the
correct positioning of the sensor in its seat: if not ok restore; if ok, replace the sensor.
NOTE
Twistgrip position sensor
HANDLE POSITION SENSOR

Function
The handle command is used to convert the driver's power demand to an electrical signal to be sent to
the electronic control unit.
in the handle command there is an integrated double track potentiometer through which the torque
demand is read (and verified). The potentiometer is watertight and magnetically controlled (contactless),
it cannot be overhauled or replaced.
Level in electrical circuit diagram
Check of the throttle valves and handle sensor
Position:
• on the vehicle: integrated in the handle command

• connector: on the left side of the filter housing
• -
Pin-out
1. A track power supply (orange/white cable)

2. Sensors 1 ground (green/pink cable)
3. A track signal (yellow/blue cable)
4. B track power supply (orange/black cable)
5. Sensors 2 ground (pink/black cable)
6. B track signal (light blue cable)
P0225 Track A handle position sensor

• short circuit to positive / open circuit, short circuit to negative
Error cause
• Short-circuit to positive: an excessive voltage was detected at PIN 39 of the ENGINE con-
nector.
ELE SYS - 139

• If open circuit, short circuit to negative: a voltage equal to zero was detected at PIN 39 of
the ENGINE connector.
This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI
warning light.
Troubleshooting
• Short-circuit to positive: check the value indicated by the parameter handle position sensor
track A: disconnect the connector and read the value indicated by the diagnostic tool: if the
voltage does not vary, there is a short circuit on the wiring harness of the relative cable, if
the voltage goes to zero, replace the handle sensor.
• open circuit, short circuit to negative: check the handle sensor connector and engine control
unit connector, if not ok restore, if ok check cable continuity between the two terminals, if
not ok restore, if ok check the ground insulation of the cable (from the handle sensor con-
nector or control unit connector): if not ground insulated, restore the wiring harness, if ground
insulated check, with key ON, that power supply is present at PIN 1 of the potentiometer
and that the ground is present at PIN 2, if present correctly replace the handle sensor, if not
present check the continuity of the malfunctioning cable: if the continuity is present replace
the control unit, if not present replace the wiring harness
P2130 Track B handle position sensor

Error cause
nector.
• If open circuit, short circuit to negative: voltage equal to zero was detected at PIN 13 of the
ENGINE connector
warning light
Troubleshooting
• short circuit to positive:check the value indicated by the parameter handle position sensor
track B: disconnect the connector and read the value indicated by the diagnostic tool: if the
voltage does not vary, there is a short circuit on the wiring harness of the relative cable, if
the voltage goes to zero, replace the handle sensor.
• open circuit, short circuit to negative: check the handle sensor connector and Marelli control
unit connector, if not ok restore, if ok check cable continuity between the two terminals, if
not ok restore, if ok check the ground insulation of the cable (from the handle sensor con-
nector or control unit connector): if not ground insulated, restore the wiring harness, if ground
insulated check, with key ON, that power supply is present at PIN 4 of the potentiometer
ELE SYS - 140

and that the ground is present at PIN 5, if present correctly replace the handle sensor, if not
present check the continuity of the malfunctioning cable: if the continuity is present replace
the control unit, if not present replace the wiring harness
P1227 Tracks A-B handle position sensor

• Signal not congruent
Error cause:
• Detected two voltages signals at PIN 39 and 13 of the ENGINE connector (tracks A-B)
warning light.
Troubleshooting:
• Check the parameters for the track A and track B Handle position sensor. The values de-
tected on track A must be comprised between 1 V (gas throttle completely closed) and 4 V
(gas throttle completely open). The values detected on track B must be comprised between
0.5 V (gas throttle completely closed) and 2 V (gas throttle completely open). If one of these
values differs significantly from the indicated value, it means that the potentiometer is faulty.
check the handle sensor connector and control unit connector; if not OK, restore. If OK,
check that cable resistance between the handle sensor cable and the control unit is a few
tenths of Ohm; otherwise, restore the wiring harness; if ok, replace the complete handle
command.
Intake pressure sensor
INTAKE AIR PRESSURE SENSOR

Function
The pressure sensors (one per cylinder) are es-
sential not only for the injection map at low an
stabilised speeds, but also for the Ride by Wire
system control: their signal is introduced in a TOR-
QUE CHIN to check the correct opening of the
throttle valves.
Membrane sensor that converts the membrane
position, in contact with the intake air, to electric
voltage.
ELE SYS - 141

intake air pressure sensor

Location:
• on the vehicle: inside the filter housing

• connector: on the sensor
Pins:
1. Power supply
2. Ground
3. Output signal
DIAGNOSTIC TOOL: PARAMETERS

Front cylinder intake sensor
Example value: 1003 mbar
Pressure read through the front sensor.
Rear cylinder intake sensor
Pressure read through the rear sensor.
Front cylinder intake estimated pressure
Pressure estimated by the control unit, based on the throttle valve position
Rear cylinder intake estimated pressure
Pressure estimated by the control unit, based on the throttle valve position
P0105 Front cylinder air pressure sensor

• short circuit to positive / open circuit, short circuit to negative, signal not plausible.
Error cause:
• Short-circuit to positive: excessive voltage detected at PIN 24 of the Marelli ECU detected.
• If open circuit, short circuit to negative: voltage equal to zero detected at PIN 24 of the Marelli
ECU.
This error is indicated by the steady on MI indicator light.

Troubleshooting:
• Short-circuit to positive: on the diagnostic tool, observe the front cylinder air pressure sensor,
which will display a value of approx. 1200 mbar; disconnect the sensor connector: if the
value does not change, this means there is a short circuit in the cable between the control
unit connector and the sensor connector; restore the wiring harness; if the value changes,
replace the sensor.
ELE SYS - 142

• If open circuit, short circuit to negative: check the Marelli control unit connector and the
sensor connector; if NOT OK restore, if everything is OK, with key OFF, check the continuity
between Marelli control unit connector PIN 24 and the sensor connector PIN 3: if there is no
continuity, restore the wiring harness, if there is continuity, check the ground insulation of
the cable: if there is continuity to ground, restore the wiring harness, if there is no continuity,
check (with key in ON position) that there is a voltage of approx. 5 V present at PIN 1 on the
sensor connector: if NOT OK, turn the key to OFF and check the continuity between the
ENGINE connector PIN 25 and PIN 1 on the sensor connector: if NOT OK, restore the wiring
harness; if ok, replace the control unit; if a voltage of 5 V is present at PIN 1, check (with
key in ON position) for continuity between PIN 3 on the sensor connector and ground: if NOT
OK, restore the wiring harness; if OK, replace the sensor.
P1105 Rear cylinder air pressure sensor

• short circuit to positive / open circuit, short circuit to negative, signal not plausible.
Error cause
• Short-circuit to positive: excessive voltage detected at PIN 49 of the Marelli ECU detected.
• If open circuit, short circuit to negative: voltage equal to zero detected at PIN 49 of the Marelli
ECU.
This error is indicated by lighting up in a fixed manner the MI warning light.

Troubleshooting
• Short-circuit to positive: verify that the parameter of the rear cylinder air Pressure Sensor
on the diagnosis instrument is approx. 1200 mbar; disconnect the sensor connector: if the
value does not change, this means there is a short circuit in the cable between the Marelli
control unit connector and the sensor connector; restore the wiring harness; if the value
changes, replace the sensor.
• If open circuit, short circuit to negative: check the Marelli control unit connector and the
sensor connector; if NOT OK restore, if everything is OK, with key OFF, check the continuity
between Marelli control unit connector PIN 49 and the sensor connector PIN 3: if there is no
continuity, restore the wiring harness, if there is continuity, check the ground insulation of
the cable: if there is continuity to ground, restore the wiring harness, if there is no continuity,
check (with key in ON position) that there is a voltage of approx. 5 V present at PIN 1 on the
sensor connector: if NOT OK, turn the key to OFF and check the continuity between ENGINE
connector PIN 25 and PIN 1 on the sensor connector: if NOT OK, restore the wiring harness;
if OK, replace the control unit; if a voltage of 5 V is present at PIN 1, check (with key in ON
position) for continuity between PIN 3 on the sensor connector and ground: if NOT OK,
restore the wiring harness; if OK, replace the sensor.
ELE SYS - 143

P1600 Error due to unexpected air intake in the front cylinder manifold
Error cause:
• Small difference detected between the estimated pressure and the measured pressure: the
measured pressure is higher than the estimated one (for example, the pipe between sensor
and throttle body is squashed or there is a hole in the intake manifold).
warning light.
Troubleshooting:
• 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.
P1601 Error due to unexpected air intake in the rear cylinder manifold
Error cause:
measured pressure is higher than the estimated one (for example, the pipe between sensor
and throttle body is squashed or there is a hole in the intake manifold).
warning light.
Troubleshooting:
P1602 Estimation error for front cylinder intake manifold pressure

• pressure too high/pressure too low.
Error cause:
• A substantial difference between the estimated pressure and the measured pressure has
been detected (for example, the pipe between sensor and throttle body is fully detached/
clogged or squashed).
warning light.
Troubleshooting:
ELE SYS - 144

reading hole is clean: there is a very evident defect in the intake and pressure reading sys-
tem.
P1603 Estimation error for rear cylinder intake manifold pressure

• pressure too high/pressure too low.
Error cause:
• A substantial difference between the estimated pressure and the measured pressure has
been detected (for example, the pipe between sensor and throttle body is fully detached/
clogged or squashed).
warning light.
Troubleshooting:
reading hole is clean: there is a very evident defect in the intake and pressure reading sys-
tem.
P1604 Front manifold pressure too low error

Error cause:
measured pressure is below the estimated one (for example, smeared throttle body).
warning light.
Troubleshooting:
P1605 Rear manifold pressure too low error

Error cause:
ELE SYS - 145

measured pressure is below the estimated one (for example, smeared throttle body).
warning light.
Troubleshooting:
Engine temperature sensor

Function
Serves the purpose of communicating the engine
temperature to the control unit in order to optimise
performance.
NTC type sensor (resistance sensor, inversely
variable with temperature).
Temperature sensors
Position:
• On the vehicle: on the front cylinder on

the internal side facing the rear cylinder
• Connector: on the sensor
• Resistance at 25°: 2.05 kOhm +/-

100%
• Resistance at 60°: 575 Ohm +/- 15%
• Resistance at 90°: 230 Ohm +/- 5%
Pin-out:
1. Brown yellow: 0-5 V signal

2. Black
3. Green/Pink: Ground
4. Black
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
ELE SYS - 146

P0115 Engine temperature sensor
• open circuit, shorted to positive / shorted to negative.
Error cause
• If open circuit, short circuit to positive: an excessive voltage was detected at PIN 12 of the
ENGINE connector. If short circuit to negative: voltage equal to zero has been detected. The
instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Troubleshooting
• If open circuit, short circuit to positive: check the sensor connector and the Marelli control
unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if OK,
check continuity between the ENGINE connector PIN 12 and the sensor PIN 3: If continuity
is absent, restore the wiring harness; if ok reconnect the control unit connector and with key
ON check the continuity between PIN 1 of the sensor connector and vehicle ground: if OK,
it means that the error is caused by the cable being shorted to positive and it is necessary
to restore the cable harness between ENGINE PIN 12 and sensor PIN 3; if there is no
continuity to ground, check the sensor connector and the Marelli control unit connector. If
not OK, restore the cable harness. If OK, check for continuity between the ENGINE con-
nector PIN 6 or 17 and the sensor connector PIN 1: restore the cable harness if there is not
continuity. If there is, it means that the control unit does not supply the ground connection
and therefore should be replaced.
• If short circuit to negative, check the correct resistance of the sensor: if resistance is null,
replace the sensor; if resistance is correct, it means that the Yellow/Brown cable has ground
connection: restore the cable harness
P0116 Engine temperature sensor

Signal not plausible.
Error cause
• An excessive temperature variation was detected: the cause could be a contact resistance
between the terminals, for example. The instrument panel indicates this error by lighting up
in a fixed manner the MI warning light.
Troubleshooting
• Check the sensor connector and the ENGINE connector of the Marelli control unit.
NOTES
No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals
are rusty: then use the diagnostic tool to check if the temperature indicated is the same as the engine
temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if
not OK; if it is OK, check the sensor connector and the Marelli control unit connector.
ELE SYS - 147

Air temperature sensor
Function
indicates to the control unit the temperature of the
intake air, used to calculate the oxygen, to opti-
mise the required fuel quantity for the correct com-
bustion
variable with temperature)
Level in the electrical circuit diagram:
Temperature sensors
Position:
• sensor: on the rear side of the filter

housing
• connector: on the sensor
Electrical specifications:Resistance
• at 0 °C (32 °F): 32.5 kΩ ± 5%

• at 25 °C (77 °F): 10.0 kΩ ± 5%
Pin out:
1. 0-5 V signal
2. Ground
Air temperature
Example value with key ON: 26 °C (78.8 °F):
This is one of the values set by the ECU in the
event of recovery mode
Air temperature before Recovery
Example value with key ON: -40 °C (-40.0 °F):
Value determined from the signal read without tak-
ing into consideration the recovery mode: the il-
lustrative value refers to an open circuit
CAUTION
ELE SYS - 148

P0110 Air temperature sensor

• open circuit, short circuit to positive / short circuit to negative
Error cause
• If open circuit, short circuit to positive: an excessive voltage was detected at PIN 37 of the
ENGINE connector. If short circuit to negative: zero voltage detected. The instrument panel
indicates this error by lighting up in a fixed manner the MI warning light.
Troubleshooting
• If open circuit, short circuit to positive: check the sensor connector and the Marelli control
unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if OK,
check continuity between the ENGINE connector PIN 37 and the sensor PIN 1: If continuity
is absent, restore the wiring harness; if ok reconnect the control unit connector and with key
ON check the continuity between PIN 2 of the sensor connector and vehicle ground: if OK,
it means that the error is caused by the cable being shorted to positive and it is necessary
to restore the cable harness between ENGINE PIN 37 and sensor PIN 1; check the sensor
connector and the Marelli control unit connector. If not OK, restore the cable harness. If OK,
check for continuity between the ENGINE connector PIN 6 or 17 and the sensor connector
PIN 2: restore the cable harness if there is no continuity. If there is, it means that the control
unit does not supply the ground connection and therefore should be replaced
• If short circuit to negative, check the correct resistance of the sensor: if the resistance is null,
replace the sensor; if the resistance is correct, it means that the Green/Pink cable is groun-
ded: restore the cable harness
Lambda sensor
(FRONT CYLINDER)
Function
In charge of telling the control unit whether the mixture is lean or rich
The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen
content between the exhaust fumes and the ambient. It does not require an external supply source but,
in order to work properly, it should reach a high operating temperature: that is why there is a heating
circuit inside
Lambda probe
Position:
• on manifold: left side of the vehicle
• connector: on the ABS support modulator (4 way black connector)
ELE SYS - 149

• Heater circuit: 7-9Ω at ambient temp.
Pin out:
1. Sensor signal + (black wire)

2. Sensor signal - (grey wire)
3. Heater ground connection (white cable)
4. Heater power supply (white cable)
Lambda probe
• Example value with key ON: about 3300 mV

• Example value with engine on: 100-1000 mV
If there is a short circuit at + 5 V or higher, the lambda probe parameter is not equal to the value read
by the control unit, but a recovery value is displayed
Lambda correction
• Example value with key ON: 0 %

• Example value with engine on: -10% / +10%
In closed loop, the value must be close to 1.00 (values not within the -15% / +15% interval indicate a
fault). In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes it as a lean
mixture condition and will try to enrich it. The value read will be +25%: once this value is reached and
kept unchanged for a certain time, the function diagnosis of the lambda probe is activated with following
deactivation of it.
This diagnosis is activated when the correction constantly arrives -25%.
CAUTION
Lambda probe: Start-up_Lean_Rich_Fault due to rich titre_Fault due to lean air-fuel mixture
• If the probe connector is disconnected (voltage almost equal to zero) it switches to the state
of Fault due to lean air-fuel mixture
Lambda check: Open loop/Closed loop/Rich in closed loop/Lean in closed loop/enriched
• Closed loop indicates that the control unit is using the lambda probe signal to keep the
combustion is close as possible to the stoichiometric value.
DIAGNOSTIC TOOL: ACTIVATIONS

Lambda probe heater
• The injection relay (No. 17 in the electrical circuit diagram, placed under the left side tank,
CHECK, however, the identification of the relay with the colour of the cables) is energised
and the heating circuit is closed to ground 5 times (Pin 3 of the Lambda probe connector).
ELE SYS - 150

Electrical continuity is required in the wiring for the relay to activate correctly: no errors are
generated in case of no activation.
P0130 Front lambda probe
• Short circuit to positive.
Error cause:
• Excessive voltage detected (battery voltage) at PIN 10 and 22 of the ENGINE connector.
Caution: the "lambda probe" parameter is not the actual read value but a recovery value is
displayed.
The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Troubleshooting:
• Short-circuit to positive: with key set to ON, disconnect the sensor connector and measure
PIN 1 voltage on the cable harness side (yellow/orange cable): if the voltage (5 or 12 V) is
present, restore the wiring harness, if the voltage is absent replace the lambda probe.
P0135 Front lambda probe heating
• short circuit to positive/ open circuit / short circuit to negative
Error cause
nector.
Troubleshooting
• Short-circuit to positive: disconnect the probe connector and check the correct sensor re-
sistance: if NOT OK, replace the sensor; if OK, restore the wiring harness (Green/Black
cable).
• If open circuit, short circuit to negative: check the continuity from the probe connector (PIN
3 and 4) to the probe: if NOT OK, replace the probe; if ok, perform the check procedure for
the sensor connector and for the Marelli control unit connector: if NOT OK restore; if OK,
with the key ON and the sensor connector disconnected, check if there is battery voltage at
PIN 4: if NOT OK, check the continuity of the Red/Brown cable between the probe connector
and the injection relay (no. 17 in the electrical circuit diagram, position under the left side of
the tank; however, CHECK the relay identification with the cable colours); if there are also
errors regarding the coils, injectors and secondary air, check the relay and its energy and
power line; if there is voltage at PIN 4, check ground insulation of the Green/Black cable
ELE SYS - 151

(PIN 3): if NOT OK, restore the wiring harness; if OK, check the continuity of the Green/
Black cable (between PIN 3 of the sensor connector and ENGINE PIN 32) and restore the
wiring harness.
and the injection relay (no. 17 in the electrical circuit diagram, position under the left side of
the tank; however, CHECK the relay identification with the cable colours); if there are also
errors regarding the coils, injectors and secondary air, check the relay and its energy and
power line; if there is voltage at PIN 4, check ground insulation of the Green/Black cable
(PIN 3): if NOT OK, restore the wiring harness; if OK, check the continuity of the Green/
Black cable (between PIN 3 of the sensor connector and ENGINE PIN 32) and restore the
wiring harness.
WARNING
The control unit does not detect the following malfunctions of the lambda probe circuit relative
to the signal: interrupted circuit, short circuit to ground or malfunction of the sensor (for ex-
ample, voltage not variable). If the indication is abnormal, perform the troubleshooting indicated
below.
Troubleshooting
• Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards 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
the continuity between the ENGINE connector PIN 10 and PIN 22 and restore the wiring
harness.
P0134 Front lambda probe
• no switching from high / no switching from low
Error cause:
• If no switching from high: is shown when the ratio control is in closed loop and when the
secondary air valve is not operating. The error is validated if the engine is in CUTOFF status
and the probe signal is close to 1V, or if the engine is in another operating condition that
requires the injection but the switching from the"HIGH RATIO" to "LOW RATIO" is missing
for a certain"adjusted" number of dead points (PMS or TDC).
• If no switching from low: is shown when the ratio control is in closed loop and when the
secondary air valve is not operating. The error is validated if during the ratio control stage,
ELE SYS - 152

the switching from "HIGH RATIO" to "LOW RATIO" is missing for a certain"adjusted" number
of upper dead points (PMS or TDC).
Troubleshooting:
• If no switching from high: the fault may be generated in the supply system (poor pin sealing)
or in the probe. Check the wiring harness. if NOT OK restore; if OK, replace the lambda
probe.
• If no switching from low: the fault may be generated in the supply system (dirty injector, low
fuel supply system pressure) or in the probe. Check the wiring harness. if NOT OK restore;
if OK, replace the lambda probe.
• For the (non polarised) type of probes, this error may be caused also by a short circuit to
the wiring harness ground.
NOTE
THIS ERROR DISABLES THE RATIO CONTROL IN CLOSED LOOP.
(REAR CYLINDER)
Function
In charge of telling the control unit whether the mixture is lean or rich
The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen
content between the exhaust fumes and the ambient. It does not require an external supply source but,
in order to work properly, it should reach a high operating temperature: that is why there is a heating
circuit inside
Lambda probe
Position:
• on manifold: on the rear part of the vehicle in correspondence with the shock absorber
• connector: on the left side, between the rear cylinder an the frame (4 way black connector)
• Heater circuit: 7-9Ω at ambient temp.
Pin out:
1. Sensor signal + (black wire)

2. Sensor signal - (grey wire)
3. Heater ground connection (white cable)
4. Heater power supply (white cable)
Lambda probe
ELE SYS - 153

• Example value with key ON: about 3300 mV

• Example value with engine on: 100-1000 mV
If there is a short circuit at + 5 V or higher, the lambda probe parameter is not equal to the value read
by the control unit, but a recovery value is displayed
Lambda correction
• Example value with key ON: 0 %

• Example value with engine on: -10% / +10%
In closed loop, the value must be close to 1.00 (values not within the -15% / +15% interval indicate a
fault). In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes it as a lean
mixture condition and will try to enrich it. The value read will be +25%: once this value is reached and
remains unchanged for a certain time, the lambda probe functional diagnosis is activated, resulting in
it being deactivated.
This diagnosis is activated when the correction constantly arrives -25%.
CAUTION
Lambda probe: Start-up_Lean_Rich_Fault due to rich titre_Fault due to lean air-fuel mixture
• If the probe connector is disconnected (voltage almost equal to zero) it switches to the state
of Fault due to lean air-fuel mixture
Lambda check: Open loop/Closed loop/Rich in closed loop/Lean in closed loop/enriched
• Closed loop indicates that the control unit is using the lambda probe signal to keep the
combustion is close as possible to the stoichiometric value.

Lambda probe heater
• The injection relay (No. 17 in the electrical circuit diagram, placed under the left side tank,
CHECK, however, the identification of the relay with the colour of the cables) is energised
and the heating circuit is closed to ground 5 times (Pin 3 of the Lambda probe connector).
Electrical continuity is required in the wiring for the relay to activate correctly: no errors are
P0150 Rear lambda probe

• Short circuit to positive
Error cause:
ELE SYS - 154

• Excessive voltage detected (battery voltage) at PIN 9 and 38 of the ENGINE connector.
Caution: the "lambda probe" parameter is not the actual read value but a recovery value is
displayed.
Troubleshooting:
• Short-circuit to positive: with key ON, disconnect the sensor connector and measure the
voltage at PIN 1, wiring harness side (grey cable): if the voltage (5 or 12 V) is present, restore
the wiring harness, if the voltage is absent replace the lambda probe
P0155 Rear lambda probe heating

• short circuit to positive/ open circuit, short circuit to negative
Error cause:
nector.
Troubleshooting:
• Short-circuit to positive: disconnect the probe connector and check the correct sensor re-
sistance: if Not OK, replace the sensor; if OK, restore the wiring harness (Green/Red cable).
and the injection relay (no. 17 in the electrical circuit diagram, position under the tank, on
the left side of the filter housing; however, CHECK the relay identification with the cable
colours); if there are also errors regarding the coils, injectors and secondary air, check the
relay and its energy and power line; if there is voltage at PIN 4, check ground insulation of
the Green/Re cable (PIN 3): if NOT OK, restore the wiring harness; if OK, check the con-
tinuity of the Green/Red cable (between PIN 3 of the sensor connector and ENGINE PIN
44) and restore the wiring harness.
WARNING
The control unit does not detect the following malfunctions of the lambda probe circuit relative
to the signal: interrupted circuit, short circuit to ground or malfunction of the sensor (for ex-
ample, voltage not variable). If the indication is abnormal, perform the troubleshooting indicated
below.
ELE SYS - 155

Troubleshooting
• Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards 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
the continuity between the ENGINE connector PIN 9 and PIN 38 and restore the wiring
harness.
P0154 Rear lambda probe

• no switching from high / no switching from low
Error cause:
• If no switching from high: is shown when the ratio control is in closed loop and when the
secondary air valve is not operating. The error is validated if the engine is in CUTOFF status
and the probe signal is close to 1V, or if the engine is in another operating condition that
requires the injection but the switching from the"HIGH RATIO" to "LOW RATIO" is missing
for a certain"adjusted" number of dead points (PMS or TDC).
• If no switching from low: is shown when the ratio control is in closed loop and when the
secondary air valve is not operating. The error is validated if during the ratio control stage,
the switching from "HIGH RATIO" to "LOW RATIO" is missing for a certain"adjusted" number
of upper dead points (PMS or TDC).
Troubleshooting:
• If no switching from high: the fault may be generated in the supply system (poor pin sealing)
or in the probe. Check the wiring harness. if NOT OK restore; if OK, replace the lambda
probe.
• If no switching from low: the fault may be generated in the supply system (dirty injector, low
fuel supply system pressure) or in the probe. Check the wiring harness. if NOT OK restore;
if OK, replace the lambda probe.
• For the (non polarised) type of probes, this error may be caused also by a short circuit to
the wiring harness ground.
NOTE
THIS ERROR DISABLES THE RATIO CONTROL IN CLOSED LOOP.
ELE SYS - 156

Injector
Function
Provide the correct amount of fuel at the correct
time.
Injector coil is energised for the petrol passage to
open
Coils and injectors
Position:
• on the vehicle: on the throttle body

• connector: on injectors
12.5 Ω ± 10% (at ambient temp.)
Pin out:
• "+": supply
• " ": ground
Cylinder injection time 1
• Example value with engine on: 1.9 ms
Cylinder injection time 2
• Example value with engine on: 1.9 ms

CAUTION

Front cylinder injector
• The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel
tank, on the right side of the filter housing; CHECK, however, the identification of the relay
with the colour of the cables) is energised for 5 seconds and the injector cable connected
to the control unit is closed to ground for 4 ms per each second. It is recommended to
disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector
activation. Electrical continuity is required in the wiring for the relay to activate correctly: no
errors are generated in case of no activation.
Rear cylinder injector
ELE SYS - 157

• The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel
tank, on the right side of the filter housing; CHECK, however, the identification of the relay
with the colour of the cables) is energised for 5 seconds and the injector cable connected
to the control unit is closed to ground for 4 ms per each second. It is recommended to
disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector
activation. Electrical continuity is required in the wiring for the relay to activate correctly: no
errors are generated if the relay fails to activate
P0201 Front cylinder injector
• Short circuit to positive / short circuit to negative / open circuit
Error cause:
• Short-circuit to positive: excessive voltage has been detected on VEHICLE PIN 53.
• If short circuit to negative: no voltage has been detected.
• If open circuit: an interruption has been detected
Troubleshooting:
• Short-circuit to positive: disconnect the injector connector, turn the key to ON, activate the
component with the diagnostic tool and check if there is voltage on the grey/red cable, on
the injector connector: if there is, restore the wiring harness of the filter housing; if not,
replace the sensor.
• If short circuit to negative: disconnect the injector connector, turn the key to On and check
if there is ground connection in the cable grey/red: if the connection is present, restore the
wiring harness, if not present replace the injector
• If open circuit: check the component correct electrical characteristic: if it is not the correct
one, replace the component; if it is correct, check the connector on the component and the
Marelli control unit connector: if not ok, restore; if ok, check the continuity of the cable be-
tween the VEHICLE PIN 53 and PIN 2 of the component and restore the wiring harness.
P0202 Rear cylinder injector
• Short circuit to positive / short circuit to negative / open circuit
Error cause:
• Short-circuit to positive: excessive voltage has been detected on VEHICLE PIN 67.
• If open circuit: an interruption has been detected.
Troubleshooting:
• Short-circuit to positive: disconnect the injector connector, turn the key to ON, activate the
component with the diagnostic tool and check if there is voltage on the white/black cable,
ELE SYS - 158

on the injector connector: if there is, restore the wiring harness of the filter housing; if not,
replace the sensor.
• If short circuit to negative: disconnect the injector connector, turn the key to ON and check
if there is ground connection in the cable white/black: if the connection is present, restore
the wiring harness, if not present replace the injector
• If open circuit: check the component correct electrical characteristic: if it is not the correct
one, replace the component; if it is correct, check the connector on the component and the
Marelli control unit connector: if not ok, restore; if ok, check the continuity of the cable be-
tween the VEHICLE PIN 67 and PIN 2 of the component and restore the wiring harness.
Fuel pump
Function
Fuel pump: keeps pressure of the injectors supply
duct.
Low fuel: tells to the instrument panel about low
fuel
Low fuel: it is a resistance that if correctly supplied
varies its electrical resistance if it is damped or not
by petrol.
Injection loads relay.
Position:
• On the vehicle: on the tank.

• Connector: under the saddle, on RH
side (black colour 4 way)
PIN 1-2: 0,5- 1 Ohm PIN 3-4: there is no need to
measure the electrical resistance of the compo-
nent because its correct operation occurs only with
a proper power supply delivered by the instrument
panel.
Check the correct operation as follows: connect in
series a bulb of approximately 2 W: it must light up
if the tank is in reserve; otherwise, it must stay off.
Pin out:
ELE SYS - 159

1. + 12 V - Orange/Green colour, from the fuel

pump to the power supply
2. ground - Blue colour - Section 1.5
3. + 12 V (signal) reserve sensor - Green/Grey
colour - Section 0.5
4. reserve sensor ground, from PIN 4 to PIN 34
of the instrument panel - Blue/black colour -
Section 0.5
CAUTION

Fuel pump
NOTES: Energy is applied for 30 seconds to the secondary injection relay (35 in the electrical circuit
diagram, located in the filter housing, right side; however, CHECK the identification of the relay with the
colour of the cables). Electrical continuity is required in the wiring for the relay to activate correctly: no
Fuel pump relay command P0230
• short circuit to positive/ open circuit, short circuit to negative
Error cause
• Short-circuit to positive: excessive voltage has been detected at PIN 73 of the VEHICLE
connector. If open circuit, short circuit to negative: a voltage equal to zero was detected at
PIN 73 of the ENGINE connector.
Troubleshooting
• Short-circuit to positive: check the relay electrical specifications are correct by disconnecting
it from the cable harness. If not OK, replace the relay; if OK, restore the cable harness
(Brown/Black cable).
• If open circuit, short circuit to negative: check the relay electrical characteristics are correct
by disconnecting it from the cable harness; if it is not OK, replace the relay, if it is OK, check
relay connector, engine-vehicle cable harness connector and VEHICLE connector of the
Marelli control unit: if not OK, restore; if OK, check continuity of cable harness (Brown/Black
cable)
ELE SYS - 160

Coil
Function
Spark generation
With inductive discharge
Coils and injectors
Position:
• on the vehicle: on the big end covers.

• connector: For each coil 3 way black
connector. Front coil on the front side
filter housing; rear coil on the rear side
of the filter housing.
0.7- 0.9 Ω at ambient temperature
Pin out:
1. Power supply +Vbatt

2. Secondary circuit ground
3. Activation from the control unit
Example value with key ON:Actual start-up ad-
vance
Example value with engine on: Indicates the ad-
vance of the cylinder in which the combustion will
take place.
CAUTION

Front coil:
The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel tank, on the
right side of the filter housing. However, CHECK the relay identification with the cables colour - blue
taping) for 5 seconds and the pink coil cable is closed to ground for 2 ms per each second. It is rec-
ommended to disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector
activation. Electrical continuity is required in the wiring for the relay to activate correctly: no errors are
ELE SYS - 161

Rear coils:
The secondary injection relay (no. 35 in the electrical circuit diagram, placed under the fuel tank, on the
right side of the filter housing. However, CHECK the relay identification with the cables colour - blue
taping) for 5 seconds and the violet/grey coil cable is closed to ground for 2 ms per each second. It is
recommended to disconnect the 4-way connector of the fuel pump to be able to hear the relay and
injector activation. Electrical continuity is required in the wiring for the relay to activate correctly: no
P0351 Front coil

short circuit to positive / short circuit to negative, open circuit.
Error cause:
nector.
Troubleshooting:
• Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil
with the diagnostic tool and check the voltage at PIN 28 of the connector: if there is voltage,
restore the wiring harness, if the voltage is 0, replace the coil.
• If open circuit, short circuit to negative: check the electrical characteristics of the coil: if not
ok, replace the coil; if ok, perform the check procedure for the coil connector and for the
Marelli control unit connector; if not ok restore; if everything is ok, check the continuity of the
cable between the two ends of the cable: if there is no continuity, restore the wiring harness;
if there is continuity, with key ON, check the cable ground insulation (from the coil connector
or control unit connector); if not ok, restore the wiring harness.
P0352 Rear coil

short circuit to positive / short circuit to negative, open circuit.
Error cause:
nector.
Troubleshooting:
ELE SYS - 162

• Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil
with the diagnostic tool and check the voltage at PIN 27 of the connector: if there is voltage,
restore the wiring harness, if the voltage is 0, replace the coil.
• If open circuit, short circuit to negative: check the electrical characteristics of the coil: if not
ok, replace the coil; if ok, perform the check procedure for the coil connector and for the
Marelli control unit connector; if not ok restore; if everything is ok, check the continuity of the
cable between the two ends of the cable: if there is no continuity, restore the wiring harness;
if there is continuity, with key ON, check the cable ground insulation (from the coil connector
or control unit connector); if not ok, restore the wiring harness.
Throttle body
Function
Sends to the injection control unit the throttle position and activates the throttle according to the control
unit
All the unit internal components (potentiometer and electric motor) are contactless; therefore, no elec-
trical diagnosis is possible for the throttle body, but for the circuits connected to it only.
Throttle check and handle grip sensor (Demand)
Position:
• on the vehicle: inside the filter box
• connector: on the throttle body, in lower position, near the throttle motors
Pin out:
1. potentiometer signal 1
2. supply voltage + 5V
3. throttle valve control command (+)
4. potentiometer signal 2
5. throttle valve control command (-)
6. ground lead
Front cylinder throttle valve correction
• Example value with key ON: 0,0°
• Example value with engine on: 0.4°
Reading the intake pressures, the system tries to balance the intake pressures through the front and
rear cylinder, operating on the throttle valves positions: an acceptable value should be between -0.5
and +0.5
Rear cylinder throttle valve correction
ELE SYS - 163

• Example value with key ON: 0,0°

• Example value with engine on: -0.2°
Reading the intake pressures, the system tries to balance the intake pressure through the front and
rear cylinder, operating on the throttle valves positions: an acceptable value should be between -0.5
and +0.5
Potentiometer front throttle valve (degrees)
• Example value with key ON: 7.8°
With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts
up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°). When the gear
is not engaged, at approximately ???? rpm the throttle valves opening s very small and the requested
torque is very low (approximately 5-7°)
Potentiometer rear throttle valve (degrees)
• Example value with key ON: 8°
Potentiometer 1 front throttle valve (voltage)

• Example value with key ON: 873 mV
• Example value with engine on: 561 mV
Potentiometer 1 rear throttle valve (voltage)

Potentiometer 2 front throttle valve (voltage)

Potentiometer 2 rear throttle valve (voltage)

Potentiometer 2 front throttle valve (degrees)

ELE SYS - 164

Potentiometer 2 rear throttle valve (degrees)
Front cylinder throttle valve Limp Home position
Voltage stored in the control unit corresponding to the Limp home position
Rear cylinder throttle valve Limp Home position
Voltage stored in the control unit corresponding to the Limp home position
Front throttle valve lower position
Voltage stored in the control unit corresponding to the throttle mechanical minimum position
Rear throttle valve lower position
Voltage stored in the control unit corresponding to the throttle mechanical minimum position
CAUTION

Front throttle valve automatic self-learning
• Ice/Interrupted/Performed/Limp home/Throttle valve stopper closed/Spring check/Limp
home acquisition/Initialization
Indicates if the self-learning performed by the control unit was performed/not performed: this is funda-
mental for understanding if the acquisition was successful at the last key ON
Rear throttle valve automatic self-learning
• Ice/Interrupted/Performed/Limp home/Throttle valve stopper closed/Spring check/Limp
home acquisition/Initialization
Indicates if the self-learning performed by the control unit was performed/not performed: this is funda-
mental for understanding if the acquisition was successful at the last key ON
Throttle self-learning with diagnostics instrument
ELE SYS - 165

• Performed/Not performed
Indicates if the self-learning with the diagnostic tool was performed/not performed: if it was performed
one time, it will always remain performed unless a control unit EEPROM reset is carried out

CAUTION
IF ERRORS ARE DETECTED ON BOTH THROTTLE BODIES, CHECK ALSO THE CORRECT SUP-
PLY OF THE CONTROL UNIT TO PIN 42.
P0120 Front throttle valve position potentiometer sensor
Error cause:
• Short-circuit to positive: excessive voltage has been detected on PIN 48. If open circuit, short
circuit to negative: voltage equal to zero detected at PIN 48.
Troubleshooting:
• Short-circuit to positive: check the value indicated by the Potentiometer 1 front Throttle valve
parameter (voltage): disconnect the connector and read the value indicated in the diagnostic
tool: if the voltage does not vary, there is a short circuit in the concerned cable; replace the
throttle body if the voltage drops to zero
• If open circuit, short circuit to negative: perform the check procedure for the throttle body
connector and control unit connector; if not ok, restore, if everything is ok, check the con-
tinuity of the circuit between the two ends; if not ok, restore the wiring harness, if ok, check
the ground insulation of the circuit (from the throttle body connector or control unit connec-
tor); if ground insulated, check that at PIN 2of the throttle boy connector there is power supply
(+5 V) and that at PIN 6 there is ground; if they are correct, replace the throttle body.
P2120 Rear throttle valve position potentiometer 1 sensor

Error cause:
Troubleshooting:
• Short-circuit to positive: check the value indicated by the Potentiometer 1 rear Throttle valve
parameter (voltage): disconnect the connector and read the value indicated in the diagnostic
tool: if the voltage does not vary, there is a short circuit in the concerned cable; replace the
throttle body if the voltage drops to zero
ELE SYS - 166

P0220 Front throttle valve position potentiometer sensor

• Short circuit to positive / open circuit, short circuit to negative.
Error cause:
Troubleshooting:
• Short-circuit to positive: check the value indicated by the Potentiometer 1 front Throttle valve
parameter (voltage): disconnect the left side connector and read the value indicated in the
diagnostic tool: if the voltage does not vary, there is a short circuit in the cable wiring; replace
the throttle body if the voltage drops to zero
P2125 Rear throttle valve position potentiometer 2 sensor

• short circuit to positive / open circuit, short circuit to negative.
Error cause:
Troubleshooting:
• Short-circuit to positive: check the value indicated by the Potentiometer 2 rear Throttle valve
parameter (voltage): disconnect the left side connector and read the value indicated in the
diagnostic tool: if the voltage does not vary, there is a short circuit in the cable wiring; replace
the throttle body if the voltage drops to zero
ELE SYS - 167

P2119 Front throttle valve command circuit
• Short circuit to positive / short circuit to negative / open circuit, excessive internal tempera-
ture over-current.
Error cause:
• Short-circuit to positive: excessive voltage detected on PIN 29 or 41 of the 7SM control unit.
If short circuit to negative: no voltage has been detected. If open circuit: an interruption of
an excessive Ampere consumption or control unit overheating was detected.
Troubleshooting:
• Short-circuit to positive: disconnect the throttle body connector, turn the key OK and check
the voltage at PIN 3: if a voltage greater than or equal to 5 V is read, there is a short circuit
of the relative cable, if the voltage is zero, replace the throttle body
• If short circuit to negative: disconnect the throttle body connector, turn the key ON and check
if PIN 3 has continuity with the vehicle ground: if there is continuity restore the wiring harness,
if there is no continuity replace the throttle body
• If open circuit, excessive internal temperature over-current: check the throttle body connec-
tor and the control unit connector: if not ok restore, if everything is ok disconnect the
connector of the throttle body and the control unit connector and check cable continuity; if
there is no continuity, restore the cable harness. If there is continuity, with the throttle body
connector connected, check that the resistance, from the throttle control unit connector,
between PIN 29 and 41 is within 1 and 2.5 Ohm; if not ok replace the throttle body, if ok
check that the throttle body is not mechanically blocked: if blocked, remove the cause or
replace the body; if not blocked, replace the control unit.

P0121 Front throttle valve position potentiometer 1 sensor
• Signal not plausible.
Error cause:
• Signal outside the specified value determined based on the values of the intake pressure.
Troubleshooting:
• Check the parameter of the Potentiometer 1 front throttle valve (voltage) to know which
signal the control unit receives and to compare it to the Potentiometer 1 rear throttle valve
(voltage). Check the throttle body connector and the control unit connector. Check that cable
resistance between the throttle body connector (PIN 1) and the control unit (PIN48) is a few
ELE SYS - 168

tenths of an Ohm. Otherwise, restore the wiring harness; if ok, replace the complete throttle
body.
P2126 Rear throttle body potentiometer 2

• Signal not plausible.
Error cause:
• Signal outside the specified value determined based on the values of the intake pressure.
Troubleshooting:
• Check the parameter of the Potentiometer 2 rear throttle valve (voltage) to know which signal
the control unit receives and to compare it to the Potentiometer 2 front throttle valve (volt-
age). Check the throttle body connector and the control unit connector. Check that cable
resistance between the throttle body connector (PIN 4) and the throttle control unit (PIN 21)
is a few tenths of an Ohm. Otherwise, restore the wiring harness; if ok, replace the complete
throttle body.
P1400 Front throttle valve Limp Home self-learning

• Test failed.
Error cause:
• Position of the throttle valve, maintained by the springs, outside the specified range (at each
key ON).
Troubleshooting:
• Check the cleanliness of the throttle body and the intake duct. If ok, replace the throttle body.
P1405 Front throttle valve mechanical (re-closing) springs self-learning

• Test failed.
Error cause:
• Throttle valve return time, in the position maintained by the springs, outside of the specified
limits: the causes can be a deterioration of spring performance or excessive throttle valve
friction (at each key ON).
Troubleshooting:
P1402 Front throttle valve minimum mechanical position self-learning

ELE SYS - 169

• Test failed.
Error cause:
• Position of the throttle valve stopper outside of the specified range (at each key ON).
Troubleshooting:
P1403 Front throttle valve recovery conditions detection (Tair,Twater)

• Ice possibly present.
Error cause:
• in conditions of low ambient temperature and engine temperature, a correct throttle valve
rotation was not detected: possible presence of ice in the duct (at each key ON).
Troubleshooting:
• Check the cleanliness of the throttle body and that there is no ice or condensate in the intake
duct. If ok, replace the throttle body.
P1404 Front throttle valve power supply voltage during self-learning.

• Low power supply voltage.
Error cause:
• The throttle valve power supply voltage is too low to correctly perform the self-learning test
(at each key ON).
Troubleshooting:
• Remove the presence of errors that prevent throttle self-learning.
P0638 Front throttle valve position error - EPOS error

• Misalignment between control and activation.
Error cause:
• The throttle valve mechanical control could be damaged.
Troubleshooting:
• Replace the throttle body.
P1406 Rear throttle valve Limp Home self-learning

• Test failed.
Error cause:
ELE SYS - 170

• Position of the throttle valve, maintained by the springs, outside the specified range (at each
key ON). The instrument panel indicates this error by lighting up in a fixed manner the MI
warning light.
Troubleshooting:
P1411 Rear throttle valve mechanical (re-closing) springs self-learning

• Test failed.
Error cause
friction (at each key ON).
Troubleshooting:
P1408 Rear throttle valve minimum mechanical position self-learning

• Test failed.
Error cause:
• Position of the throttle valve stopper outside of the specified range (at each key ON).
Troubleshooting:
P1409 Rear throttle valve recovery conditions detection (Tair,Twater)

• Ice possibly present.
Error cause:
• in conditions of low ambient temperature and engine temperature, a correct throttle valve
rotation was not detected: possible presence of ice in the duct (at each key ON). The in-
strument panel indicates this error by lighting up in a fixed manner the MI warning light.
Troubleshooting:
• Check the cleanliness of the throttle body and that there is no ice or condensate in the intake
duct. If ok, replace the throttle body.
P1410 Rear throttle valve power supply voltage during self-learning

• Low power supply voltage.
Error cause:
ELE SYS - 171

• The throttle valve power supply voltage is too low to correctly perform the self-learning test
(at each key ON). The instrument panel indicates this error by lighting up in a fixed manner
the MI warning light.
Troubleshooting:
• Remove the presence of errors that prevent throttle self-learning.
P0639 Rear throttle valve position error - EPOS error

• Misalignment between control and activation
Error cause:
• The throttle valve mechanical control could be damaged.
Troubleshooting:
• Replace the throttle body.
P1401 Rear throttle valve mechanical springs self-learning (opening)

• Test failed
Error cause:
• The recognition of this error is enabled during the throttle self-learning procedure.
friction (at each key ON)

Troubleshooting:
• Using the diagnostic tool, erase the error, then perform the throttle self-learning procedure.
If the error is displayed again, it may mean a mechanical problem at the throttle boy.
• Check the cleanliness of the throttle body and the intake duct. Check if there are any me-
chanical ruptures. Replace the throttle body, if necessary.
P1407 Front throttle valve mechanical springs self-learning (opening)

• Test failed
Error cause:
• The recognition of this error is enabled during the throttle self-learning procedure.
friction (at each key ON)

Troubleshooting:
ELE SYS - 172

• Using the diagnostic tool, erase the error, then perform the throttle self-learning procedure.
If the error is displayed again, it may mean a mechanical problem at the throttle boy.
• Check the cleanliness of the throttle body and the intake duct. Check if there are any me-
chanical ruptures. Replace the throttle body, if necessary.
DIAGNOSTIC TOOL: ADJUSTABLE PARAMETERS

Throttle self-learning.
NOTE
AT EVERY "KEY ON", THE CONTROL UNIT PERFORMS A TEST ON THE THROTTLE VALVES
TO CHECK THEIR MOBILITY, ASSESSING THE NECESSARY FORCE TO MOVE THEM AN THE
POTENTIAL PRESENCE OF OBSTACLES. AT EVERY 150 "KEY ON", THE SYSTEM PERFORMS
A STOPPER LEARNING FOR EACH THROTTLE BODY; IF START-UP IS ATTEMPTED DURING
THIS PROCEDURE (THAT REQUIRES APPROXIMATELY 3 SECONDS), THE ENGINE WILL NOT
START.
THROTTLE BODY RESET PROCEDURE
If a throttle body is replaced, or if it needs to perform automatic learning, proceed as follows:
After key ON, do not start the engine for the next 3 seconds, during which the throttle automatic learning
is performed by the control unit: according to the throttle body concerned, check that the "Front throttle
automatic self-learning" or the "Rear throttle automatic self-learning" status indicates: "completed". If
the indication is not "completed", remove any errors that may exist on the vehicle and at the next key
On check that the statuses are "completed". Where appropriate, perform the throttle self-learning from
the "settings" screen and check that the "Throttle self-learning with diagnostics instrument" status in-
dicates: "completed" and that the "Front throttle automatic self-learning" or "Rear throttle automatic self-
learning" statuses indicate: "completed".
Engine oil pressure sensor
Function
Indicates the instrument panel if there is enough
oil pressure (0.5 +/-0.2 bar) in the engine.
Switch normally closed (control unit signal to
ground). The switch opens at pressure values
above 0.5 ± 0.2 bar.
Low fuel and oil pressure
Position:
• on the vehicle: front side of the engine,

next to the oil filter.
• connector: on the sensor.
Electrical specifications: -
ELE SYS - 173

Pin out:
1. Voltage: 5 V
CAUTION
Dashboard
Oil sensor FAULT error B0001
Error cause
• An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is
open. The test is performed only once when the key is set to ON. There is an error when
the general warning light turns on.
Troubleshooting
• Check the sensor connector and the instrument panel connector (PIN 13): if they are not
OK, restore. If OK, check continuity of the purple cable between the sensor connector and
the instrument panel connector PIN 13: if not OK, restore the wiring harness; if OK, replace
the sensor.
Oil pressure FAULT error B0002

Error cause
• An oil sensor fault is signalled when, with engine running, it is detected that the sensor circuit
is closed. There is an error when the general warning light turns on.
Troubleshooting
• Check if oil pressure is low with the specific gauge.
Neutral sensor
Function
Indicates to the control unit the position of the
gearbox, from 1st gear to 6th gear, and if the gear-
box is in neutral or drive.
The sensor is comprised of 2 circuits: one to indi-
cate the gear engaged, whose resistance varies
depending on the engaged gear: in this way, the
injection control unit, depending on the detected
ELE SYS - 174

electric voltage, identifies the engaged gear and

transmits the information via CAN to the instru-
ment panel, the other for the idle indication whose
voltage is reduced to zero if in the neutral position.
Position:
• on the vehicle: under the chain pinion,

behind the pinion cover.
• connector: fitted under the filter hous-
ing, left side (3 way white connector).
PIN 64:
• neutral indication: closed circuit (con-

tinuity);
• gear engaged: open circuit (infinite re-
sistance).
Gear circuit resistance:
• 1st gear\: 0.8 kohm;

• 2nd gear: 0.5 kohm;
• 3rd gear: 15.0 kohm;
• 4th gear: 6.9 kohm;
Pin out:
From the sensor to the connector:
• White/black: ground from ECU

• Light blue: + 12V from ECU (neutral)
• Pink: + 5V from ECU (drive).
From the connector to the wiring harness:
• Pink/black: ground from ECU

• Yellow: + 12V from ECU (neutral)
• Grey/Black: + 5V from ECU (drive).
CAUTION
ELE SYS - 175


Gearbox in neutral
• Yes/No
gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6
P0914 Gear sensor
• short circuit to positive or open circuit/ short circuit to negative.
Error cause
• If open circuit, short circuit to positive: excessive voltage has been detected on PIN 72.
• If short circuit to negative: voltage equal to zero detected at PIN 72.
Troubleshooting
• If open circuit, short circuit to positive: the error is detected only with a gear engaged. check
the sensor connector and the VEHICLE connector of the control unit: if not OK, restore. if
ok, check the continuity of the Grey/Black cable between the two connectors: if not OK,
restore. if ok, with key ON and with the control unit connector disconnected, check from the
control unit connector side if the cable is energised: if energised, disconnect the sensor
connector and check if the cable is energised: in this case, restore the wiring harness; if not
energised, replace the sensor (there is an interruption or a short circuit to positive of the
White/Black cable on the segment that goes from the sensor connector to the sensor or
inside the sensor).
• If short circuit to negative: Disconnect the sensor connector and, with key ON, check the
voltage of the Grey/Black cable: if it is zero, restore the wiring harness; if it approximately 5
V, replace the sensor (there is short circuit to ground of the Pink cable on the segment that
goes from the sensor connector to the sensor or inside the sensor).
Clutch lever sensor
Function
Indicates the clutch lever position to the control
unit.
If a gear is engaged but the clutch is engaged, that
is circuit closed to ground, there is consent to start
the vehicle.
Position:
ELE SYS - 176

• on the vehicle: on the handlebar.

• connector: on the sensor.
• Clutch engaged: closed circuit (con-

tinuity)
• Clutch released: open circuit (infinite
resistance).
Pin out:
1. voltage 5V
2. ground lead
CAUTION
P0704 Clutch switches plausibility error

Diagnosis:
Error cause:
• If there is one contact: the plausibility diagnosis cannot occur only at key ON but during
operation. The control unit logic requires that the released/engaged and engaged/released
witching time does not exceed a certain threshold. If the operating time is too long, the error
is shown. To check the origin of the problem, it is enough to connect the diagnostic tool to
see if , despite the clutch lever operations, the status remains "ENGAGED". Check the wiring
harness or the sensor.
• If there are two contacts: the plausibility diagnosis can occur at key ON. Since there are two
contacts that cannot be both "CLOSED" or both "OPEN" (excepting fraction of a second
while switching from "RELEASED" to "ENGAGED" and vice versa), if they are, the error is
shown.
The presence of this error is signalled by the fixed lighting of the general warning light.
Troubleshooting:
• If the error is active only with the lever released: the problem is generated by the released
clutch contact of the which is interrupted or by the engaged clutch contact which is in short
circuit to ground.
ELE SYS - 177

• If the error is active only with the lever engaged: the problem is generated by the engaged
clutch contact of the which is interrupted or by the released clutch contact which is in short
circuit to ground.
• If the error is always active: both contacts are open or in short circuit to ground.
Depending on the case, check the concerned parts of the wiring harness and the sensor.
NOTE
THIS ERROR DISABLES THE CRUISE CONTROL.
Side stand sensor

Funzione
indica alla centralina la posizione del cavalletto
laterale
Funzionamento / Principio di funzionamento
Se innestata la marcia ed il cavalletto è aperto,
quindi circuito aperto, la centralina impedisce l'av-
viamento o effettua lo spegnimento del motore se
in rotazione
Livello appartenenza schema elettrico:
Consensi all'avviamento
Posizione:
• sul veicolo: sul cavalletto

• connettore: tra il telaio e il motore, lato
destro, sopra al coperchio volano (con-
nettore bianco a 2 vie)
Pin out:
1. Massa
2. Tensione 12V
Caratteristiche elettriche:
• Cavalletto su: circuito chiuso (continu-

ità)
• Cavalletto giù: circuito aperto (resis-
tenza infinita)
CAUTION

P1850 Side stand diagnosis
ELE SYS - 178

Side stand functional diagnosis:

up/down
Troubleshooting:
• Indication on the diagnostic tool always down: perform the connector check procedure: if
not ok, restore; if ok, disconnect the two ends from the sensor and check the PIN 1 continuity
to ground: if there is no continuity, restore cable harness; if there is, replace the sensor
• Indication on the diagnostic tool always up: disconnect the two ends from the sensor and
check if, with the stand down, there is continuity between the two PINS: if there is continuity
replace the sensor; if open circuit, it means that there is short circuit to ground of the brown/
green cable that goes from PIN 2 of the sensor to PIN 70 of the VEHICLE connector: restore
the wiring harness
Bank angle sensor
Function
indicates the vehicle position to the control unit.
When the sensor is in reverse position, the ground
circuit is closed: detecting this ground, the Marelli
control unit prevents the start-up or stops the en-
gine.
Level in electrical circuit diagram:start enable
switches
Position:
• on the vehicle: under the saddle

• connector: close to the sensor
• Vertical sensor: open circuit ( 62 kohm

resistance)
• Reverse sensor: closed circuit (con-
tinuity)
Pin-out:
1. Voltage - Orange/Black colour, from VEHI-

CLE PIN 63 to the fall sensor, passing
through multiple connector - Section 0.5
ELE SYS - 179

2. Signal - Pink/White colour, from VEHICLE

PIN 65 to the fall sensor, passing through
multiple connector - Section 0.5
3. Ground - Green/Pink colour, from ENGINE
PIN6/PIN17 to the fall sensor, passing
through multiple connector - Section 0.5
Air temperature sensor - instrument panel

Function
Indicates the ambient air temperature to the in-
strument panel.
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Position:
• on the vehicle: in the front urn indica-

tors support, under the headlamp.
• connector: behind the headlamp.
• Resistance at 0 °C (32 °F) : 32.5 kOhm

+/- 5%
• Resistance at 25 °C (77 °F) : 10.0
kOhm +/- 5%
Pin-out:
1. 5 V voltage
2. Ground
DIAGNOSTIC TOOL: PARAMETERS
Troubleshooting:
• Check the sensor connector and the instrument panel connector (PIN 5 and 34): if not ok,
restore; if ok, check the continuity of the pink cable between the sensor connector and PIN
5 of the instrument panel connector: if not ok, restore the wiring harness; if ok, check if the
sensor resistance is correct: if not ok, replace the sensor; if ok, check the continuity of the
blue/black cable between the sensor connector and PIN 34 of the instrument panel con-
nector: if not ok, restore the wiring harness; if ok, check (with key ON) the voltage at PIN 1
of the sensor connector: if there is no voltage, replace the instrument panel; if there is ap-
ELE SYS - 180

proximately 12 V, restore the wiring harness (there is a short circuit to battery); if 5 V, connect
a 10 kohm resistance to PIN 1 of the sensor connector and to he vehicle ground: if, with key
ON, the measured voltage upstream the resistance decreases, replace the instrument pan-
el; if it continues to be 5 V, restore the pink cable (there is a short circuit at + 5V)
Notes
In case of short circuit to ground detected at PIN 5 of the instrument panel connector, the display shows
the "-" indication for the air temperature.
Check the ground insulation of the sensor connector pink cable: if connected to ground, restore the
wiring harness; if insulated from the ground, check if the sensor resistance is correct: if not ok, replace
the sensor; if ok, replace the instrument panel.
Electric fan circuit
Function
Activates coolant radiator fan
When the ECU detects a temperature of approxi-
mately 101°C, it closes the connection between
the fan control relay excitation circuit and ground
electric fan
Position:
• sensor: relay located in the front recess
of the chassis, to the right
• connector: on relay
• relay normally open;
• drive coil resistance 110 Ohm (+/- 10
%)
DIAGNOSTIC TOOL:STATUSES
Fan relay
• on/off
DIAGNOSTIC TOOL:ACTIVATIONS
Fan
• Energy is applied for 10 seconds to the
fan relay (36 in the electrical circuit di-
agram, position in the steering head-
stock recess, to the right; however,
ELE SYS - 181

CHECK the identification of the relay

with the colour of the cables). Electrical
continuity is required in the wiring for
the relay to activate correctly: no errors
are generated if the relay fails to acti-
vate
CAUTION
P0480 Cooling fan command

• short circuit to positive/ short circuit to negative / open circuit
Error cause:
• Short-circuit to positive: excessive voltage has been detected at PIN 61 of the VEHICLE
connector.
• If open circuit: 5V voltage has been detected. Error recognition carries out only when the
fan relay is activated.
Troubleshooting:
• Short-circuit to positive: check the relay electrical specifications are correct by disconnecting
it from the cable harness. If not OK, replace the relay; if OK, restore the cable harness (Brown
cable)
• If short circuit to negative: check the relay electrical specifications are correct by discon-
necting it from the cable harness. If not OK, replace the relay; if OK, restore the cable harness
(Brown cable)
• If open circuit: check the relay electrical characteristics are correct by disconnecting it from
the cable harness; if it is not OK, replace the relay, if it is OK, check relay connector, engine-
vehicle cable harness connector and VEHICLE connector of the Marelli control unit: if not
OK, restore; if OK, check continuity of cable harness (Brown cable)
ELE SYS - 182

RUN/STOP switch
Function
Indicates the control unit if the rider wishes to en-
able engine start-up or to keep the engine running.
If you want to stop the engine or to prevent it from
starting, the switch must be open, meaning that
PIN 78 of the VEHICLE connector of the Marelli
control unit must not be grounded.
Position:
• on the vehicle: Right hand light switch.

• connector: under the steering head-
stock, inside the protection case (black
colour, 4 way).
• STOP position: open circuit

• RUN position: closed circuit (continui-
ty)
Pin out:
1. Ground - Green/Pink colour
2. 5V signal - Engine start-up - Pink/Brown colour
3. Ground - Green/Pink colour
4. 5V signal - Engine stop - Pink/Yellow colour
CAUTION

RUN/STOP switch
• Run/Stop
NOTES
• Indication on the diagnostic tool always STOP: disconnect the connector and check with the
RUN switch if there is continuity towards the two Blue/Green and Yellow/Red cables: if it is
missing, replace the sensor; if there is, perform the connector check procedure: if not ok,
restore the wiring harness; if ok, check with the key ON if there is voltage on the Yellow/Red
ELE SYS - 183

cable: if it is missing, restore the wiring harness; if there is, check the ground insulation of
the Yellow/Red cable: if there is continuity with the ground, restore the wiring harness; if ok,
turn the key to OFF and perform the VEHICLE connector and engine-vehicle wiring harness
connector check: if not ok, restore; if ok, check the continuity of the Yellow/Pink cable be-
tween the switch connector and the VEHICLE connector PIN C7 and PIN 78: if not ok, restore
the wiring harness; if ok, replace the Marelli control unit.
• Indication on the diagnostic tool always RUN: disconnect the connector and check with the
switch in STOP of there is continuity between the two cables of the switch: if there is, replace
the switch, if there is no continuity it means that, with the key ON, the Yellow/Pink cable
(between the switch and PIN C7 of the engine-vehicle wiring harness connector or between
the latter and PIN 78 of the control unit connector) is in short circuit to positive: restore the
wiring harness.
Throttle control unit
THROTTLE CONTROL UNIT

Function
It receives the throttles target position from the Marelli control unit and it moves them so that they reach
that target by reading their position through the potentiometers (2 per throttle body).
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
ELE SYS - 184

ECU
Engine pinout key:
• PIN 1 -
• PIN 2 -
• PIN 3 - Motorised throttle valve (+) (rear cylinder)
• PIN 4 - Analogic ground 2
• PIN 5 - Power ground
• PIN 7 -
• PIN 8 -
• PIN 9 - Rear cylinder lambda probe (+)
• PIN 10 - Front cylinder lambda probe (+)
• PIN 11 -
• PIN 12 - Water temperature sensor input
• PIN 13 - B handle input
• PIN 14 - Serial line
• PIN 15 - Motorised throttle valve (-) (rear cylinder)
• PIN 16 - Power ground
• PIN 18 -
• PIN 19 -
ELE SYS - 185

• PIN 20 - Engine rpm sensor (-)

• PIN 21 - Throttle valve potentiometer 2 signal (rear cylinder)
• PIN 22 - Front cylinder lambda probe (-)
• PIN 23 -
• PIN 24 - Intake pressure sensor signal (front cylinder)
• PIN 25 - 1 reference voltage output
• PIN 27 - Rear cylinder coil
• PIN 28 - Front cylinder coil
• PIN 29 - Motorised throttle valve (-) (front cylinder)
• PIN 30 -
• PIN 31 -
• PIN 32 - Front cylinder lambda probe heater
• PIN 33 -
• PIN 34 -
• PIN 35 - Engine rpm sensor (+)
• PIN 36 - Throttle valve potentiometer 1 signal (rear cylinder)
• PIN 37 - Air temperature sensor input
• PIN 38 - Rear cylinder lambda probe (-)
• PIN 39 - A handle input
• PIN 40 - Ignition switched live
• PIN 41 - Motorised throttle valve (+) (front cylinder)
• PIN 43 -
• PIN 44 - Rear cylinder lambda probe heater
• PIN 45 -
• PIN 46 -
• PIN 47 -
• PIN 48 - Throttle valve potentiometer 1 signal (front cylinder)
• PIN 49 - Intake pressure sensor signal (rear cylinder)
• PIN 50 - Throttle valve potentiometer 2 signal (front cylinder)
• PIN 52 - Battery power supply
ELE SYS - 186

Vehicle pinout key:
• PIN 53 - Front cylinder injector

• PIN 54 -
• PIN 55 -
• PIN 56 - Clutch sensor
• PIN 58 - Engine start-up
• PIN 59 -
• PIN 60 -
• PIN 61 - Fan command relay
• PIN 62 -
• PIN 64 - Neutral input
• PIN 65 - Fall sensor input
• PIN 66 - L CAN line
• PIN 67 - Rear cylinder injector
• PIN 68 -
• PIN 69 - Start-up enable
• PIN 70 - Side stand input
• PIN 71 -
• PIN 72 - Gear input
• PIN 73 - Secondary injection relay command output
ELE SYS - 187

• PIN 74 -
• PIN 75 -
• PIN 76 -
• PIN 77 -
• PIN 78 - Engine stop input
• PIN 79 -
• PIN 80 - H CAN line
Engine-vehicle connector pinout key:
• PIN A1 - Key (+)

• PIN A2 - Oil temperature sensor
• PIN A3 -
• PIN A4 - 2 reference voltage output
• PIN A5 - Fall sensor
• PIN A6 -
• PIN A7 - Analogic ground
• PIN A8 - Battery
• PIN B1 - Injection power supply
• PIN B2 - CAN line (high)
• PIN B3 - CAN line (low)
• PIN B4 - Key
• PIN B5 - Electric fan relay control
• PIN B6 -
• PIN B7 -
• PIN B8 - Power ground 1
• PIN C1 - Injection power supply
• PIN C2 - K serial line for diagnosis
• PIN C3 - Clutch engaged
• PIN C4 - "Start engine" button
• PIN C5 - Start-up
• PIN C6 - Injection relay
• PIN C7 - Engine stop
• PIN C8 - Power ground 2
ELE SYS - 188

Dashboard
Instrument panel pinout key:
• PIN 1 -
• PIN 2 - Antenna 1
• PIN 3 - Antenna 2
ELE SYS - 189

• PIN 4 - Oil temperature sensor

• PIN 5 - Air temperature sensor
• PIN 6 - Arrow reset
• PIN 7 - Light relay
• PIN 8 -
• PIN 9 - Battery positive
• PIN 10 -
• PIN 11 -
• PIN 12 -
• PIN 13 - Oil pressure
• PIN 14 - High beam lights IN
• PIN 15 - Mode UP
• PIN 16 - Key positive
• PIN 18 -
• PIN 19 - Mode DOWN
• PIN 20 - Mode SET
• PIN 21 - LH arrow control
• PIN 22 - RH arrow control
• PIN 23 -
• PIN 24 - Ground
• PIN 25 - Ground
• PIN 26 -
• PIN 27 - RH front arrow
• PIN 28 - RH rear arrow
• PIN 29 - LH front arrow
• PIN 30 - LH rear arrow
• PIN 31 - Fuel reserve
• PIN 32 - L CAN line (high speed)
• PIN 33 - H CAN line (high speed)
• PIN 34 - Sensor ground
ELE SYS - 190

ABS Modulator
ABS control unit pinout key:

• PIN 1 - Power ground 1
• PIN 3 -
• PIN 5 - H CAN line
• PIN 6 - CAN L line
• PIN 7 -
• PIN 8 -
• PIN 9 -
• PIN 10 -
• PIN 11 - Rear ABS sensor positive
• PIN 12 - Rear ABS sensor negative
• PIN 13 - Rear ABS sensor negative
• PIN 14 - Front ABS sensor positive
• PIN 16 - Serial line
• PIN 17 -
Can line
Function
Allows the communication between the Marelli injection control unit, the instrument panel, the ABS
modulator.
CAN SYSTEM ADVANTAGES
A CAN line (Area network controller) is a connection between various electronic devices of a vehicle,
set up as a computer network (internet). The CAN network allowed to significantly simplify the layout
ELE SYS - 191

of the electric system and consequently its total mass. With this communication line, it was possible to
avoid useless duplications of various sensors on the motorcycle, since the signals coming from them
are divided among the three electronic processing units (instrument panel, control unit and ABS).
• Cable number reduction: The CAN line travels through a twisted cable to several nodes.
• These nodes can also isolate the errors without causing a system breakdown (FaultsCon-
fination).
• Immunity to interference: the signal travels through two cables and the signal reading is
differential (voltage difference between the two signals on both cables). If the two signals
are disturbed by an external factor, their difference remains unaltered.
• Communication speed: The messages travel at a bit rate of approximately 500 kbps (de-
pending on the sent data package, the information may arrive at the nodes in a time carrying
from 4 ms to 100 ms).
CAN PROTOCOL (CONT. NETWORK AREA)
The communication protocol is CSMA/CD (Carrier Sense Multiple Access w/ Collision Detection).
In order to transmit, every nod must first check that the BUS (the connection among all devices) is free
before attempting to send a message with BUS (Carrier Sense).
If during this period there is no activity on BUS, every nod has the same chance to send a message
(Multiple Access). If two nodes start transmitting simultaneously, the nodes recognise the "colli-
sion" (Collision Detection) and initiate an exchange action based on message priority (messages remain
unaltered during exchange and there is no delay for high priority messages).
CAN protocol is based on messages and not on addresses. The message itself is divided into several
parts (frames), each of which has a meaning: message priority, data contained, error detection, recep-
tion confirmation, etc.
Every network nod receives all the messages sent through the BUS (with reception confirmation or error
messages) and each nod decides if the message is to be processed or rejected. Besides, every nod
can request information from the other nodes (RTR = Remote Transmit Request).

CAN Line
• between PIN 66 and 80 of the control unit: approx. 120 Ohm
• between PIN 32 and 33 of the instrument panel: approx. 120 Ohm
Pin out:
• Line L: cable X1 between ABS control unit PIN 66, instrument panel PIN 32 and ABS mod-
ulator PIN 6.
• Line H: cable X2 between Marelli control unit PIN 80, instrument panel PIN 33 and ABS
modulator PIN 5.
CAUTION
ELE SYS - 192

U1125 Frame counter "Sensor Box" CAN line diagnosis

• Intermittent signal or communication error
Error cause:
• Probable bad contact in the CAN line.
This error is not indicated even in the ATT status.

Troubleshooting:
• Perform the check procedure for the VEHICLE connector at PIN 66 and PIN 80 and of the
engine-vehicle wiring harness connector at PIN B2 and B3; if NOT OK, restore; if ok, check
the general operation of the Marelli control unit; in case of anomalies, replace it.
NOTE
U1121 Diagnosis of "ABS control unit" CAN line or CLF frame counter
• Signal absent
Error cause:
• If there is no signal, no signal is received from the ABS control unit.

Troubleshooting:
• Missing signal - Perform the check procedure for PIN 5 and PIN 6 of the ABS control unit
connector, for PIN 66 and PIN 80 of the Marelli control unit vehicle connector: if NOT OK,
restore; if OK with key OFF, disconnect the ABS control unit connector; if NOT OK replace
the wiring harness, if OK check the correct power supply to PIN 18 (12V) and the grounding
of ABS control unit PIN 1; if NOT OK, restore the wiring harness, if OK, replace the ABS
control unit.
NOTE
THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON-
TROL AND THE CRUISE CONTROL.
P1800 Rear wheel radius learning diagnosis
• CAN error while learning / Signal not plausible.
Error cause:
ELE SYS - 193

• In case of CAN error during acquisition, system warns that the procedure can not be com-
pleted due to a communication problem on the CAN line.
• If the signal is not plausible, there was a transcription error of the value of the rear wheel
radius from the non volatile memory (EEPROM) to the volatile memory (RAM) at key ON.
In this case the default value is used.
This error is indicated by lighting up in a fixed manner the MI warning light

NOTE
ELE SYS - 194

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle SHIVER 900
CHASSIS
for fastening the side fairings to the
engine
2 TORX cyl. head screws used for fas- M12x53 4 80 Nm (59.00 lb ft) -
tening the trellis to the frame side
fairings
3 Cyl. head, hex. socket screw used for M10x30 1 50 Nm (36.88 lb ft) Pre-impregnated
fastening the shock absorber coun- screw
ter-plate to the right hand frame side
fairing
for fastening the saddle support to screws
the frame
fastening the silencer support brack-
et to the saddle support
ENG VE - 196
SHIVER 900 Engine from vehicle
ENGINE - ACCESSORIES - LEVER MECHANISMS

1 Flanged, hex. head screw used for M10x1.25x26 1 50 Nm (36.88 lb ft) Pre-impregnated
fastening the pinion screw
fastening the gear lever to the gear-
box output shaft
3 TORX screw used for fastening the M6x22 1 8 Nm (5.90 lb ft) Loct. 270
gear lever pedal
fastening the pinion cover guard
Vehicle preparation
• Disconnect the battery and remove the

fuel tank, the coolant radiator and the
exhaust system.
• Remove the filter box and disconnect
the water temperature sensor connec-
tor (1).
ENG VE - 197
• Disconnect the timing sensor (3) and

the voltage regulator connectors (4).
• Remove the three clutch pump fasten-

ing screws (4).
• Remove the clutch pump (5) and use

the clamps to secure the pump so that
the piston cannot fall out.
See also
Fuel tank
Removing the
radiator
Removing the tail pipe
Removing the
exhaust manifold
ENG VE - 198
• Remove the two screws (6) used to

fasten the pinion cover (7), taking care
to retrieve the respective bushings.
• Remove the cover (7).
• Remove the two clutch pump support

fastening screws (8).
• Remove the clutch pump support (9).
• Loosen the screws (10) used to fasten

the gear lever.
ENG VE - 199
• Remove the gear lever (11)
• Disconnect the vehicle stand switch

connector (12).
• Remove the three screws (13) used to

fasten the stand support.
• Remove the stand support (14).
ENG VE - 200
• Remove the screw (15) used to fasten

the pinion, retrieving the washer (16)
and the spring washer (17) and taking
care to reposition them correctly during
reassembly.
• Remove the pinion (18) and detach the

drive chain (19).
• Working on both sides of the vehicle, remove the screws (20) used to fasten the ABS sup-
port, taking care to retrieve the spacer (21).
• Access the left hand side of the motor-

cycle and remove the screw (22) used
to fasten the cable clamp positioned
inside the frame, on the left hand side.
ENG VE - 201

secure the cable clamp (24) positioned
under the swingarm, and remove it.

fasten the right hand rider's footrest.
• Disconnect the engine oil pressure

sensor connector (26).
• Remove the clamp (27), disconnect

the connector (28) from the sensor ...
and free the wiring harness.
ENG VE - 202

fasten the plate positioned under the
steering headstock.
• Move the complete ABS system (30)

towards the outside so that it is easier
to remove the engine.
Removing the engine from the vehicle
• Carry out the operations described in

the vehicle preparation procedure.
cycle, unscrew the upper central nut
(1) and remove it.

cycle, unscrew the lower nut (2) and
remove it.
ENG VE - 203

cycle, unscrew the front nut (3) and
remove it.
• Access the right hand side of the mo-

torcycle, partially extract the central pin
(4) and remove the spacer (5) position
on the internal, left hand side of the
frame.
• Remove the pin (4), complete with
washer (6).
See also
Vehicle preparation

torcycle, partially extract the lower pin
(7) and remove the spacer (8) posi-
tioned inside the frame, on the left hand
side.
washer (9).

torcycle, partially extract the front pin
(10) and remove the spacer (11) posi-
tioned inside the frame, on the left hand
side.
washer (12).
ENG VE - 204
• Position a central stand in order to sup-

port the engine and a trestle under the
rear of the motorcycle in order to raise
it.
• Lower the engine partially, unscrew the
screws (13) used to fasten the earth
cables to the engine, and remove
them.
• Lower the engine completely, and

raise the rear of the motorcycle so that
it is possible to remove the engine
completely.
Installing the engine to the vehicle

NOTE
IN ORDER TO INSTALL THE ENGINE ON THE VEHICLE, REPEAT THE "REMOVING THE ENGINE
FROM THE VEHICLE" PROCEDURE IN REVERSE ORDER, AND CARRY OUT THE "PREPARING
THE VEHICLE" PROCEDURE.
See also
Removing the engine from the vehicle
Vehicle preparation
ENG VE - 205
INDEX OF TOPICS
ENGINE ENG
SHIVER 900 Engine
Gearbox
Diagram
Key
1. Complete desmodromic
2. Fork
3. Primary fork
4. Fork shaft
5. complete index lever
6. Gear stopper lever spring
7. Threaded rod
8. Selector stopper plate
9. Screw
10.Selector shaft
11.Flat washer 14x30x1
12.Selector spring
13.Threaded rod M8x1.25
14.Selector sprocket
15.Gear selector drum
16.Sprocket ratchet
ENG - 207
Engine SHIVER 900
17.Spring
18.Tip for spring
19.Domed head torx screw
20.O-Ring
21.Gear sensor
22.Spacer
23.O-Ring
24.Selector stopper
25.Self-locking nut
Gearbox shafts
Gearbox shafts diagram
Key:
1. Primary transmission shaft Z=14

2. 2nd gear on primary Z=17
3. 3rd - 4th gear on primary Z=20/22
4. 5th gear on primary Z=23
5. 6th gear on primary Z=24
6. Shoulder washer
7. Snap ring
ENG - 208
SHIVER 900 Engine
8. Shoulder washer
9. Shoulder washer
10.Snap ring
11.Floating bushing
12.Secondary transmission shaft
13.1st gear on secondary Z=36
14.2nd gear on secondary Z=32
15.3rd gear on secondary Z=30
16.4th gear on secondary Z=28
19.Floating bushing
20.Shoulder washer
21.Shoulder washer
22.Shoulder washer
23.Shoulder washer
24.Snap ring
25.Shoulder washer
26.Floating bushing
Disassembling the gearbox
• Remove the gear shift selector as de-

scribed in the Crankcase Opening sec-
tion.
• Remove the two fork pins.
• Extract the desmodromic control.
ENG - 209
Engine SHIVER 900
• Remove the three gear selection forks.

CAUTION
THE FORK FOR THE PRIMARY SHAFT IS SMALLER THAN
THAT OF THE SECONDARY SHAFT.
THE FORKS FOR THE SECONDARY SHAFT ARE THE
SAME.
• Remove the shim.
• Carefully turn the engine support.

• Carefully extract the entire gearbox as-
sembly.
FITTING
• Repeat the removal operations in the opposite order, taking care to check that the shim is
present on the secondary shaft.
VERIFICATION OF PINION FASTENING ON SECONDARY SHAFT

Perform the following procedure in order to check the hole for fastening the pinion onto the gearbox's
secondary shaft.
• Measure the external diameter of the countersink on the hole for fastening the pinion onto
the secondary shaft.
• In order to reduce the measurement error, lock the bore gauge after having set it to 15.5
mm, then check whether the two ferrules are inside or outside the countersink.
CAUTION
THE RELIABILITY OF THE MEASURED VALUE IS FUNDAMENTAL.
ENG - 210
SHIVER 900 Engine
• If the external diameter of the counter-

sink is equal to or less than 15.50 mm,
rework the threading with a male M10
x 1.25. Use a manual male finisher or
a low input machine series male.
• Blow with compressed air.
• Wash with degreasing spray.
• Blow with compressed air.
• Replace the pinion's fastening ele-
ments with upgraded fastening ele-
ments, as indicated in the Spare Parts
Catalogue.
• If the external diameter of the counter-

sink is greater than 15.50 mm, replace
the secondary shaft and the pinion's
fastening elements with upgraded
components, as indicated in the Spare
Parts Catalogue.
Gear selector
ENG - 211
Engine SHIVER 900
GEAR SELECTOR
1 Gear sensor fastening screw M5 2 6 Nm (4.43 lb ft) Loct. 270
2 Selector plate fastening screw M5x12 3 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353
3 Desmodromic drum/sprocket fasten- M8x1.25x17 1 15 Nm (11.06 lb ft) 3M SCOTCH GRIP
ing screw 2353
4 Selector pin fastening screw M10x1.5 1 16 Nm (11.80 lb ft) Loct. 242
5 Ratchet pin fastening screw M6 1 12 Nm (8.85 lb ft) Loct. dry loc 2040
Removing the gear selector
• After having removed the clutch side

cover and the complete clutch, the
gear shift selector shaft can be extrac-
ted, taking care to retrieve the flat
washer.
Checking the gear selector
Selector spring
Make sure that the spring ends on the two shifting
positions (forward = downshifting and backward =
up-shifting) are always in contact with the selector
plate
Make sure that the clearance between the end of
the spring on the selector plate and the stop pin is
almost null, when in home position (see diagrams)
Pawl
Make sure that both pawl tips run free, without
jamming
ENG - 212
SHIVER 900 Engine
Selector plate spring

With a thickness gauge, check that the spring is
not deformed by over-stretching.
Gearbox Selector Shaft
Removal
• Place the left hand crankcase in a

press and extract the roller cage with
the specific tool.
NOTE
REPEAT THE SAME OPERATION FOR THE RIGHT HAND
CRANKCASE HALF.
Specific tooling
020724Y Punch cage with rollers gearbox con-
trol stem
INSTALLATION
• Place the left hand crankcase in a

press and install the roller cage with the
specific tool.
CAUTION
TO INSTALL THE ROLLER CAGE IN THE RIGHT HAND
CRANKCASE HALF, WORK WITH THE CYLINDER ON THE
SIDE OF THE 1 mm (*) STEP ON THE TOOL TURNED TO-
WARD THE ROLLER CAGE, WHEREAS TO INSTALL THE
CAGE IN THE LEFT HAND CRANKCASE HALF, USE THE
CYLINDER ON THE SIDE OF THE 2 mm (**) STEP ON THE
TOOL.
Specific tooling
020724Y Punch cage with rollers gearbox con-
trol stem
ENG - 213
Engine SHIVER 900
Starter motor
IGNITION
2353
grease both of the
coupling surfaces
cover
cover
screw
screw
fastening screw
ENG - 214
SHIVER 900 Engine
Removing the starter motor
• In order to remove the starter motor

complete with the support bracket, it is
necessary to remove the two screws
(1).
• If the bracket needs to be removed
from the starter motor, first remove the
two screws (2) and then the other
screws (1).
Generator side
IGNITION
2353
grease both of the
coupling surfaces
cover
cover
screw
ENG - 215
Engine SHIVER 900

screw
fastening screw
• Remove the flywheel cover inspection

cap.
• Unscrew and remove the ten screws (1

- 2).
NOTE
THE SCREW (2) FOR THE FLYWHEEL COVER IS SHORT-
ER THAN THE OTHER SCREWS (1).
• Position the appropriate tool in screw it

in a clockwise direction until the fly-
wheel cover has been partially extrac-
ted.
Specific tooling
020712Y Handle for removing the flywheel cov-
er
• Remove the flywheel cover.
Specific tooling
020712Y Handle for removing the flywheel cov-
er
ENG - 216
SHIVER 900 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 REMOVED SIMUL-
TANEOUSLY AS THEY ARE PART OF THE SAME ELEC-
TRICAL BRANCH.
Magneto flywheel removal
• Remove the flywheel cover.

• Unscrew and remove the screw and
remove the retention plate.
• Use a heater to heat the flywheel mag-

net.
• Use the appropriate tool to block the
flywheel and loosen the screw.
Specific tooling
ENG - 217
Engine SHIVER 900
• Remove the tool from the rotor and re-

move the screw complete with the
washer.
• Screw the special tool's left-handed pin

onto the outer body.
• Keeping the outer body blocked, screw
in the pin in such a way as to extract
the flywheel from the crankshaft.
Specific tooling
• Unscrew and remove the special tool's left-handed pin from the outer body.
• Unscrew the screw from the crankshaft.
Specific tooling
• Remove the flywheel complete with the

free wheel
• Retrieve the wrench from the crank-

shaft.
ENG - 218
SHIVER 900 Engine
• Remove the starter's transmission

gear bearing.
• In the event of a malfunction, the start-
er's transmission gear bearing cannot
be overhauled and must be completely
replaced.
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 starter's transmission gear,

after having coated it with a layer of
grease.
• Apply the wrench to the crankshaft.
ENG - 219
Engine SHIVER 900
• Apply the flywheel to the crankshaft.
• Apply the screw and the washer with-

out tightening.
• Position the appropriate tool to lock the

flywheel in place.
• Holding the flywheel still using the ap-
propriate tool, tighten the screw on the
crankshaft.
• Remove the special tool.
Specific tooling
• Position the retention plate.
• Tighten the screw.
ENG - 220
SHIVER 900 Engine
Clutch side
CLUTCH COVER
tening screw
ENG - 221
Engine SHIVER 900
CLUTCH
WATER PUMP
tening screw
ENG - 222
SHIVER 900 Engine

nut
• Remove the water pump cover.

• Undo and remove the eleven screws
working in a diagonal sequence.
• Collect the gasket.
Removing the clutch cover
CLUTCH COVER
tening screw
ENG - 223
Engine SHIVER 900

Based on the engine design development, there are two types of clutch crankcases, associated to the
specific water pumps.
The second generation cover is distinguished through punch marks, as indicated in the image.
CAUTION
THE CLUTCH CRANKCASES MUST BE COUPLED TO THE CORRESPONDING WATER PUMPS.

THE COMPONENTS ARE NOT INTERCHANGEABLE.
THE CRANKCASE WITH THE PUNCH MARKS MUST BE COUPLED TO THE WATER PUMP WITH
PUNCH MARKS.
INCORRECT COUPLING MAY CAUSE SERIOUS DAMAGE TO THE ENGINE.
• Unscrew and remove the retaining

screws.
• Remove the clutch cover.
The removal of the clutch cover is recommended

for the replacement of the clutch discs. If the entire
clutch unit is removed, it is recommended to re-
move the clutch side crankcase.
However, the entire clutch unit can be removed,
by removing only the clutch cover. In this case,
perform the following operations:
• measure the overhang of he clutch

housing from the crankcase, before re-
moval;
ENG - 224
SHIVER 900 Engine
• upon refitting, before tightening the

clutch nut, check that the measure has
not changed. If it is different, turn the
crank shaft in such a way as to properly
align the engine's oil pump control gear
on the clutch bell with the oil pump's
driven gear.
See also
Removal
Disassembling the clutch
CLUTCH
ENG - 225
Engine SHIVER 900
• Remove the clutch crankcase.

• Unscrew and remove the six screws,
loosening them by a quarter of a turn
at a time, by stages, and working in a
diagonal fashion, while recovering the
washers and the clutch springs.
• Remove the thrust plate.
• Remove the mushroom-head clutch

control rod
• Remove the discs.
ENG - 226
SHIVER 900 Engine
• Block the clutch bell using the appro-

priate tool and unscrew the nut on the
hub.
Specific tooling
• Remove the disc spring.
• Remove the clutch hub.
• Remove the special washer between

the clutch hub and the clutch bell.
ENG - 227
Engine SHIVER 900
• Remove the clutch bell.
• Retrieve the spacer and the roller bear-

ings.
• Retrieve the shim.
Checking the clutch plates
• Lay the friction discs and steel discs on

a level surface and check them for
cracks and potential distortions.
Maximum distortion allowed: 0.20 mm (0.0079

in)
• Measure the driving plate thickness at

four positions, replace them all if not
complying with specifications.
CAUTION
THE STEEL DISCS MUST SHOW NO SCORES OR TEM-
PERING COLOUR.
ENG - 228
SHIVER 900 Engine
• Measure the thickness of the clutch

discs at four positions, replace them if
not complying with specifications.
Thickness of nine drive discs: 2.5 mm (0.10 in).

Driven disc thickness: 2,75 - 2,85 mm (0.108 ÷
0.112 in).
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.

• Remove the seeger ring.
• Remove the oil pump's drive gear.
DURING REASSEMBLY, THE COLLAR OF THE GEAR

MUST ALWAYS BE FACING THE CLUTCH BELL.
ENG - 229
Engine SHIVER 900
• Remove the pin that blocks the rotation

of the oil pump control gear.
Check for any damage or signs of wear on the clutch bell that could lead to irregular clutch functionality.
Grind down the teeth or replace the bell if necessary.
PRIMARY DRIVEN GEAR CONTROL

Check for the presence of any damage or signs of wear on the primary driven gear, and replace the
primary transmission's driven gear and the clutch bell, if necessary.
Verify that the noise level is not too high during operation; replace the primary transmission's driven
gear and the clutch bell, if necessary.
Checking the pusher plate
Check the thrust plate and the bearing for damage

and wear. If necessary, replace the parts.
Checking the clutch hub
Check the clutch hub for damage and wear that

may result in clutch irregular operation. If neces-
sary, replace the bell.
ENG - 230
SHIVER 900 Engine
Checking the springs
• Check the springs for signs of damage,

and replace them if necessary.
• Measure the free length of the clutch
springs, and replace them if necessa-
ry.
Free length of the clutch spring: 66.5 mm (2.62

in)
Assembling the clutch
• Fit the shim washer.
• Fit the needle bearing and the spacer.
• Fit the clutch housing.

• Make sure that the oil pump control
drive gear of the clutch housing engag-
es correctly with the oil pump driven
gear.
ENG - 231
Engine SHIVER 900
• Place the washer correctly between

the clutch housing and the hub.
• Position the clutch hub.
• Install the clutch cover.

• Before tightening the clutch nut, check
to make sure that the measurement
has not changed with respect to that
which was measured during the disas-
sembly phase. If it is different, turn the
crank shaft in such a way as to properly
align the engine's oil pump control gear
on the clutch bell with the oil pump's
driven gear.
• Insert the safety washer.
ENG - 232
SHIVER 900 Engine
• Position the clutch hub nut and tighten

it using the appropriate tool.
Specific tooling
• After having tightened the nut, proceed

with the chamfering.
• Insert the flat ring (1).

• Insert the disc ring (2).
CAUTION
MAKE SURE THE DISC RING IS INSERTED FACING THE RIGHT DIRECTION; THE RING'S CONE
MUST BE FACING THE ENGINE.
• Insert the turned drive disc (3).
• Insert the nitride steel disc (4).
• Insert the clutch discs starting with the

discs with friction material, and alter-
nating them with steel discs.
• Position the control rod.
ENG - 233
Engine SHIVER 900
• Position the thrust plate.
• Fit the clutch springs.

• Fit the screw washers.
• Tighten the six screws operating in
stages and diagonally.
• Replace the gasket upon refitting.
Head and timing
ENG - 234
SHIVER 900 Engine
HEAD COVER
1 Special head cover fastening screw M6 8 9 Nm (6.64 lb ft) -
HEAD
ening
head - Tightening
ing outside
ing inside
Head
Head
the discharge
ENG - 235
Engine SHIVER 900
Removing the head cover
The following operations are valid for both of the

heads.
• Unscrew and remove the four screws,

and retrieve the rubber blocks.
• Remove the head cover.
Removing the cylinder head

NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO THE REMOVAL OF ONE HEAD ONLY, BUT
ARE VALID FOR BOTH.
• Pre-emptively remove the camshafts,
the chain tensioners, and the timing
system.
• Remove the four nuts (1) on the stud
bolts and the two screws (2).
• Remove the four external screws (3, 4, 5).
ENG - 236
SHIVER 900 Engine
Cylinder head
HEAD
ening
head - Tightening
ing outside
ing inside
Head
Head
the discharge
ENG - 237
Engine SHIVER 900
Removing the overhead camshaft
• Remove the clutch side crankcase.

• Turn the crankshaft of the head for
which the camshafts need to be re-
moved to TDC.
In order to remove the head camshafts, it is nec-

essary to remove the head covers.
Mark the camshafts, le relative cogwheels, and the
cam towers in order to avoid mixing them up during
the reassembly phase.
• Unscrew and remove the cam tower's

eight screws, proceeding in a diagonal
fashion and by stages.
• Carefully remove the cam tower in or-
der to avoid damaging the calibrated
grub screws' lodgings.
• Remove the camshafts complete 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.
ENG - 238
SHIVER 900 Engine
• Remove the bucket tappets and the

adjustment shims using a magnet.
• Compress the valve springs with the

specific wrench and with the spring
compressing tool.
Specific tooling
AP8140179 Valve springs compressor
020721Y Valve removal adaptor
• Remove the cotters using a magnet.
ENG - 239
Engine SHIVER 900
• Release the valve springs.

• Remove the valve spring fittings and
the springs.
• Remove the valves.
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; otherwise,
replace the camshaft and the relevant
toothed wheel.
• Use a micrometer to check the sizes
(a) and (b) of the camshaft lobes.
Camshaft lobes sizes:

Inlet
• a: 36.28 / 36.32 mm (1.4283 / 1.4299

in); Limit: 36.15 mm (1.4232 in);
• b: 28 mm (1.1023 in);
Outlet
ENG - 240
SHIVER 900 Engine
• a: 35.13 / 35.17 mm (1.3831 / 1.3846

in); Limit: 35.00 mm (1.3779 in);
• b: 28 mm (1.1023 in);
• Fasten the camshaft in horizontal po-

sition, as shown in the figure, and make
it spin to check the eccentricity with a
dial gauge; if necessary, replace the
component.
Camshaft eccentricity maximum limit 0.040

mm (0.0016 in)
Valve check
CAUTION
REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST
BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL.
CAUTION
THE SEAT (1) ON THE VALVE HEAD CANNOT BE REGROUND. IF REQUIRED, REPLACE THE
VALVE.
GRINDING WITH ABRASIVE PASTE IS ALLOWED; VALVE STEM END REGRINDING IS NOT AL-
LOWED.
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);
limit: 0.080 mm (0.00315 in)
outlet: 0.025 - 0.052 mm (0.00098 - 0.00205 in);
limit: 0.100 mm (0.00394 in)
ENG - 241
Engine SHIVER 900
Check the valve eccentricity:

valve stem (3) maximum eccentricity allowed:
0.05 mm (0.00197 in)
valve head (4) maximum eccentricity allowed:
0.05 mm (0.00197 in)
Check that the fixing grooves (5) of the valve cot-
ters are in proper conditions.
VALVE SPRINGS
Carry out a measurement and a visual inspection
of the valve springs for damage, distortion or loss
of tension.
Measure the spring length at release position.
Valve springs: minimum wear limit (6) 42.5 mm
(1.673 in).
Valve springs: minimum wear limit (7) 38 mm
(1.496 in).
Checking the cylinder head
• Using a round scraper, clean off any carbon deposits in the combustion chamber.
CAUTION
DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK
PLUG THREADS OR THE VALVE SEATS.
• Check the head for damage or scratches and replace it if necessary.
• 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.
Maximum cylinder head distortion: 0.03 mm (0.0012 in)
• Check that the tappet covers and the camshaft toothed wheel cover are not damaged or
worn; replace the defective part(s).
Installing the overhead camshaft
The camshaft refitting procedure is described in the "Timing" section.
See also
Timing
ENG - 242
SHIVER 900 Engine
Timing
TIMING SYSTEM
1 Cam shaft gear fastening nut M15x1 4 88 Nm (64.91 lb ft) Thoroughly de-
grease both of the
coupling surfaces
(axle cone and gear
cone)
2 Timing lay shaft fastening screw M24x1.5 2 88 Nm (64.91 lb ft) 3M SCOTCH GRIP
2353
ENG - 243
Engine SHIVER 900

3 Special mobile / fixed slider fastening M8 4 18 Nm (13.28 lb ft) 3M SCOTCH GRIP
screw 2353
4 Cam tower / head fastening screws M6x37 16 13 Nm (9.59 lb ft) Follow the number-
ing sequence stam-
ped on the cam tow-
ers
5 Cam tower / plate fastening screws M4x10 8 3 Nm (2.21 lb ft) 3M SCOTCH GRIP
2353
6 Decompressor fastening screws M8 2 28 Nm (20.65 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
7 Decompressor fastening screw M5x12.9 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
CYLINDER
1 Chain tensioner fastener screw M6x30 4 13 Nm (9.59 lb ft) -
2 Cylinder plate fastening screw M6x16 4 9 Nm (6.64 lb ft) -
3 Chain tensioner adjustment screw M6 2 5 Nm (3.69 lb ft) -
ENG - 244
SHIVER 900 Engine
Removing the chain tensioner
• Unscrew and remove the screw, and

retrieve the washer and the internal
spring.
• Unscrew and remove the two screws.

• Remove the chain tensioner and re-
trieve the gasket.
Chain removal
• Remove the chain tensioner.

• Remove the mobile chain slider and
free the fixed chain slider from the fas-
tener.
• Heat the pin for the intermediate gear
and loosen it.
• Hold the intermediate gear still and re-

move the pin.
ENG - 245
Engine SHIVER 900
• Extract the timing chain from the crank-

shaft.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
• Remove the timing chain complete

with the gear.
See also
Removing the
chain sliders
Removing the
chain tensioner
Removing the chain sliders
• Remove the chain tensioner and the

camshafts for the head in question.
FRONT HEAD
• In order to remove the front head's

chain sliders, it is necessary to remove
the clutch cover.
• Unscrew and remove the mobile chain
tensioner slider's screw.
• Remove it by extracting it from the
head.
ENG - 246
SHIVER 900 Engine
• Unscrew and remove the fixed chain

• The head must be removed in order to
remove it.
REAR CYLINDER HEAD
• In order to remove the rear head's

chain sliders, it is necessary to remove
the flywheel.
• Unscrew and remove the mobile chain
• Remove it by extracting it from the
head.
• Unscrew and remove the fixed chain

• The head must be removed in order to
remove it.
See also
Removing the
chain tensioner
Removing the
head cover
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.
ENG - 247
Engine SHIVER 900
Installing the chain tensioner
• Fit the chain tensioner body on the cyl-

inder and insert a new paper gasket.
• Tighten the two screws to the prescri-
bed torque.
• Insert the spring and tighten the screw

together with the washer.
Cam timing
Timing
• Position the plate (1) of the specific

timing tool and lock it in place using the
two screws (2) on the cover.
• Insert the tool (3) on the crankshaft,
making sure that the pin (4) mounted
on the crankshaft is inserted into the
seat on the tool (5).
Specific tooling
020720Y Timing tool
ENG - 248
SHIVER 900 Engine
• Rotate the crankshaft anticlockwise

until the front cylinder piston is posi-
tioned at top dead centre, while check-
ing that there is sufficient play on the
camshafts.
• The front cylinder top dead centre po-
sition must correspond to position (A).
If necessary, remove the distribution gearwheels

from the cam shafts:
• Position the cam shaft, complete with

distribution gearwheel, in a vice, en-
suring that the shaft is adequately pro-
tected.
• Unscrew the nut and remove it.
BOTH REAR CYLINDER SHAFTS ARE FITTED WITH LEFT-

HANDED THREAD NUTS, WHICH HAVE BEEN STAMPED
WITH A ANTICLOCKWISE ARROW.
• Retrieve the washer.

• Remove the distribution gearwheel
from the cam shaft.
• Clean the surfaces of the gearwheels

(camshaft cone and gearwheel cone).
• Pre-assemble the gearwheel on the
camshaft so that it is free to rotate.
• Position the two camshafts in the hous-
ings in the front big end, aligning the
two bores on the camshaft with the cor-
responding holes on the big end. The
camshaft cams must be convergent.
ENG - 249
Engine SHIVER 900
• Align the play compensation gear-

wheel with the main distribution gear-
wheel using the dedicated tool.
Specific tooling
• Position the cam tower.

• Tighten the screws provisionally.
• Time the camshafts, using the appro-

priate pins.
Specific tooling
020719Y Timing pin
• Pre-tighten the nuts on the camshaft gearwheels.
FIT THE NUTS SO THAT THE MACHINED SURFACE IS FACING THE GEARWHEEL (MATERIAL
CODE VISIBLE).
• Remove the cam tower and the cam-
shafts, place them in a vice using a pair
of aluminium jaws, then tighten the
nuts, applying the pre-defined torque.
NEVER APPLY THE DEFINITIVE TIGHTENING TORQUE TO

THE CAMSHAFT NUTS WHILE THE SHAFT IS MOUNTED
ON THE CYLINDER.
THIS WOULD DAMAGE THE HEAD IRREVERSIBLY.
ENG - 250
SHIVER 900 Engine
• Remove the gearwheel alignment tool.
Specific tooling
• Reposition the cam tower and the cam-

shafts, applying the pre-defined tight-
ening torque.
• Rotate the camshaft anticlockwise until
the rear cylinder piston is at TDC (B).
• Repeat the timing procedure for the
front cylinder.
Specific tooling
020720Y Timing tool
CAUTION
AT TDC THE REAR BIG END CAMS MUST BE DIVERGENT.
Cylinder-piston assembly
Removing the cylinder
• After having removed the head com-

plete with the timing system, extract
the cylinder from the stud bolts.
ENG - 251
Engine SHIVER 900
• Remove the gasket on the cylinder

base.
See also
Chain removal
Removing the
cylinder head
Disassembling the piston
• Remove the big end and the cylinder.

• Extract the pin locking ring.
• Lock the connecting rod using the spe-

cific tool.
• Slide the pin and remove the piston.
Specific tooling
020716Y Connecting stem lock
ENG - 252
SHIVER 900 Engine
• Lock the connecting stem with elastic

straps
FOR SAFETY REASONS, COVER THE CRANKCASE WITH

A CLEAN MATERIAL TO AVOID THE FALL OF THE SAFE-
TY RINGS IN THE CRANKCASE.
• Remove the upper ring, the second

ring and the oil ring.
See also
Removing the
cylinder head
Removing the
cylinder
ENG - 253
Engine SHIVER 900
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.
CAUTION
IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT, REPLACE THE CYLINDER AND
THE PISTON.
• Clean off lime scales on the cylinder
cooling slots.
• Measure the cylinder bore at a dis-
tance of 10 - 40 - 98.5 mm (0.39 - 1.57
- 3.88 in) from the head coupling sur-
face; the highest value should be con-
sidered to estimate wear limits.
Cylinder bore "C": 92,000 mm (3.6220 in)

(Key: C = max D1 or D2)
Cylindricity limit: 0.028 mm (0.0011 in)
Replace the cylinder, the piston and the piston ring
all together if not complying with specifications.
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
(0.00197 - 0.00252 in) Limit: 0.100 mm (0.00039
in)
• Replace the cylinder, the piston and

the piston ring all together if not com-
plying with specifications.
ENG - 254
SHIVER 900 Engine
PISTON RINGS
• Clean off any carbon deposits from the

grooves in the piston rings and from the
rings themselves.
• Measure the piston ring side clearance
and replace the piston and the piston
rings all together if not complying with
specifications.
Piston ring side clearance:

Top ring (1st slot): 0.030 - 0.065 mm (0.0012 -
0.0026 in)
Intermediate ring (2nd slot): 0.020 - 0.055 mm
(0.0008 - 0.0022 in)
Oil scraper ring (3rd slot): 0.010 - 0.045 mm
(0.0004 - 0.0018 in)
• Fit the piston ring to the cylinder.

• Level the installed piston ring with the
piston crown.
• Measure piston ring port and replace it
if not complying with specifications.
CAUTION
IT IS NOT POSSIBLE TO MEASURE THE CLEARANCE OF
THE END OF THE OIL SCRAPER RING: IF THERE IS EX-
CESSIVE PLAY, REPLACE THE THREE ELASTIC RINGS.
Piston ring end gap:

Top ring: 0.15 - 0.35 mm (0.0059 - 0.0138 in)
The second ring: 0.20 - 0.40 mm (0.0079 -
0.0157 in)
Oil scraper ring: 0.20 - 0.70 mm (0.0079 - 0.0276
in)
PISTON PIN
• Clean off combustion residues from the piston crown and from the area above the top ring.
• Check for cracks on the piston and for compression on the piston sliding surface (seizing);
Replace the piston if required.
CAUTION
SMALL STRIATIONS ON THE PISTON LINER ARE ADMISSIBLE.
ENG - 255
Engine SHIVER 900
• Measure the pin outside diameter (a)

and if not complying with specifica-
tions, replace the pin.
Pin outside diameter: 22.00 - 21.97 mm (0.8661

- 0.8650 in) Limit: 21.96 mm (0.8646 in)
• Measure the pin housing diameter (b)

and replace the piston if not complying
with specifications.
Pin housing diameter (b): 22.010 - 22.015 mm

(0.8665 - 0.8667 in)
• Calculate the clearance between pin

and pin hole and, if not complying with
specifications, replace both pin and
piston.
Pin - piston clearance: C = b - a

0.010 - 0.045 mm (0.0004 - 0.0018 in)
Limit: 0.060 mm (0.0024 in)
CAUTION
TO ANY CYLINDER TYPE THE SPECIFIC PISTON MUST BE COUPLED.
PISTON - CYLINDER COUPLING

Cylinder-piston class A coupling Cylinder: 91.990 - 91.997 mm (3.6216 - 3.6219 in)
Piston: 91.933 - 91.940 mm (3.6217 - 3.6197 in)
Cylinder-piston class B coupling Cylinder: 91.997 - 92.004 mm (3.6219 - 3.6222 in)
Piston: 91.940 - 91.947 mm (3.6197 - 3.6199 in)
Cylinder-piston class C coupling Cylinder: 92.004 - 92.011 mm (3.6222 - 3.6225 in)
Piston: 91.947 - 91.954 mm (3.6199 - 3.6202 in)
Cylinder-piston class D coupling Cylinder: 92.011 - 92.018 mm (3.6225 - 3.6227 in)
Piston: 91.954 - 91.961 mm (3.6202 - 3.6205 in)
Fitting clearance 0.050 - 0.064 mm (0.00197 - 0.00252 in)
Fitting the piston
The top of the piston is stamped with an arrow that indicates the direction of installation, towards the
cylinder's output.
• In order to reinstall the seal rings on the piston, position that arrow stamped on outside of
the pinion so that it is facing the operator.
ENG - 256
SHIVER 900 Engine
• The elastic bands are different from

one another, and must be mounted
with the "N" marking facing upwards.
• Apply the lower oil scraper ring to the

piston with the opening facing the out-
put side.
• Apply the remaining seal rings to the piston so that they are offset in relation to one another
by 90°.
• Apply the lock ring to the appropriate

tool.
• To facilitate its insertion onto the pis-
ton, move the ring near to the edge of
the tool.
Specific tooling
• Insert the lock ring positioned on the appropriate tool onto the piston.
Specific tooling
ENG - 257
Engine SHIVER 900
• Position the piston on the connecting

rod and insert the pin using the appro-
priate tool.
Specific tooling
• Insert the piston's missing stopper ring

using the appropriate tool, as descri-
bed above, to lock the pin in place.
Specific tooling
Installing the cylinder
• If previously removed, install the stud bolts.

CAUTION
THE STUD BOLTS MUST BE MOUNTED SO THAT THEY PROTRUDE.
THE PRE-IMPREGNATED PART MUST BE SCREWED ONTO THE CRANKCASES.
SCREW THE STUD BOLT ONTO THE CRANK CASE UNTIL A PROTRUSION OF 138 MM (5.43 IN)
IS OBTAINED, THEN WAIT FOR THE SEALANT TO DRY.
• Insert a new cylinder base gasket of
the same thickness as that which was
previously removed: 0.50 - 0.60 - 0.70
mm (0.0197 - 0.0236 - 0.0275 in).
• The silicon side must be facing the
crankcase.
CAUTION
IF THE THICKNESS OF THE ORIGINAL GASKET CANNOT
BE VERIFIED, OR IN THE CASE OF A CYLINDER RE-
PLACEMENT, REFER TO THE SECTION TITLED "BASE
GASKET SELECTION".
ENG - 258
SHIVER 900 Engine
• Using the band tightener, compress

the piston's bands and insert the cylin-
der onto the stud bolts.
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.
See also
Selecting the base gasket
Selecting the base gasket
• Once the seal rings have been applied

to the piston and it has been mounted
on the connecting rod, position the
special tool on the piston itself.
• Use a clamp to lock the special tool in
place.
Specific tooling
AP8140302 tool for installing seal rings
• Provisionally mount the piston on the
cylinder, without the base and head
gasket.
• Remove the clamp from the seal ring
locking tool.
• Remove the special connecting rod
locking tool.
• Fit a dial gauge on the specific tool.

• Zero the dial gauge on a reference sur-
face with an average preload of 5 mm
(0.2 in), for example. Maintaining the
zero position, mount the tool on the cyl-
inder and secure it with two nuts (10
Nm - 7.38 lb ft), as shown in the figure.
Specific tooling
ENG - 259
Engine SHIVER 900

• Turn the crankshaft to TDC (the rever-
sal point of the dial gauge's rotation).
• Lock the crankshaft at TDC using the
appropriate tool.
• Calculate the difference between the
two measurements: use the chart be-
low to identify the thickness of the cyl-
inder base gasket to be used for
refitting. Correctly identify the cylinder
base gasket thickness to keep the cor-
rect compression ratio.
• Remove the special tool and the cylin-
der.
Specific tooling
020720Y Timing tool
BASE GASKET
Protrusion detected from 0.6 to 0.75 mm (0.0236 / 0.0295 in) Gasket 0.5 mm (0.0197 in)
Protrusion detected from 0.75 to 0.85 mm (0.0295 / 0.0335 in) Gasket 0.6 mm (0.0236 in)
Protrusion detected from 0.85 to 1 mm (0.0335 / 0.0394 in) Gasket 0.7 mm (0.0275 in)
Installing the cylinder head
• Position the chain guide slider in the

appropriate lodging on the cylinder.
ENG - 260
SHIVER 900 Engine
• Position the gasket on the cylinder

base.
• Insert the head onto the stud bolts.
• Apply the nuts (1) to the stud bolts and

tighten them to the required torque val-
ue, proceeding in a crossover fashion.
• Insert and tighten the internal screws
(2).
• Insert and tighten the external screws (3, 4, 5).
Installing the head cover

CAUTION
ENG - 261
Engine SHIVER 900
END AND THE COVER.
CAUTION
REPLACE THE FOUR RUBBER INSERTS AND THE GASKET EACH TIME THE BIG END COVER
IS REMOVED.
CAUTION
END AND THE COVER.
• Apply THREEBOND around the perim-
eter of the big end cover along the
gasket housings.
• Apply THREEBOND to the head at the

points indicated in figure.
• In order to complete the remaining operations, repeat the removal procedure in reverse
order.
ENG - 262
SHIVER 900 Engine
Crankcase - crankshaft
CRANKCASE I
1 Crankcase-cylinder-head fastening M10x1.25x166 8 Distance-based tighten- SCOTCH GRIP
stud bolts ing 2510 GREEN
2 Bearing retainer fastening screws M6x12 3 10 Nm (7.38 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
3 Threaded plug M8x1 5 15 Nm (11.06 lb ft) 3M SCOTCH GRIP
2353
4 Piston oil jet fastening screw M5x16 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353 or Loct. DRI-
LOC 2045 BLUE
ENG - 263
Engine SHIVER 900
CRANKCASE II
3 Special oil calibration screw M10x1 1 14 Nm (10.33 lb ft) -
ENG - 264
SHIVER 900 Engine
CRANKSHAFT
1 Primary crankshaft fastening net M24x1.5 1 294 Nm (216.84 lb ft) Thoroughly de-
grease both of the
coupling surfaces
(shaft cone and
gear cone)
2 Connecting rod fastening screws - M10x1x40 4 15 Nm (11.06 lb ft) Lubricate the
Pre-torque threads before tight-
ening
2 Connecting rod fastening screws - M10x1x40 4 30 Nm (22.13 lb ft) + 50° -
Torque +/- 2°
2 Connecting rod fastening screws - M10x1x40 4 70 Nm (51.63 lb ft) -
Control
Splitting the crankcase halves

• Remove the water pump, the oil pump, the clutch, the flywheel, the intermediate gearwheel
and the head-engine block-piston assembly complete with distribution.
CAUTION
BEFORE USING THE "PRIMARY GEARWHEEL LOCK TOOL - 020850Y", IT IS NECESSARY TO
MAKE THREE HOLES SO THAT IT MAY BE POSITIONED CORRECTLY ON THE ENGINE GUARD.
THE HOLES ARE ILLUSTRATED IN THE FOLLOWING IMAGE.
• Mount the tool used to block the pinion, securing the three screws (1) on the guard.
CAUTION
TO AVOID DAMAGING THE OIL FEEDER COUPLING (2) POSITIONED ON THE GUARD, INSERT
SPACER WASHERS (3) BETWEEN THE TOOL AND THE GUARD, SO AS TO ENSURE A MINIMUM
DISTANCE OF 5mm (0.20 in)
Specific tooling
ENG - 265
Engine SHIVER 900
020850Y Primary gear lock
• Heat up the crankshaft gearwheel re-

taining nut using a suitable heater
• Remove the nut and the flat washer.
• Remove the motor pinion locking tool.

• Using a generic extractor tool, remove
the water pump gearwheel (4) and the
primary drive gearwheel (5) simultane-
ously.
See also
Removing the
cylinder
ENG - 266
SHIVER 900 Engine
• Remove the gearbox control rod, tak-

ing care to retrieve the washer.
• Heat up the gearbox selector support

plate screws.
• Unscrew the three gearbox selector

plate fastening screws and remove
them..
• Remove the plate.
ENG - 267
Engine SHIVER 900
• Press the springs on the selector

sprocket simultaneously in order to re-
move it.
• Unscrew the threaded pin used to fas-

ten the selector drum and remove it.
• Move the index lever to one side so

that it is possible to remove the selector
drum.
• Remove the idle sensor fastening

screws, then remove the sensor.
ENG - 268
SHIVER 900 Engine
• Remove the clutch control rod.
• Working on the left hand side, unscrew

and remove the nine M8 crankcase
fastener screws.
• Working on the left hand side, unscrew

and remove the nine M6 crankcase
fastener screws.
• Remove the fuel vapour breather pipe

mounting plate.
CAUTION
DURING REASSEMBLY, REMEMBER TO FIT THE FUEL
VAPOUR BREATHER PIPE MOUNTING PLATE NEAR THE
PINION.
ENG - 269
Engine SHIVER 900
• Rotate the engine and the engine sup-

port to the horizontal position.
• Using a rubber mallet, strike the guards
gently in order to separate them.
• Open the guards.
• If necessary, unscrew the two pick-up

tube fastening screws and remove
them.
• Remove the pick-up tube.
Removing the crankshaft
• Remove the crankshaft.
See also
Splitting the
crankcase halves
ENG - 270
SHIVER 900 Engine
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. Clean the seal surfaces and check
that they are not damaged.
CAUTION
TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE.
Check that both crankcase halves are not cracked or damaged.
Check that all threads are in proper conditions.
Check that all oil seals remaining in their position are not worn or damaged.
Check all ball bearings for clearance, smoothness and potential distortions.
CAUTION
LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING.
If the internal ring does not rotate smoothly and silently or if there is some noise while it turns, it means
that the bearing is faulty and must be replaced.
OIL FILTER AND OIL DELIVERY PIPE CHECK

Check the oil filter for damage. If necessary, replace the part.
Clean the oil net with petrol and inspect the net links for potential damage.
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.
ENG - 271
Engine SHIVER 900
• Replace the O-ring on the oil passage

duct.
Before refitting
UPON REFITTING THE CRANKSHAFT, GREASE THE SHAFT BUSHING-CONNECTING ROD

COUPLING.
Inspecting the crankshaft components
Checking crankshaft endfloat
• The shaft axial clearance on the crank-

case should be checked with a dial
gauge mounted on the specific dial
gauge support.
• The clearance should be between 0.10
and 0.26 mm (0.0039 - 0.0102 in).
• If the clearance is beyond tolerance,
check the reference surfaces.
Specific tooling
Main bearing journal
Removal
• Mark the position of the original semi-bushings on the crankcase.
ENG - 272
SHIVER 900 Engine
• Remove the bushings with the crank-

case cold, using a press and the spe-
cific tool and pushing inward from the
outside of the crankcase.
Specific tooling
020726Y Bushing extractor
Installing
• The orientation of the semi-bushings

must match the specifications indica-
ted in the drawing as closely as possi-
ble.
NOTE
WHEN REPLACING THE SEMI-BUSHINGS ALONE, THE
NEW COMPONENTS MUST BE THE SAME COLOUR AS
THE REMOVED COMPONENTS. IF THE COLOUR OF THE
OLD COMPONENTS IS NO LONGER VISIBLE, USE THE
TABLE TO IDENTIFY THE CORRECT COMPONENTS, RE-
FERRING TO THE CRANKCASE AND CRANKSHAFT
CLASSES.
Key:
* Semi-bushing joint line.
• Fit the new bushings with the crank-

case cold, using a press and the spe-
cific tool and pushing outward from the
inside of the crankcase, until the punch
comes into contact with the crankcase
surface.
Specific tooling
020727Y Bushing punch
Assembling the connecting rod

CAUTION
TO FIT THE CONNECTING RODS, CHECK THE COUPLING TYPES INDICATED IN THE "CRANK-
CASE- CRANKSHAFT CONNECTING ROD" SECTION, IN THE "CHARACTERISTICS" CHAPTER
OF THE WORKSHOP MANUAL.
ENG - 273
Engine SHIVER 900
Installing the crankshaft
• Place the left side crankcase half on

the engine support adequately.
• Place the crankshaft on the seat of the
crankcase half with caution.
Refitting the crankcase halves
• In order to reposition the guards, repeat the procedure described in the section "OPENING
THE GUARDS" in reverse order.
CAUTION
TAKE CARE NOT TO MAKE EXCESSIVE USE OF THREEBOND AS THIS COULD PREVENT THE
OIL FROM PASSING BETWEEN THE GUARDS.
CAUTION
ENSURE THAT THE AL GUARDS ARE POSITIONED AS PERPENDICULARLY AS POSSIBLE, IN

ORDER TO AVOID DAMAGING THE MAIN HALF BEARINGS.
See also
Splitting the
crankcase halves
Lubrication
ENG - 274
SHIVER 900 Engine
Conceptual diagrams
Key:
1. Filter head support.

2. Oil pump.
3. Oil pressure regulator valve.
4. Oil pressure sensor.
ENG - 275
Engine SHIVER 900
5. Oil filter.
6. Oil pressure regulator screw.
7. Secondary transmission shaft lubrication.
8. Primary transmission shaft lubrication.
9. Clutch discs lubrication.
10.Oil pressure sensor.
11.Main bushing lubrication.
12.Piston oil jets.
13.Water pump shaft lubrication.
14.Distribution command gearwheels.
15.Front big end cam axis.
16.Rear big end cam axis.
ENG - 276
SHIVER 900 Engine
Oil pump
LUBRICATION
1 Oil drainage plug M16x1.5 1 17 Nm (12.54 lb ft) +/- -
15%
2 Oil pressure sensor M10x1 1 13 Nm (9.59 lb ft) -
3 Fitting fixing of the oil filter - 1 20 Nm (14.75 lb ft) -
ENG - 277
Engine SHIVER 900

4 Oil filter - 1 14 Nm (10.33 lb ft) -
5 Oil pressure regulation valve M16x1.5 1 41 Nm (30.24 lb ft) -
6 Oil pump / bulkhead fastening M6x45 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
screws 2353
7 Strainer fastening screws - 2 12 Nm (8.85 lb ft) -
8 Oil pump gear fastener nut M6 1 11 Nm (8.11 lb ft) -
9 Gear sensor fastening screws M5x16 2 5 Nm (3.69 lb ft) 3M SCOTCH GRIP
2353
10 Oil temperature sensor M10x1 1 13 Nm (9.59 lb ft) -
Removing
• Press the raised side of the safety

washer back into place
• Block the pump gearwheel using a

commercial hook spanner and un-
screw the nut, taking care to retrieve
the safety washer.
• Remove the water pump gearwheel
ENG - 278
SHIVER 900 Engine
• Retrieve the shim.
• Undo and remove the two screws fixing

the oil pump.
• Remove the entire pump.
Inspection
• Undo and remove the two fixing

screws.
ENG - 279
Engine SHIVER 900
• Using a thickness gauge check clear-

ance between rotor and stator and re-
place the rotor / stator unit if necessary.
clearance between rotor and stator: 0.04 ± 0.10

mm (0.0016 in - 0.0039 in).
• Slide off the shaft with the cover.
• Collect the lock pin from the shaft.
• Remove the oil pump rotor.
ENG - 280
SHIVER 900 Engine
• Remove the oil pump stator.

CAUTION
CHECK THAT THE ROTOR AND STATOR ARE NOT DAM-
AGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTH-
ER MARKS).
Installing
NOTE
PAY ATTENTION TO ALIGN THE REFERENCES ON STA-
TOR AND ROTOR DURING INSTALLATION AND CHECK
CLEARANCE WITH A FEELER GAUGE.
IF REQUIRED, REPLACE THE STATOR / ROTOR UNIT.
• Fit the oil pump in its seat.
ENG - 281
Engine SHIVER 900
• Tighten both oil pump fixing screws.
• Fit the shim washer.
• Insert the oil pump gearwheel, making

sure that the machined groove coin-
cides with the pin on the pump.
• Insert the safety washer.

• Using a commercial hook spanner,
lock the pump in position and tighten
the nut, applying the predefined tor-
que.
ENG - 282
SHIVER 900 Engine
• Using a screwdriver, raise and bend

the safety washer on the side opposite
the slot until it is touching the nut.
ENG - 283
INDEX OF TOPICS
POWER SUPPLY P SUPP

SHIVER 900 Power supply
Fuel pump
TANK
fastening screws
Removing

• Remove the six nuts fixing the fuel
pump.
P SUPP - 285
Power supply SHIVER 900
• Remove the fuel pump.
Injection
Removing the throttle body
THROTTLE BODY
1 Flanged, hex. head screws used for M6x60 8 12 Nm (8.85 lb ft) Loct. 242
fastening the inlet coupling
2 Button head, hex. socket screws M6 8 12 Nm (8.85 lb ft) Loct. 242
used for fastening the throttle body to
the bracket
3 Flanged, hex. head screws used for M6 2 12 Nm (8.85 lb ft) Loct. 242
fastening the Injectors
P SUPP - 286
SHIVER 900 Power supply
• Remove the filter casing.

• Working on both bodies, undo and re-
move the four screws and slide off the
filter support.
• Remove the upper plate.
• Remove both bodies.
UPON REFITTING, REPLACE THE THROTTLE

BODY GASKET WITH A NEW ONE OF THE
SAME TYPE.

move the two plate screws.
P SUPP - 287
Power supply SHIVER 900
• Remove the plate.

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.
CAUTION
NEVER UNDO THE SCREWS IN THE FIGURE
Use of diagnostics instrument for injection system
L'elenco completo di tutti i parametri, stati, errori,…ecc è disponibile nella home page del sito
www.serviceaprilia.com nella sezione ricerca: Parametri PADS.
Gli stessi parametri, stati, errori,.. ecc…suddivisi per componente a cui si riferiscono sono presenti
all'interno della sezione Impianto elettrico, capitolo: Verifiche e controlli
P SUPP - 288
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions SHIVER 900
Front
Handlebar
HANDLEBAR-CONTROLS
1 Stainless steel, cyl. head Pozidriv M8x25 4 25 Nm (18.44 lb ft) -
screws used for fastening the upper
U-bolt to the lower U-bolt
2 Electronic accelerator control fasten- - 1 4 Nm (2.95 lb ft) -
ing screws
3 Light switch fastening screws - 2 1.5 Nm (1.11 lb ft) -
4 Cyl. head, hex. socket anti-vibration M6x45 2 10 Nm (7.38 lb ft) -
counterweight fastener screws
Removing
• Remove the rearview mirrors and re-

move the rubber clamps used for fas-
tening the column switch and ride-by
wire control wiring to the brake and
clutch pipe.
SUSP - 290
SHIVER 900 Suspensions
• Remove the two screws used for fas-

tening the front brake pump U-bolt.
• Move the front brake pump to one side.

tening the clutch pump U-bolt.
• Move the clutch pump to one side.
SUSP - 291
• Remove the anti-vibration weights.
• Remove the left hand knob with the as-

sistance of compressed air.

tening the left hand column switch and
disconnect it from the handlebars
• Remove the screw used for fastening

the Ride By Wire gas control and slide
it off the handlebars
SUSP - 292

tening the left hand column switch.
• Remove the four screws and the U-

bolt.
• Remove the handlebars
SUSP - 293
Front fork
FRONT FORK
closing the fork feet
used for fastening the sensor to the
right hand fork foot
Adjustment
The front suspension consists of a hydraulic fork

connected to the headstock by means of two
plates.
The right stem of the fork has an upper nut (2) for
adjusting the spring pre-load and an upper adjust-
ment screw (1) for adjusting the hydraulic braking
in rebound.
DO NOT FORCE THE ROTATION OF THE ADJUSTMENT

SCREW BEYOND THE LIMIT STOP IN BOTH DIRECTIONS,
IN ORDER TO PREVENT ANY DAMAGE.
WHEN SPRING PRE-LOAD IS INCREASED, REBOUND
DAMPING MUST ALSO BE INCREASED TO PREVENT EX-
CESSIVE SUSPENSION KICKBACK WHEN RIDING.
SUSP - 294
The standard front fork setting is adjusted to suit

most high and low speed riding conditions, wheth-
er the vehicle is partially or fully loaded.
However, the setting can be modified for specific
needs according to vehicle use.
TO COUNT THE NUMBER OF CLICKS AND/OR REVOLUTIONS OF ADJUSTMENT SETTINGS

ALWAYS START FROM THE MOST RIGID SETTING (WHOLE CLOCKWISE ROTATION OF THE
SETTING).
FRONT FORK - ADJUSTING

Description Pilot Pilot + Passenger +
Baggage
Rebound damping adjustment, screw (1) from completely closed (*) un- from completely closed (*) un-
screw (**) 6 / 7 clicks screw (**) 6 / 7 clicks
Spring preload (2) 2 notches (4 total) 2 notches (4 total)
Extracting the fork (A) (from below the lower plate to the centre 480 mm (18.90 in) 480 mm (18.90 in)
of the wheel)
(*) = clockwise
(**) = anticlockwise
Removing the fork legs
• Position a central stand in order to sup-

port the motorcycle and remove the
front wheel and mudguard.
• Remove the ABS sensor fastening
screw.
SUSP - 295
• Remove the cable clamp fastening

screw positioned inside the fork foot in
order to free the ABS sensor wiring
hardness.
NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO ONE
ROD ONLY, BUT APPLY EQUALLY TO BOTH RODS.
• Unscrew the screw that fastens the rod

to the upper steering plate.
• Unscrew the screws that fasten the rod

to the lower steering plate.
• Slide the rod of the steering plates and

remove it.
Disassembling the fork

NOTE
THE STEMS ARE NOT THE SAME, THEREFORE THEY REQUIRE SEPARATE REMOVAL PRO-
CEDURES.
SUSP - 296
THE FOLLOWING OPERATIONS APPLY WHEN

REMOVING THE RIGHT HAND STEM
• Taking care not to damage it, secure

the fork vertically in a vice, using the
appropriate protection devices.
• Unscrew the upper cap (1).
Specific tooling
• Using the special tool (2), fastened to
the pre-loading pipe (3), compress the
spring and, with the assistance of a
second operator, insert the separator
plate (4) under the cap retaining nut
(5).
Specific tooling
020888Y Preload tube clamp
• Ensure that the cap (1) cannot rotate,
and then loosen the nut (5).
• Unscrew and remove the cap (1).
SUSP - 297
• Extract the shaft (6) and remove it.
• After removing the locking plate and

the device used to compress the
spring, remove the upper plate (7) and
the pre-loading pipe (3).
• Remove the spring (8) allowing the oil

inside the stem to drip out.
• Drain the oil into a container having

sufficient capacity, extending the stem
several times in order to ensure the oil
is drained completely.
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND
TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED
OIL COLLECTION CENTRE.
SUSP - 298

the sleeve horizontally in a vice, using
the appropriate protection devices.
• Extract the dust guard (9).
Specific tooling
• Remove the seeger ring (10) from in-

side the sleeve.
• Pull the stem repeatedly towards your-

self in order to remove it from the
sleeve.
• Secure the stem in a vice and remove

the plunger fastening screw (11), tak-
ing care not to lose the copper washer
(12).
SUSP - 299
• Remove the complete plunger (13).
• Observing the indicated sequence, ex-

tract and remove the slider bushing
(14), the guide bushing (15), the ring
(16), the oil seal (17), the seeger ring
(10) and the dust guard (9).

REMOVING THE RIGHT HAND STEM

the fork vertically in a vice, using the
appropriate protection devices.
• Unscrew the upper cap (1).
Specific tooling
• Ensure that the cap (1) cannot rotate,
and then loosen the special nut (2).
SUSP - 300
• Unscrew and remove the cap (1).
• Unscrew the special nut (2) and re-

move it.
• Remove the buffer (3).
• Drain the oil into a container having

sufficient capacity, extending the stem
several times in order to ensure the oil
is drained completely.
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND
TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED
OIL COLLECTION CENTRE.
SUSP - 301

the sleeve horizontally in a vice, using
the appropriate protection devices.
• Extract the dust guard (4).
Specific tooling
• Remove the seeger ring (5) from inside

the sleeve.
• Pull the stem repeatedly towards your-

self in order to remove it from the
sleeve.

tract and remove the slider bushing (6),
the guide bushing (7), the ring (8), the
oil seal (9), the seeger ring (5) and the
dust guard (4).
Checking the components
Stem
Check that the sliding surface is not scratched or scored.
Any scoring can be removed by sanding with damp sandpaper (grain 1).
SUSP - 302
If the scratches are deep, replace the stem.

Using a dial gauge, check than any bending of the stem is below the limit value.
If it is over the limit, replace the stem.
CAUTION
A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK-
ENED MAKING THE VEHICLE DANGEROUS TO USE.
Characteristic
Bending limit:
0.2 mm (0.00787 in)
Sleeve
Check for damage and/or cracks; if it is damaged, replace it.
Spring
Check the condition of the spring, making sure that the length is within the acceptable limits.
If not, replace the spring.
MINIMUM LENGTH OF FREE SPRING: ... mm (... in)
Check the condition of the following components:
• slider bushing;
• guide bushing;
• plunger.
If there is evidence of excessive wear or damage, replace the component concerned.

CAUTION
REMOVE ANY IMPURITIES FROM THE BUSHINGS, BEING CAREFUL NOT TO SCRATCH THEIR
SURFACES.
Replace the following components with new ones:
• Oil seal.
• Dust guard.
• - O-ring on the cap.
Reassembling the fork

CAUTION
THE STEMS ARE NOT THE SAME, THEREFORE THEY REQUIRE SEPARATE MOUNTING PRO-
CEDURES.
SUSP - 303

MOUNTING THE RIGHT HAND STEM

tract and remove the dust guard (1),
the seeger ring (2), the oil seal (3), the
ring (4), the guide bushing (5) and the
slider bushing (6).
• Insert the complete plunger (7).
• Secure the stem in a vice and, after in-

serting the screw (8) used to fasten the
plunger, complete with the copper
washer (9), apply the pre-defined tight-
ening torque.
• - Insert the stem in the sleeve.
SUSP - 304
• Using a suitable tool, complete with

striking hammer, insert oil seal into its
housing (3).
Specific tooling
AP8140189 Tool for fitting oil seal for 43 mm
(1.69 in) diameter hole
AP8140146 Weight
• Position the seeger ring (2) inside the

sleeve.
• Insert the dust guard (1) into its hous-

ing correctly.
• Place the fork stem vertically on a work

surface.
• Fill the stem with the quantity of oil in-
dicated in the "Refilling oil" section.
SUSP - 305
• Insert the spring (10).
• Insert the pre-load tube (11), making

sure that it is aligned correctly. The
narrower part must be inserted into the
spring.
• Insert the upper plate (12) on the pre-

load pipe
• After positioning the device (13) on the

pre-load pipe (11) and the plunger sup-
port shaft (14), with the assistance of a
second operator, raise the plunger so
that it is possible to insert the plate (15)
under the cap locking nut.
Specific tooling
020888Y Pre-load pipe clamp
AP8140150 Bored shaft for bleeding plunger
air
SUSP - 306
• Insert the shaft (16) into the plunger.
• Before positioning the cap, adjust the

hydraulic regulator screw so that the
internal distance is as close as possi-
ble to 13 mm (0.51 in).
• Screw the cap (17) onto the plunger as

far as it will go.
• Ensure that the cap cannot rotate, and

then tighten the nut.
SUSP - 307
• Tighten the cap on the sleeve, applying

the pre-defined torque.

MOUNTING THE LEFT HAND STEM

tract and remove the dust guard (1),
the seeger ring (2), the oil seal (3), the
ring (4), the guide bushing (5) and the
slider bushing (6).
• - Insert the stem in the sleeve.
• Using a suitable tool, complete with

striking hammer, insert oil seal into its
housing (3).
Specific tooling
AP8140189 Tool for fitting oil seal for 43 mm
(1.69 in) diameter hole
AP8140146 Weight
SUSP - 308
• Position the seeger ring (2) inside the

sleeve.
• Insert the dust guard (1) into its hous-

ing correctly.

surface.
• Fill the stem with the quantity of oil in-
dicated in the "Refilling oil" section.
• Insert the buffer (7).
SUSP - 309
• Insert the special nut (8) and tighten it

as far as it will go.
• Insert the cap (9) and tighten it as far

as it will go.
• Ensure that the cap cannot rotate, and

then tighten the nut.
• Tighten the cap on the sleeve, applying

the pre-defined torque.
SUSP - 310
Filling oil

MOUNTING THE RIGHT HAND STEM

surface.
• Fill the STEM with the indicated quan-
tity of oil.
WARNING
OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR
BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.
THE FORK MUST BE PERFECTLY UPRIGHT IN ORDER TO

MEASURE THE CORRECT OIL LEVEL.
Characteristic
Quantity of oil for RH STEM
522 cm³ (31.85 cu in)
• Check the oil level from the rim of the

sleeve.
Characteristic
Oil level (from sleeve rim, without the spring
and with the pump all the way lowered)
90 mm (3.54 in)

MOUNTING THE LEFT HAND STEM

surface.
• Fill the STEM with the indicated quan-
tity of oil.
WARNING
OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR
BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.
THE FORK MUST BE PERFECTLY UPRIGHT IN ORDER TO

MEASURE THE CORRECT OIL LEVEL.
Characteristic
Quantity of oil for LH stem
401 cm³ (24.47 cu in)
SUSP - 311
Steering bearing
STEERING
1 Headstock ferrule (pre-tightening) M25 1 50 Nm (36.88 lb ft) Steering assembly
settling
1 Headstock ferrule (tightening) M25 1 15 Nm (11.06 lb ft) -
ing nut (stop)
2 Flanged upper steering plate fasten- M22 1 25 Nm (18.44 lb ft) Loct. 243
ing nut (pre-tightening)
ing nut (tightening)
the upper plate
4 Low profile, cyl. head, hex. socket M8x30 1 25 Nm (18.44 lb ft) -
screw used for fastening the steering
headstock to the upper plate
the lower plate
6 Cyl. head, hex. socket screws for fas- M10x60 2 50 Nm (36.88 lb ft) Loct. 243
tening the lower U-bolt to the upper
steering plate
SUSP - 312
Adjusting play
• Secure the rear of the motorcycle using

suitable belts and position a central
stand under the engine in order to
maintain the front wheel in a raised po-
sition.
• After removing the instrument panel
support and the front light assembly,
maintain the fuel tank in raised position
and remove the four handlebar U-bolt
retaining screws.
• Move the handlebar to one side.
• Remove the upper steering plate fas-

tening nut.
• Remove the washer.
See also
Instrument cluster support
SUSP - 313
Headlight assy.
• Unscrew the three screws used for fas-

tening the upper steering plate.
• Remove the upper steering plate.
• Apply the pre-tightening torque to the

ferrule using the dedicated tool.
• Execute two complete rotations to the
left, and two to the right.
• Loosen the ferrule by executing a 90°
rotation, and then apply the definitive
tightening torque.
Specific tooling
020884Y 46 mm wrench for steering ferrule
• Reposition the upper steering plate
and settle it into place by striking it gen-
tly with a rubber mallet.
SUSP - 314
• Tighten the sleeving blocking screws,

• Loosen the nut used for fastening the

upper steering plate again.
• Tighten the upper steering plate cen-
tral closure screw, applying the pre-
defined torque.
• Tighten the upper steering plate nut

again, applying the predefined torque.
• After refitting the handlebars, apply a

dynamometer to the ends of the grips
and check the rotation resistance.
Characteristic
Rotation resistance
500 +100/-300 g (1.10 +0.22/-0.66 lb)
Rear
SUSP - 315
Shock absorbers
SHOCK ABSORBER
1 Cyl head, hex. socket upper shock M10x50 1 50 Nm (36.88 lb ft) Pre-impregnated
absorber fastening screw screw
2 Cyl head, hex. socket lower shock M10x59 1 50 Nm (36.88 lb ft) -
absorber fastening screw
Adjusting
The rear suspension consists of a spring-shock

absorber unit connected to the frame by uniball
joints.
To adjust the setting, the shock absorber has an
adjuster screw (1) for adjusting the rebound hy-
draulic braking, a ring nut for adjusting the spring
preload (2) and a locking ring nut (3).
CAUTION
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE
INTERVALS RECOMMENDED IF THE VEHICLE IS USED IN
WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING
APPLICATIONS.
CHECK AND IF NECESSARY, ADJUST THE REAR SHOCK
ABSORBER.
THE STANDARD REGULATION OF THE REAR SHOCK AB-
SORBER IS INTENDED TO SATISFY NORMAL TOUR DRIV-
ING CONDITIONS.
IN ANY CASE IT IS POSSIBLE TO INSERT PERSONAL
SETTINGS, DEPENDING ON VEHICLE UTILIZATION.
SUSP - 316
TO COUNT THE NUMBER OF CLICKS OF THE ADJUSTER

(1) ALWAYS START FROM THE MOST RIGID SETTING
(COMPLETE CLOCKWISE ROTATION).
TO PREVENT DAMAGE TO THE ADJUSTER SCREWS (1),
NEVER FORCE THEM BEYOND THE END OF TRAVEL IN
EITHER DIRECTION.
• Using the specific spanner, unscrew

the locking ring nut (3).
• Use the adjuster ring nut (2) to adjust
the preload of the spring (A).
• Once the adjustment is done, screw
the ring nut (3).
• Use the screw (1) to adjust the shock
absorber rebound hydraulic braking.
SET SPRING PRELOADING AND SHOCK ABSORBER RE-

BOUND DAMPING ACCORDING TO THE VEHICLE USE
CONDITIONS.
IF THE SPRING PRE-LOADING IS INCREASED, IT IS NEC-
ESSARY TO INCREASE THE REBOUND DAMPING AC-
CORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING.
REAR SHOCK ABSORBER - ADJUSTMENT

Description Pilot Pilot + Passenger +
Baggage
Spring length (preloaded) 168 mm (6.61 in) 160 mm (6.30 in)
Rebound adjustment 12 6/7
SUSP - 317
(*) = clockwise
(**) = anticlockwise
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.
• Unscrew and remove the lower screw
and retrieve the nut.
• Remove the shock absorber.
SUSP - 318
INDEX OF TOPICS
CHASSIS CHAS
Chassis SHIVER 900
Wheels
Front wheel
FRONT WHEEL
Removal
• Position the motorcycle on the central

and rear stand so that the front wheel
is slightly raised.
• Remove the front brake callipers, the
mudguard, the nut and the washer.
CHAS - 320
SHIVER 900 Chassis
• Working on both sides, loosen the

screws on the fork feet
• Slide out the pin from the left hand side

of the motorcycle.
• Remove the wheel.
See also
Front
mudguard
• Retrieve the spacer present on the left

hand side.
CHAS - 321
Chassis SHIVER 900
Checking
FRONT WHEEL BEARINGS

Check the bearings installed on the wheel.
CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS

FOLLOWS IN PARTICULAR.
CHECKING ROTATION
• Manually rotate the inner race of each bearing. The race must turn smoothly without im-
pediment or noise.
If one or both bearings are not conformant:
• Replace both wheel bearings.
CHECKING RADIAL AND AXIAL PLAY
• Check the radial and axial play.
Axial play: minimal axial play is permitted.

Radial: none.
If one or both bearings are not conformant:
ALWAYS REPLACE BOTH BEARINGS.

ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE.
SEALS
• Check the condition of the seals; replace if damaged or excessively worn.
ALWAYS REPLACE BOTH SEALS TOGETHER.

ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE.
WHEEL AXLE
• Use a dial gauge to check the wheel

axle eccentricity. Replace the wheel
axle if the eccentricity exceeds the limit
value.
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
CHAS - 322
SHIVER 900 Chassis
• Using a dial gauge, check that the ra-

dial (A) and the axial (B) eccentricities
of the rim do not exceed the limit value.
An excessive eccentricity is usually
caused by worn or damaged bearings.
Replace the rim if, after replacing the
bearings, the value is not within the
specified limit.
Characteristic
Maximum radial and axial eccentricity:
2 mm (0.0079 in)
Rear wheel
REAR WHEEL
calliper support
on the hub
CHAS - 323
Chassis SHIVER 900
Rimozione
• Place the vehicle on a suitable rear

support stand.
• To make it easier to carry out these op-
erations, we recommend removing the
chain guard.
• Remove the external screw (1).

cycle and loosen the internal screw (2).
• Detach the chain guard (3) from the in-

ternal screw and remove it.
• Loosen the nut (4) without removing it.
CHAS - 324
SHIVER 900 Chassis
• Working on both sides of the vehicle,

loosen the locknuts (5) and adjust the
regulator screws (6) in order to release
the tension on the drive chain.
• Rotate the wheel forwards and disen-

gage the drive chain (7) from the
sprocket.
• Remove then nut (4) and the spacer

washer (8).
• Partially extract the wheel shaft and re-

move the guide (9) on the right hand
side.
CHAS - 325
Chassis SHIVER 900
• Remove the wheel shaft (10), com-

plete with guide (11).
• Remove the rear wheel (12).
• Remove the spacers from both sides (13).
• Remove the complete sprocket as-

sembly (14).
CHAS - 326
SHIVER 900 Chassis
• Remove the internal spacer (15)
Checking
CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS

FOLLOWS IN PARTICULAR.
REAR WHEEL BEARINGS
Check the bearings installed on the wheel.
CHECKING ROTATION
• Manually rotate the inner race of each bearing. The race must turn smoothly without im-
pediment or noise.
If one or both bearings do not fall within the control parameters:
ALWAYS REPLACE BOTH BEARINGS.

ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE.
• Check the radial and axial play.
Axial play: minimal axial play is permitted.

Radial: none.
If one or both bearings do not fall within the control parameters:
REAR WHEEL GASKETS
• Check that the gaskets are in good conditions; replace them if they show signs of damage
or excessive wear.
ALWAYS REPLACE BOTH SEALS TOGETHER.

ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE.
CHAS - 327
Chassis SHIVER 900
REAR WHEEL AXLE
• Use a dial gauge to check the wheel

axle eccentricity (1). Replace the
wheel axle if the eccentricity exceeds
the limit value (1).
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
REAR WHEEL RIM
• Using a dial gauge, check that the ra-

dial (A) and the axial eccentricity (B) of
the rim (2) do not exceed the limit val-
ue.
An excessive eccentricity is usually caused by

worn or damaged bearings. Replace the rim (2) if
after replacing the bearings, the value is not within
the specified limit.
Characteristic
Maximum radial and axial eccentricity:
2 mm (0.0079 in)
CHAS - 328
SHIVER 900 Chassis
Swinging arm
SWINGARM
swingarm bolt regulator bushing
3 Swingarm pivot bolt fastening swing- - 1 60 Nm (44.25 lb ft) -
arm bolt ferrule
4 Button head, hex. socket shoe cap M5x12 3 6 Nm (4.43 lb ft) -
fastening screws
used for fastening the chain guard on
the chain guide shoe
7 Chain tensioner adjustment screws - 2 Manual -
8 Flanged, self-locking nut on the M8 2 Manual -
chain tensioner shoe regulator screw
Removing
• Remove the ABS sensor.
CHAS - 329
Chassis SHIVER 900
• Remove the rear wheel.

• Support the vehicle by means of the
engine service stand and a hoist with
belts fastened to the rear section of the
frame.
• Remove the rear service stand.
• Undo and remove the two lower swing-
arm screws.
• Remove the cable guide.
• Slide off the rear calliper holding plate,
keeping it linked to the brake pipe.
CAUTION
DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER
REMOVING THE WHEEL. OTHERWISE, THE CALLIPER
PLUNGERS COULD GO OUT OF THEIR SEAT, RESULTING
IN BRAKE FLUID LEAKAGE.
See also
Removing the
rear wheel
• 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.
SUPPORT THE SWINGARM FROM THE FRONT TO AVOID
ACCIDENTAL FALLS.
PLACE A WOODEN SUPPORT UNDER THE FRONT PART
OF THE REAR SWINGARM TO PREVENT IT FROM LOW-
ERING AND TO KEEP IT UPRIGHT.
See also
CHAS - 330
SHIVER 900 Chassis
Removing the
rear wheel
• Working on the right side, unscrew and

remove the swingarm bolt.
UPON REMOVING THE REAR SWINGARM PAY ATTEN-

TION NOT TO JAM THE GEARING CHAIN.
See also
Removing the
rear wheel
Drive chain
Removing
The transmission chain, although "closed", has a

different coloured hammerlock (where provided),
which should be used to perform opening / disas-
sembling procedures.
NOTE
WHERE PRESENT, THE HAMMERLOCK (1) MAY ALSO BE
IDENTIFIED BY A SIGN (2) APPLIED IN THE MOUNTING
LINES DURING MANUFACTURING.
CHAS - 331
Chassis SHIVER 900
To dismantle and remove the chain, proceed as

follows:
• Partially remove the pins (3) using a

generic chain breaker.
• Remove the outer plate (4).
• Remove the outer O-ring rings (5).
• Remove the inner plate (6).
CHAS - 332
SHIVER 900 Chassis
• Collect the inner O-ring rings (7) and

completely remove the transmission
chain.
Installing
• After fitting the chain on the pinion and

on the crown, put the inner O-rings (1)
back onto the hammerlock pins (2) and
connect the two ends of the transmis-
sion chain.
• Place the outer O-rings (3) on the pins.
• Compress the outer plate (4) using the

appropriate generic tool.
CAUTION
BE CAREFUL NOT TO COMPRESS TOO THE OUTER
PLATE TOO MUCH AS THIS COULD SEIZE THE CHAIN.
CHAS - 333
Chassis SHIVER 900
• Check that the links in the transmission

chain are not seized and that it can
move in both directions.
• Use a generic clincher to re-tighten the pins of the link (checking riveting at points "A").
• Turn the pin of the specific tool 90° and re-engage the link pin again (checking riveting at
points "B").
• Grease the chain and record the clearance.
Adjusting
The vehicle has an endless chain, without master link.

NOTE
USE.
CHAS - 334
SHIVER 900 Chassis
BACKSLASH CHECK
To check clearance:
• Shut off the engine.

• Rest the vehicle on its stand.
• Engage neutral gear.
• Check that the vertical oscillation at a
point between the pinion and the
sprocket on the lower branch of the
chain is around 25 mm (0,98 in).
• Move the vehicle forward so as to
check vertical oscillation of the chain in
other positions too. clearance should
remain constant at all wheel rotation
phases.
ADJUSTMENT
CAUTION
THE SPECIFIC OPTIONAL REAR SUPPORT STAND IS
NECESSARY TO ADJUST THE CHAIN.
If you need to adjust chain tension after the check:
• Place the vehicle on its rear service

stand (OPT).
• Loosen the nut (1) completely.
• Loosen both lock nuts (4).
• Actuate on the adjuster screws (5) and
adjust the chain clearance checking
that the references (2-3) match on both
sides of the vehicle.
• Tighten both lock nuts (4).
• Tighten the nut (1).
• Check chain clearance.
CAUTION
WHEEL CENTRING IS CARRIED OUT USING THE IDENTI-
FIABLE FIXED REFERENCES (2-3) INSIDE THE CHAIN
TENSIONER PAD MOUNTS ON THE SWINGARMS, IN
FRONT OF THE WHEEL AXLE.
CHECKING WEAR OF CHAIN, PINION AND SPROCKET

Also regularly check the following parts and make sure that the chain, the pinion and the sprocket do
not show:
• damaged rollers;
CHAS - 335
Chassis SHIVER 900
• loosened pins;
• dry, rusty, flattened or jammed chain links;
• excessive wear;
• missing sealing rings;
• excessively worn or damaged pinion or sprocket teeth;
IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSE AND/OR THE SEAL RINGS
ARE DAMAGED OR MISSING, THE ENTIRE CHAIN UNIT (PINION, SPROCKET AND CHAIN)
NEEDS TO BE REPLACED.
LUBRICATE THE CHAIN REGULARLY, ESPECIALLY IF THERE ARE DRY OR RUSTY PARTS.
CRUSHED OR SEIZED LINKS MUST BE LUBRICATED AND RESTORED TO PROPER WORKING
ORDER.
THE DRIVE CHAIN HAS SEAL RINGS BETWEEN THE LINKS, WHICH KEEP THE GREASE INSIDE.
BE EXTREMELY CAREFUL WHEN ADJUSTING, LUBRICATING, WASHING AND REPLACING
THE CHAIN.
CLEANING AND LUBRICATION
Do not wash the chain with water jets, vapour jets, high-pressure water jets and highly flammable sol-
vents.
• Wash the chain with naphtha or kerosene. If it tends to rust quickly, carry out the mainte-
nance operations more frequently.
Lubricate the chain at the intervals shown in the routine maintenance table and whenever necessary.
• After washing and drying the chain, lubricate it with spray grease for sealed chains.
CHAS - 336
SHIVER 900 Chassis
Pedaline
FOOTRESTS
fastening the rider/passenger rubber
footrests
for fastening the rider's footrest sup-
port to the frame plates
used for fastening the luggage rack
to the rider's footrest support
for fastening the passenger footrest
supports to the saddle support
Rimozione
LEFT RIDER FOOTREST
• Remove the two fastening screws (1).
CHAS - 337
Chassis SHIVER 900
• Remove the complete footrest.
To dismantle the footrest, proceed as follows:

fasten the heel guard plate.
• Remove the heel guard plate (3).
• Remove the seeger ring (4)
CHAS - 338
SHIVER 900 Chassis
• Extract the pin (5) and remove it.
• Remove the pedal, complete with

spring (6).

fasten the rubber pad.
• Separate the pedal (8) from the rubber

pad (9).
CHAS - 339
Chassis SHIVER 900
• Remove the pin (10).
RH RIDER FOOTREST
• Remove the fastening screw (1) from

the brake pipe retaining plate in order
simplify the mounting operations.
• Remove the two fastening screws (2).
• Position the cloth in order to protect the

frame from scratches and remove the
two rear brake pump fastening screws
(3).
CHAS - 340
SHIVER 900 Chassis
• Remove the safety O-ring (4) from the

pin that blocks the brake pump control
rod.
• Rotate the pin (5) to release the brake

pump control rod and slide it out in or-
der to remove it.
• Remove the brake switch (6).
• Remove the complete footrest.
CHAS - 341
Chassis SHIVER 900
To dismantle the footrest, proceed as follows:
• Disconnect the brake lever return

spring (7) and remove it.
• After unscrewing the pin (8) it is possi-

ble to remove the complete brake lever
(9).
The pin (8) consists of the following elements:
• An external washer (10)

• An O-ring (11)
• An internal washer (12)
CHAS - 342
SHIVER 900 Chassis
• Undo the screw (14) in order to remove

the peg (15) from the lever, complete
with rubber protection pad.
• Unscrew the brake lever spring cou-

pling pin (16) and remove it.

fasten the heel guard plate.
• Remove the heel guard plate (18).
CHAS - 343
Chassis SHIVER 900
• Extract the pin (20) and remove it.
• Remove the pedal, complete with

spring (21).

fasten the rubber pad.
CHAS - 344
SHIVER 900 Chassis
• Separate the pedal (23) from the rub-

ber pad (24).
• Remove the pin (25).
PASSENGER FOOTRESTS
THE FOLLOWING OPERATIONS ARE VALID
FOR BOTH FOOTRESTS

fasten the support bracket.
• Remove the support bracket (2) com-

plete with pedal.
CHAS - 345
Chassis SHIVER 900
• Extract the pin (4).
• While pressing the side plates, remove

the complete pedal.
Check that the plates (5) are aligned correctly be-

fore dismantling the pedal, taking care not to lose
the spring (6) and the ball (7).
• Remove the two screws (8) used to fasten the rubber pad.
• Separate the pedal (9) from the rubber pad (10).
CHAS - 346
SHIVER 900 Chassis
Stand
STAND
fastening the stand plate to the en-
gine
2 Screw for fastening the stand to the M10x1.25 1 10 Nm (7.38 lb ft) -
plate
3 Low profile nut used for fastening the M10x1.25 1 30 Nm (22.13 lb ft) -
stand to the plate
for fastening the stand switch
5 Self-locking, low profile nut used for M5x16 2 7 Nm (5.16 lb ft) -
fastening the stand switch
Side stand
• Release the two side stand support

springs (1) and remove them.
CHAS - 347
Chassis SHIVER 900
• Release the spring coupling plate (2)

and remove it.
• Unscrew the nut (3) and remove it,

complete with washer (4).
• Unscrew the pin (5) and remove it.
• Remove the stand (6).
CHAS - 348
SHIVER 900 Chassis
• To remove the stand, complete with

support plate, disconnect the side
stand switch connector and remove
the three screws (7) that fasten the
plate to the engine.
Exhaust
SILENCER
1 Lambda probes - 2 40 Nm (29.50 lb ft) -
2 Flanged, self-locking used for fasten- M8 4 12.5 Nm (9.22 lb ft) -
ing the exhaust flanges to the big
ends
for fastening the shock absorber pro-
tection
4 Manifold fastening clamps M6 2 7 Nm (5.16 lb ft) -
5 Terminal fastening clamp M6 1 7 Nm (5.16 lb ft) -
fastening the terminal front coupling
to the support bracket
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.
CHAS - 349
Chassis SHIVER 900
Removing the tail pipe
• Remove the saddle, the rear grab-bar,

the rear light assembly and the number
plate support.
• Loosen the clamp between the ex-
haust end and the manifold.
• Remove the two support bracket fas-

tening screws (2) and retrieve the
spacer washers.
• Slide the exhaust terminal (3) off from

the rear.
• Remove the exhaust terminal support

bracket fastening screws (4)
CHAS - 350
SHIVER 900 Chassis
• Retrieve the washers (5), the spacers

(6) and the rubber grommets (7), and
replace them if necessary.
Removing the exhaust manifold
FRONT MANIFOLD
• Remove the lower fairing and cut the

upper clamp (1) that fastens the front
lambda probe wiring harness to the
ABS pump support frame.
• Remove the lower clamp (2).
• Disconnect the front lambda probe

connector (3) and free the wiring har-
ness.
CHAS - 351
Chassis SHIVER 900
• Loosen the clamp (4) that unites the

front manifold with the central manifold
• Remove the two nuts (5) used to fasten

the front manifold to the head.
• Remove the front manifold (6).
• Loosen the lower clamp (7) that con-

nects the rear manifold to the central
manifold.
CHAS - 352
SHIVER 900 Chassis
• Loosen the upper clamp (8) that con-

nects the terminal to the central mani-
fold.
• Remove the central manifold (9).
REAR MANIFOLD
• Remove the clamp (10) that fastens

the rear lambda probe wiring harness
to the rear frame.
• Remove the clamp (11) that fastens

the rear lambda probe wiring harness
to the metallic cable clamp and discon-
nect the connector.
CHAS - 353
Chassis SHIVER 900
• Remove the two nuts (12) used to fas-

ten the rear manifold to the head.
• Remove the rear manifold (13), sliding

out from underneath the motorcycle.
CHAS - 354
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system SHIVER 900
Interventions rules
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
ABS
ABS BRAKING SYSTEM

support
2 Front fastening, flanged self-locking M6 1 10 Nm (7.38 lb ft) -
nut
3 Flanged, hex. head screw used for M6x25 2 10 Nm (7.38 lb ft) Loct. 270
support
fastening the spacers on the ABS
support
fastening the ABS support on the en-
gine
6 Flanged, hex. head screws for fas- M8x25 1 25 Nm (18.44 lb ft) Loct. 243
tening the spacer plate on the frame
plate
for fastening the pipes under the
steering headstock
BRAK SYS - 356

SHIVER 900 Braking system
Foreword
Key:
1. Rear brake calliper

2. Modulator
3. Front bleed valve
4. Front brake reservoir
5. Front brake callipers
6. Rear brake pump
7. Rear brake reservoir
BRAK SYS - 357

Operating diagram
Key:
1. Instrument panel
2. Ignition switch
3. Main injection relay
4. ABS control unit
BRAK SYS - 358

5. Front ABS sensor

6. Rear ABS sensor
7. Start-up relay
8. ABS control unit fuse
9. Main fuse
10.Battery
11.BLUEDASCH set-up (optional)
12.Diagnostics socket
13.7SM engine control unit
ABS Electronic Control Unit pin-out
• PIN1 - Power ground 1

• PIN3 -
• PIN4 - Ignition switched live
• PIN5 - CAN H line
• PIN6 - CAN L line
• PIN7 -
• PIN8 -
• PIN9 -
• PIN10 -
• PIN11 - Rear ABS sensor positive
• PIN12 - Rear ABS sensor negative
• PIN13 - Front ABS sensor negative
• PIN14 - Front ABS sensor positive
• PIN16 - Serial line
• PIN17 -
• PIN18 - Battery power supply
BRAK SYS - 359

ABS OPERATION
General specifications:
The front circuit is the same as the rear one.
• The ABS inlet valve (10 - 12) is normally open and it is closed only when the system inter-
venes to avoid wheel locking.
• The exhaust valve (13 - 15) is normally closed and it is opened only when the system in-
tervenes to avoid wheel locking.
BRAK SYS - 360

• With the system in stand-by mode, the ABS processor controls the wheel speed instant by
instant to assess any slippage of the wheels.
• When in standby, the system does not intervene at all when the rider brakes; the braking
system is the same as the one without ABS.
ABS Cycle phases (the following operations refer to the front circuit but they are also valid for
the rear):
A - Brake activation: the rider starts braking as he would usually do.
B - Pressure reduction: coincides with the recognition of the dangerous situation (wheel slippage
exceeds the threshold): the system closes the inlet valve (10-12) and opens the exhaust valve (13-15)
temporarily.
At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the
pressure on the callipers partially. The excess fluid temporarily fills the front reservoir (18-19) until the
ABS pump (17) self-activates and delivers the fluid back to the brake pump (2-5).
C - Maintaining pressure: the pressure in the callipers (8-9) remains low until total recovery of speed /
wheel grip.
The system restores the fluid taken from the calliper (8-9) in the section of the system between the
brake pump (2-5) and the ABS inlet valve (10-12).
D - Pressure restoration: by opening the inlet valve (10-12) momentarily, the pressure of the callipers
(8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the
braking back to the rider.
E - If the wheel does not reach complete grip, the system continues operating as before until complete
grip is obtained or until the vehicle stops. An error may be shown in the event that the duration of the
pressure reduction phase exceeds a predetermined time limit.
ABS SYSTEM DESCRIPTION

The ABS system is a device to avoid wheels locking in case of emergency braking, increasing vehicle
braking stability when compared to a traditional braking system.
The ABS system enhances control over the vehicle, taking into consideration never to exceed the
physical limits of vehicle grip on the road. The rider is fully responsible for riding at a suitable speed
based on weather and road conditions, always leaving an appropriate safety margin. Under no circum-
stances can the ABS system compensate for the rider's misjudgement or improper use of brakes.
Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it
difficult to control the vehicle.
A position sensor (3) on the tone wheel (2), forming an integral unit with the vehicle wheel, "reads" the
status of the vehicle wheel spotting any possible lock.
BRAK SYS - 361

A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly.
CAUTION
WHEN THE ABS STARTS WORKING, A PULSING IS FELT ON THE BRAKE LEVER.
THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND.
AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLE BAR TURNED, ON UN-
EVEN OR SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT
TO HANDLE. THEREFORE, RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADU-
ALLY. BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT
EVEN ABS CAN ELIMINATE.
When sensors (3) detect a significant speed difference between the rear and the front wheels (for
example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation.
In this case, 2 things may occur:
- the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the
same speed of the other wheel; it is not possible to brake for an instant.
- if the speed difference lasts long, the system may detect an error and deactivates the ABS system.
As a consequence, the system works as any regular braking system.
Riding with an active ABS system
• During the vehicle start-up, after the in-

strument panel initial check, the ABS
warning light stops flashing when the
speed is under 5 km/h (3.1 mph).
If the ABS warning light remains on when the

vehicle is running, it means that a fault has
been detected and the ABS system has been
automatically deactivated.
IN CASE OF FAILURE OR WITH ABS DISCONNECTED,

THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS
SYSTEM.
BRAK SYS - 362

Attivazione/Disattivazione dispositivo ABS

Soltanto a moto ferma è possibile modificare lo
stato di attivazione/disattivazione del sistema ABS
ed è possibile farlo in due modi distinti:
1) Dalla schermata principale, mediante uno spos-
tamento breve verso sinistra o verso destra è pos-
sibile disattivare o riattivare il sistema ABS
Per tornare al menù "ABS" premere centralmente
in modo breev il selettore MODE.
CAUTION
IT IS DISABLED ONLY TEMPORARILY, WHEN THE KEY IS
INSERTED THE SYSTEM IS ALWAYS ACTIVE.
2) Entering the MENU, in the "RIDING MODE"

section and then in the "ABS" item Through a brief
central pressing on the central part of the MODE
selector, the "ABS" function is highlighted in red.
Briefly moving to left or right deactivates the func-
tion "Off".
This function allows you to disable the ABS system
that is normally active "On".
To return to the main "MENU", select the "EXIT"
menu item and briefly press on the central part of
the MODE selector.
CAUTION
IT IS DISABLED ONLY TEMPORARILY, WHEN THE KEY IS
INSERTED THE SYSTEM IS ALWAYS ACTIVE.
Guide to diagnosis
FOREWORD
Each time the key is set to ON, if at least one cur-
rent or stored error is detected*, the ABS warning
light turns on permanently.
The ABS system is automatically deactivated
The system operates perfectly just as any other
braking system without ABS
* Diagnosis is possible when exceeding 5 km/
h (3.1 mph).
Each time the key is set to ON, if at least one current or stored error is not detected immediately
in the system:
BRAK SYS - 363

• the ABS warning light flashes.
Once the vehicle speed exceeds 5 km/h (3.1 mph):

- if errors are not detected: the ABS warning light turns off
- if at least one malfunction is detected: the ABS warning light turns on permanently.
The ABS system is deactivated!
However, the system is perfectly operative as any other braking system without ABS.
The detection of malfunctions may require more or less time according to the type of failure.
Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist
within a given time.
If during this given time one of the conditions is missing but then it comes back, the timer is reset and
the system is no longer able to diagnose the error.
The ABS system continues to be inactive.
Use of diagnostics instrument for ABS system
Abs screen pages
ECU INFO screen page
This screen shows general data regarding the con-

trol unit, for example software type, mapping, con-
trol unit programming date
CONTROL UNIT DATA

P.A.D.S. characteristic. Value/example Units of Notes
measure
ment
Frame number - - -
SW version - - -
Vehicle code - - -
Vehicle manuf. or encoding - - -
Vehicle ID from PIN 2 and 15 - - -
BRAK SYS - 364

PARAMETERS screen page
This screen shows the parameters measured by

the several sensors (engine revs, engine temper-
ature, etc.) or values set by the control unit (injec-
tion time, ignition advance, etc.)
PARAMETERS AND STATUSES

measure
ment
Speed of the front wheel - km/h -
Speed of the rear wheel - km/h -
Quality test of the sensors

When turning the wheel or acting on the brake, a variation of parameters must be detected.
ACTIVATION screen page
On this screen, you can delete the errors from the

memory of the controller and you can enable some
systems controlled by the control unit.
ACTIVATIONS
measure
ment
ABS Warning Light
BRAK SYS - 365

ERRORS screen page
This display shows potential errors detected in the

vehicle (ATT) or stored in the control unit (MEM)
and it allows to check error clearing (STO).
ERRORS
Description Code Symptom
Front wheel speed sensor 5D90 Electrical fault
Front speed sensor - Functional fault 5D91 the signal changes in irregular manner
Front speed sensor - Functional fault 5D92 the signal becomes weak periodically
Front speed sensor - Functional fault 5D93 missing signal or wheel speed comparison
Front speed sensor - Functional fault 5D94 excessive duration for pressure reduction stage
Front speed sensor - Functional fault 5D95 too high wheel speed - too low wheel speed
Rear wheel speed sensor 5DA0 electrical fault
Rear speed sensor - Functional fault 5DA1 the signal changes in irregular manner
Rear speed sensor - Functional fault 5DA2 the signal becomes weak periodically
Rear wheel speed sensor 5DA3 -
Rear wheel speed sensor 5DA4 signal plausibility
Rear wheel speed sensor 5DA5 dauble frequency check
Control unit software error 5DD3 -
Recirculation pump 5DF0 -
Recirculation pump 5DF1 -
Control unit hardware error 5DF2 -
Control unit hardware error 5DF5 -
Low voltage 5DF3 Long period detection
Low voltage 5DF4 -
High voltage 5DF7 -
Incorrect control unit encoding 5E59 -
CAN Line 5E11 Bus off
CAN Line 5E16 missing vehicle code message
CAN Line 5E1F incorrect vehicle code
CAN Line 5E15 missing ABS switch status
ABS switch fault 5E5A -
CAN Line D347 Transmission time out
PADS report mode

In the following are described the procedure to be
performed through the diagnostic tool in order to
generate an errors report:
• When started the program, select the

brand.
BRAK SYS - 366

• Select the vehicle and the component.
• Select Self-diagnosis.
• Go to the page Error codes.
• Select an error and show the Ambient

parameter error(where provided).
• Repeat the operation by selecting each

error and showing the corresponding
Ambient parameter error (where provi-
ded).
BRAK SYS - 367

• Go to the page Report and then on

Print and select the virtual PDF printer.
• If there is no PDF printer, there are

several free programs, ask the infor-
mation systems to install it.
• Name the file with a name that contains
the main information of the vehicle and
the analysed component e.g. CN1200-
Chassis0465-Instrument panel.
SETTINGS screen page
This screen is used to adjust some control unit pa-

rameters.
BRAK SYS - 368

ADJUSTMENTS
measure
ment
Front bleed - - -
Rear bleed - - -
Encoding Resets the vehicle code and obtains it automati-
cally from the CAN line at the next key ON
Modulator
MODULATOR REMOVAL
• Remove the fairing lug.

• Release clamp (1) and disconnect con-
nector (2).
• By unscrewing the nuts, remove and

plug the brake oil pipes following this
sequence: (3) - (4) - (6) - (5).
• Slide off the rear system pipes from the hooks (7).
• Undo and remove the three screws,

collect the washers and remove the
ABS modulator.
BRAK SYS - 369

Rear brake calliper
REAR BRAKE CALLIPER

ing screw
used for fastening the brake pipe pro-
tection
BRAK SYS - 370

Front brake calliper
FRONT BRAKE CALLIPERS

1 Flanged, hex. head screws for fas- M10x1.25 4 50 Nm (36.88 lb ft) -
tening the brake callipers to the fork
stanchions
brake pipe to the callipers
BRAK SYS - 371

Rear brake disc
REAR WHEEL
calliper support
on the hub
Removal
• Remove the rear wheel.
BRAK SYS - 372

• Unscrew the five screws (1) used to

fasten the brake disc and remove
them.
• Remove the phonic wheel (2) and the
brake disc (3).
DURING REFITTING, APPLY LOCTITE 243 ON THE

THREAD OF THE BRAKE DISC SCREWS (1).
CAUTION
DURING REFITTING, SCREW ALL THE SCREWS (1) MAN-
UALLY AND TIGHTEN THEM OPERATING DIAGONALLY
FOLLOWING THIS SEQUENCE: A-B-C-D-E.
See also
Rimozione
Disc Inspection
CAUTION
THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI-
FICATIONS OF THE SYSTEM.
• The following operations are to be car-
ried out with brake disc fitted on the
wheel.
• Check the disc for wear by measuring
the minimum thickness with a micro-
meter in different points. If the mini-
mum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.
Disc thickness minimum value: 4.5 mm (0.18

in)
BRAK SYS - 373

Front brake disc
FRONT WHEEL
Removal
• Remove the front wheel
BRAK SYS - 374

• Unscrew the six screws (1) used to fas-

ten the brake disc and remove them.
• Remove the phonic wheel (2) and the
brake disc (3).
DURING REFITTING, APPLY LOCTITE 243 ON THE

THREAD OF THE BRAKE DISC SCREWS (1).
CAUTION
DURING REFITTING, SCREW ALL THE SCREWS (1) MAN-
UALLY AND TIGHTEN THEM OPERATING DIAGONALLY
FOLLOWING THIS SEQUENCE: A-B-C-D-E-F.
See also
Removal
Disc Inspection
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
• The following operations must be car-
ried out with the brake discs fitted on
the wheel; they refer to a single disc,
but are valid for both.
• Check the disc for wear by measuring
the minimum thickness with a micro-
meter in different points. If the mini-
mum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.
Disc thickness minimum value: 4 mm (0.16 in)
• Using a dial gauge, check that the max-

imum oscillation of the disc does not
exceed the tolerance; otherwise, re-
place it.
Disc oscillation tolerance: 0.15 mm (0.0059 in)
Front brake pads
BRAK SYS - 375

Removal
• Turn the pins and remove both cotter

pins.
• Remove both pins.
• Collect the anti-vibration springs.
• Extract one pad at a time.

CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER
PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
Installing
• Insert two new pads, placing them so that the holes are aligned with the calliper holes.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED IN-
SIDE THE CALLIPER.
• Position the anti-vibration plate.
• Insert both pins.
• Position both split pins.
• Abut the plungers against the pads,
acting on the brake pump lever several
times.
• Check the brake fluid level in the res-
ervoir.
BRAK SYS - 376

Rear brake pads
Removal
• Remove the safety circlip.
• Unscrew and remove the pin.
• Extract one pad at a time.

CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKAGE.
BRAK SYS - 377

Installing
• Insert two new pads, placing them so
that the holes are aligned with the cal-
liper holes.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY

ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
• Screw the pin.
• Install the safety circlip.
Bleeding the braking system

PREPARING THE VEHICLE
• It is important to ensure that there is always a sufficient quantity of brake fluid in the tank.
• These operations may be simplified by using a bleeding device when carrying out the "Re-
placing the brake fluid" operations
• In this case, when performing the bleeding procedure, it is also necessary to operate the
brake pedal a few times with the bleeder device connected (approximately five times for
each wheel circuit).
REPLACING THE BRAKE PUMP

PRELIMINARY OPERATIONS
BRAK SYS - 378

• Replace the damaged brake pump with a new one.

• Connect the brake pipe to the new brake pump.
• Fill the tank with fresh brake fluid.
CAUTION
PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT
THE END OF THE CHAPTER.
• Fill the tank up to the "MAX" level mark and replace the plug.
• Check the stroke and sensitivity of the brake pedal and lever.
• If the brake pedal or lever stroke is too long after carrying out the bleeding procedure, check
the braking system for leaks and, if none are found, bleed the system using PADS, as de-
scribed.
• Disconnect the flexible bleeder pipes and re-tighten the bleeder screws, applying the correct
torque.
See also
Front
Rear
REPLACING THE ABS CONTROL UNIT

PREPARING THE VEHICLE
• Connect the bleeder bottles to the front

and rear calliper bleeder screws and
open them.
• Press the brake pedal and lever as far
as they will go and block them in posi-
tion using the clamping devices.
• Close the front and rear calliper bleed-
er screws and remove the bleeder bot-
tles.
• Remove the damaged ABS control
unit.
Note: First of all, disconnect the brake pipes

between the ABS control unit and the brake
pump (1-4) and seal the open couplings on the
ABS control unit immediately using protective
plugs.
Next, remove the pipes between the ABS con-
trol unit and the brakes (2-3) and seal these
couplings using protective plugs too.
BRAK SYS - 379

• Install the fully pre-filled, new control

unit.
• In order to ensure that the brake fluid
remains inside the ABS control unit,
first remove the protective plugs from
the braking circuit couplings and con-
nect the corresponding pipes.
Once all the braking circuit pipes have been

connected, remove the protective plugs from
the brake pump couplings and connect the
brake pump pipes to the ABS control unit.
• Remove the clamping device from the

brake pedal and lever.
• Remove the plug from the tank and fill
it up to the "MAX" level mark with fresh
brake fluid.
CAUTION
PERFORM THE STANDARD BRAKING SYSTEM BLEED-
ING PROCEDURE, AS DESCRIBED AT THE END OF THE
CHAPTER.
scribed.
torque.
See also
Front
Rear
REPLACING THE CALLIPERS

PREPARING THE VEHICLE - The operations
are described for the front system, but they are
identical for both braking systems.
• Connect the bleeder bottle to the front

calliper bleeder screw and open it.
• Press the lever down as far as it will go
and block it in position using a clamp-
BRAK SYS - 380

ing device in order to prevent the liquid

from escaping from the system when it
is open.
• Close the front calliper bleeder screw
and remove the bleeder bottle.
• Replace the damaged calliper with a
new one.
• Remove the clamp from the brake lev-
er.
• Remove the plug from the tank and fill
it up to the "MAX" level mark with fresh
brake fluid.
CAUTION
PERFORM THE STANDARD BRAKING SYSTEM BLEED-
ING PROCEDURE, AS DESCRIBED AT THE END OF THE
CHAPTER.
scribed.
torque.
See also
Front
Rear
BLEEDING SYSTEM WITH PADS

If the brake pedal and lever still feel "spongy" after completing these checks, it is necessary to
bleed the brakes using this type of procedure.
The operations are described for the front system, but they are identical for both systems.
FRONT
• Ensure PADS is connected correctly, then select the "FRONT BRAKE BLEEDING PRO-
CEDURE" function.
• The pump starts running.
• While the pump is executing a rotation cycle, activate and release the front brake lever until
the cycle complete message is received on PADS.
• This procedure allows the air to circulate and accumulate.
BRAK SYS - 381

• Once the procedure with PADS has been completed, repeat the TRADITIONAL BLEEDING
procedure to remove any remaining air from the system.
CAUTION
PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT
THE END OF THE CHAPTER.
See also
Front
Rear
Front
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency.
CAUTION
IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT
MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO
ITS NORMAL OPERATING CONDITIONS.
NOTE
THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY, BUT ARE
VALID FOR BOTH. THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE BLEEDING
THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF
BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN
THE RESERVOIR.
CONVENTIONAL AIR PURGING SYSTEM
• Remove the rubber protection cover

from the bleed valve.
• Insert the transparent plastic pipe in
the front brake calliper bleed valve and
slide the other end of this pipe in a con-
tainer to collect the fluid.
• Remove the front brake fluid reservoir
cap.
• Operate the brake lever and then open
the bleed valve on the calliper 1/4 of a
turn to let the air out.
• Close the bleed again before reaching
the lever end of the stroke and repeat
the operation until there is no air.
• Repeat the procedure for both callip-
ers.
• Screw the bleeding valve and remove the pipe.
BRAK SYS - 382

• Top-up the reservoir until the correct brake fluid level is obtained.
• Refit and block the front brake oil reservoir cap.
• Refit the rubber protection cover.
Rear
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency.
CAUTION
IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT
MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO
ITS NORMAL OPERATING CONDITIONS.
NOTE
THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE BLEEDING THE HYDRAULIC
SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK
THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
CONVENTIONAL AIR PURGING SYSTEM
• Remove the rubber protection cover

from the bleed valve.
• Insert the transparent plastic pipe in
the rear brake calliper bleed valve and
insert the other end of this pipe into a
container to collect the fluid.
• Remove the rear brake fluid reservoir
cap.
• Operate the brake lever and then open
the bleed valve on the calliper 1/4 of a
turn to let the air out.
• Close the bleed again before reaching
the lever end of the stroke and repeat
the operation until there is no air.
• Screw the bleeding valve and remove the pipe.

• Top-up the reservoir until the correct brake fluid level is obtained.
• Refit and lock the rear brake oil reservoir cap.
• Refit the rubber protection cover.
BRAK SYS - 383

INDEX OF TOPICS
CLUTCH SYSTEM CLU SYS

SHIVER 900 Clutch system
CLUTCH CONTROL
1 Clutch pump U-bolt fastening screws - 2 10 Nm (7.38 lb ft) -
to the clutch cylinder
to the clutch pump
cylinder
cylinder
Adjustment
It is possible to adjust the distance between the

end of the lever (1) and the grip (2), turning the
adjuster (3).
• Push the control lever (1) forwards and

turn the adjuster (3) until the lever (1)
is at the desired distance.
• Turning the adjuster anticlockwise, the
lever (1) gets closer to the grip (2).
CLU SYS - 385

Clutch system SHIVER 900
Removing the clutch master cylinder
• Remove the rear-view mirror, drain the

oil from the clutch system and, after re-
moving the rubber clamp (1), remove
the pump pipe retaining screws (2).
• Disconnect the clutch switch connec-

tors (3).
• Unscrew and remove the two clutch

pump U-bolt (5) fastening screws (4).
• Remove the complete friction pump.
CLU SYS - 386

SHIVER 900 Clutch system
Removing the clutch slave cylinder
• Drain the oil from the clutch system and

remove the retaining screw (1) from the
control cylinder pipe.
• Undo and remove the three control cyl-

inder fastening screws (2)
• Remove the complete cylinder (3) and

replace the rubber o-ring (4) if neces-
sary.
CLU SYS - 387

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

SHIVER 900 Cooling system
COOLING SYSTEM
1 Flanged, hex. head used for fasten- M6x20 1 10 Nm (7.38 lb ft) -
ing the trellis expansion tank
fastening the trellis radiator
3 Button cyl. head screw used for fas- 4.2x20 3 3 Nm (2.21 lb ft) -
tening the electric fan to the radiator
fastening the radiator bracket
Circuit diagram
• The cooling circuit diagram is shown below
COOL SYS - 389

Cooling system SHIVER 900
Key:
Yellow = Air purge
Orange = Refilling
Red = From engine
Blue = To the pump
Key:
1. Front cylinder.
2. Rear cylinder.
3. Thermostat.
4. Direction of travel of vehicle.
COOL SYS - 390

Electric fan
• Remove the radiator

• Undo and remove the three screws
and collect the washers; remove the
electric fan.
See also
Removing the
radiator
Coolant replacement
• Remove the right side fairing.

remove the protection.
• Place a container of suitable capacity.

• Loosen the screw, move the clamp and
slide off the sleeve.
COOL SYS - 391

• Remove the cap.
• Empty the system into the specific con-

tainer.
• Loosen the screw and move the clamp.
• Slide off the sleeve and empty the sys-

tem completely.
CAUTION
SHOULD GREASE BE NOTED IN THE WATER THIS IS TO
BE CONSIDERED NORMAL BECAUSE DURING THE AS-
SEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LU-
BRICATION OF THE SAME IS REQUIRED IN ORDER TO
PREVENT DAMAGE.
• 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, fit the expansion tank cap.
• Refit the front protection and tighten the screw.
• Fit the right side fairing.
COOL SYS - 392

Water pump
WATER PUMP
tening screw
nut
Removal
Based on the engine design development, there are two types of water pumps, associated to the specific
clutch crankcases.
The second generation water pumps are distinguished through the punch marks, as indicated in the
image.
CAUTION
THE WATER PUMPS MUST BE COUPLED TO THE CORRESPONDING CLUTCH CRANKCASES.

THE COMPONENTS ARE NOT INTERCHANGEABLE.
THE WATER PUMP WITH THE PUNCH MARKS MUST BE COUPLED TO THE CRANKCASE WITH
PUNCH MARKS.
INCORRECT COUPLING MAY CAUSE SERIOUS DAMAGE TO THE ENGINE.
COOL SYS - 393

• Drain the cooling circuit completely.

• - Unscrew the and remove the five wa-
ter pomp cover fastening screws.
• - Loosen the clip and remove the cover.
REMOVING THE PUMP ROTOR
• Remove the H2O pump cover.

• Unscrew the rotor and remove it, not-
ing the left hand thread on the pin.
COOL SYS - 394

REMOVING THE COMPLETE H2O PUMP
• Remove the clutch cover.

• Unscrew and remove the three H2O
pump retaining screws.
• Remove the H2O pump and extract the

control chain.
NOTE
WHEN REMOUNTING THE PUMP, REPLACE THE "O-
RINGS"
Installing
MOUNTING THE COMPLETE H2O PUMP
• - Insert the control chain and position

the H2O pump in its housing.
• Insert the three H2O pump retaining

screws, applying the pre-defined tight-
ening torque.
COOL SYS - 395

• Apply a large quantity of grease to the

sides of the H2O pump so that it is eas-
ier to insert the cover.
CAUTION
WHEN MOUNTING THE COVER, MAKE SURE THAT IT IS
INSERTED PERPENDICULARLY TO THE GUARD, APPLY-
ING EVEN PRESSURE OVER THE ENTIRE SURFACE IN
ORDER TO AVOID DAMAGING THE O-RINGS.
Removing the radiator

• Locate a suitable recipient for collect-
ing the coolant.
• Remove the filler cap.

cycle, loosen the clamp and move it to
one side so that it is possible to dis-
connect the tube and drain the coolant.
• Loosen the clamp and remove it, then

disconnect the tube from the radiator,
collecting the coolant in the recipient.
COOL SYS - 396

• Remove the screw that fastens the

horn support bracket to the engine
• Disconnect the horn from its connec-
tors and remove it.
• Disconnect the electric fan connector.
• Release the clamps of the pipes that

connect the radiator to the expansion
tank and disconnect them from the ra-
diator.
• Remove the radiator fixing screw.
COOL SYS - 397

• Operating from the right side of the mo-

torcycle, release and remove the radi-
ator from the chassis.
Removing the expansion tank
• Remove the right side fairing.

remove the protection.
• Loosen and move the clamp.

• Slide off the pipe.
• Undo and remove the screw and col-

lect the washer.
• Slide off the expansion tank.
COOL SYS - 398

Thermostatic valve
Traditional circuit, three-way thermostatic valve:
1. Hot water inlet from big ends.

2. Outlet to short circuit (direct to the pump).
3. Outlet to radiator
Thermostat specifications:
Characteristic
Temperature at start of stroke
85° +/- 2°
Valve stroke at 100°
>=7mm
Valve tightness pressure
2 bar
Working pressure
1.2 bar
Maximum working temperature
125°
COOL SYS - 399

INDEX OF TOPICS
BODYWORK BODYW
SHIVER 900 Bodywork
Seat
• Rest the vehicle on its stand.

• Insert the key (1) in the lock.
• Turn the key (1) anticlockwise, pull out
and lift the saddle (2).
There is a handy document/tool kit compartment

in the vehicle tail fairing. Remove the saddle (2) to
reach it.
To lock the saddle (2):
• Move the saddle (2) so that the front

retainers fasten correctly.
• Press on the middle of the saddle (2),
at the rear fasteners, to insert them
correctly.
• Press down and push the saddle (2)
forwards, engaging the lock.
CAUTION
BEFORE LOWERING AND LOCKING THE SADDLE,
CHECK THAT THE KEY HAS NOT BEEN LEFT IN THE GLO-
VEBOX / TOOL KIT COMPARTMENT.
BEFORE SETTING OFF, MAKE SURE THAT THE SADDLE

IS CORRECTLY LOCKED INTO POSITION.
BODYW - 401
Bodywork SHIVER 900
Headlight assy.
HEADLAMP
used to fasten the headlight bracket
to the bottom yoke
used to fasten the direction indica-
tors
3 Self-locking, flanged direction indica- M5 2 2 Nm (1.48 lb ft) -
tor fastening nuts
fastening nuts
5 Flanged, self-locking lower headlight M6 1 10 Nm (7.38 lb ft) -
fastening nut
• After removing the instrument panel

support, disconnect the main wiring
harness connector from the headlight.
BODYW - 402
SHIVER 900 Bodywork
• Disconnect the direction indicator con-

nectors.
• After removing the lower front light as-

sembly fastening nut, remove the pin,
taking care to retrieve the "T" bushings
from both sides.
See also
• Remove the complete front light as-

sembly.
BODYW - 403
Bodywork SHIVER 900
Taillight assy.
TAILLIGHT
1 Button head hex. socket upper tail- M5x16 2 4 Nm (2.95 lb ft) -
light fastening screw
2 Rear indicators fastening M6 2 3 Nm (2.21 lb ft) -
3 Reflector fastening M5 2 2 Nm (1.47 lb ft) -
4 License plate light fastening M5 1 5 Nm (3.69 lb ft) -
5 Button head hex. socket lower tail- M5x25 1 4 Nm (2.95 lb ft) -
light fastening screw
• Remove the saddle and the rear wiring

harnesses protection cover in order to
cut the clamps and free the rear light
assembly wiring harness.
• Undo and remove the two upper rear
light assembly fastening screws (1)
and retrieve the two bushings (2).
BODYW - 404
SHIVER 900 Bodywork
• Access the vehicle from underneath

the exhaust terminal and unscrew the
lower rear light assembly fastening
screw (3) and retrieve the "T" bushing
(4).
• Remove the rear light assembly (5).
License plate holder
• Remove the saddle and the rear light

assembly.
• Unscrew the three upper screws (1)
and remove them.
• Remove the two screws (3) that fasten

the number plate support to the ex-
haust terminal, taking care to retrieve
the washers.
BODYW - 405
Bodywork SHIVER 900
• To make it easier to route the direction

indicators/license plate light wiring har-
ness, we recommend removing the
rear light assembly in order to remove
the clamp (2) used to fasten the wiring
harness to the number plate support
frame.
• Remove the license plate holder (4).
See also
Seat
Air box
BODYW - 406
SHIVER 900 Bodywork
AIR FILTER CASING

1 Self-tapping, SWP air pressure sen- 5x20 2 2 Nm (1.48 lb ft) -
sor fastening screws
2 Self-tapping air temperature sensor 2.9x12 2 2 Nm (1.48 lb ft) -
fastening screws
3 SWP filter box lid fastening screws 5x20 8 2 Nm (1.48 lb ft) -
4 SWP screws used to fasten the up- 5x20 10 2 Nm (1.48 lb ft) -
per part of the filter box
5 SWP screws used to fasten the filter 5x20 3 2 Nm (1.48 lb ft) -
box side cover
6 SWP wiring harness support bracket 5x20 3 2 Nm (1.48 lb ft) -
fastening screws
7 SWP control unit cover fastening 3.9x14 2 2 Nm (1.48 lb ft) -
screws
8 SWP control unit support fastening 5x14 2 2 Nm (1.48 lb ft) -
screws
• Remove the saddle, the fuel tank com-

plete with lateral ducts and the radiator
• Disconnect the air temperature sensor
connector (1)
• Disconnect the blow-by breather tube

(2) and remove it.
• Remove the eight filter box lid fasten-

ing screws (3)
BODYW - 407
Bodywork SHIVER 900
• Unscrew the intake ducts (4) anticlock-

wise and remove them.
• Remove the air filter (5).
• Remove the starter relay (6) from the

support present on the base of the filter
box.
• Detach the Ride by Wire control con-

nector (7) from the support present on
the vase of the filter box
BODYW - 408
SHIVER 900 Bodywork
• Remove the fan control relay (8) from

the support present on the base of the
filter box.
• Remove the main injection relay (9)

from the support present on the base
of the filter box.
• Detach the front ABS speed sensor

connector (10) from the support
present on the base of the filter box.
• Remove the secondary injection relay

(11) from the support present on the
BODYW - 409
Bodywork SHIVER 900
• Remove the lights relay (12) from the

support present on the base of the filter
box.
• Remove the highbeam lights relay (13)

from the support present on the base
of the filter box.
• Remove the two instrument cannister

support fastening screws (14).
• Remove the two clamps (15) used to

fasten the main wiring harness to the
cannister support.
• Disconnect the main wiring harness connector (16) and detach it from its support on the
BODYW - 410
SHIVER 900 Bodywork
• Remove the nine screws used to fas-

ten the cover (17).
• Remove the tenth screw used to fasten

the cover (18) positioned in corre-
spondence with steering headstock.
• Remove the metallic cable clamp (19),

taking care to retrieve the washer (20).
BODYW - 411
Bodywork SHIVER 900
• Remove the upper part (21) of the filter

box.

fasten the air pressure sensors.
• Disconnect the connectors and re-
move the sensors.
• Remove the two clamps (23) used to

fasten the wiring harness to the throttle
body.
NOTE
DURING REASSEMBLY, REPLACE THE CLAMPS IN THE
POSITIONS IDENTIFIED BY THE GREY TAPE.
• Disconnect the two connectors (24)

from the throttle body.
BODYW - 412
SHIVER 900 Bodywork

torcycle and remove the three screws
(25) used to fasten the side panel
mounted on the filter box in order per-
mit the passage of the wiring harness.
NOTE
• Remove the side panel (26).

• Insert a suitable screwdriver through
the hole in the side panel and loosen
the two clamps used fasten the throttle
body to the manifolds.
NOTE
DURING REASSEMBLY, MAKE SURE THAT THE METAL-
LIC CLAMPS ARE POSITIONED CORRECTLY SO AS TO
GUARANTEE THEY ARE TIGHTENED PROPERLY WHEN
REPOSITIONING THE THROTTLE BODY.
• Disconnect the throttle body and re-

move the injector connectors (27).
CAUTION
THE FRONT INJECTOR CONNECTOR IS COLOURED
GREEN IN ORDER TO DISTINGUISH IT FROM THE REAR
CONNECTOR.
TAKE CARE NOT TO INVERT THE TWO CONNECTORS AS
THIS WOULD RESULT IN THE MOTORCYCLE NOT FUNC-
TIONING CORRECTLY, AS WELL AS GENERATING ELEC-
TRICAL ERRORS.
• Remove the complete throttle body

(28).
• Extract the internal wiring harness
through the side of the filter box.
• Unclip the coil connectors (29) from their support on the base of the filter box, and disconnect
them.
BODYW - 413
Bodywork SHIVER 900
• Disconnect the cable clamp (30) from

the base of the filter box.
• Remove the clamps (31) in order to de-

tach the wiring harness from the base
of the filter box.
• Remove the two screws (32) that fas-

ten the plate used to connect the filter
box to the frame.
• Unscrew the nut (33) in order to remove the rubber spacer (34) and the plate (35).
BODYW - 414
SHIVER 900 Bodywork
• Remove the two screws (35) used to fasten the control unit cover.
• Slide the control unit cover (36) off ver-

tically.
• Disconnect the two connectors (37)

from the control unit.
BODYW - 415
Bodywork SHIVER 900
• Slide the control unit (38) out vertically.
• Remove the screw (39) used to fasten

the control unit support to the base of
the filter box.
• Remove the clamp (40) from the con-

trol unit support and release the wiring
harnesses.
• Detach the support (41) from the pin present on the base of the filter box and slide it out
from the front.
BODYW - 416
SHIVER 900 Bodywork
• Detach the cable clamp (42) from the

• Remove the four clamps positioned on

the front part of the filter box (43) and
release the wiring harness.
NOTE
• Working on both sides, loosen the metallic clamps (44) that fasten the filter box rubber
manifolds to the aluminium manifolds on the heads.
NOTE
DURING REASSEMBLY, MAKE SURE THAT THE METALLIC CLAMPS ARE POSITIONED COR-
RECTLY SO AS TO GUARANTEE THEY ARE TIGHTENED PROPERLY WHEN REPOSITIONING
THE FILTER BOX.
• Raise the filter box slightly and discon-

nect the gear sensor connector (45)
and the engine oil temperature sensor
(46) from their supports.
• Disconnect the two front/rear breather
tubes (47) from the filter box.
BODYW - 417
Bodywork SHIVER 900
• Remove the three screws (48) that fas-

ten the cable guide (49) and free the
wiring harness.
• Remove the base from the filter box

(50).
Lower cowl

BODYW - 418
SHIVER 900 Bodywork

support
• After positioning the vehicle on the side

stand, unscrew and remove the lower
fairing fastening screws, working on
both sides of the vehicle.
• Remove the lower fairing, taking care

to retrieve the "T" bushings.
Fuel tank
BODYW - 419
Bodywork SHIVER 900
LOCKS
1 Button head, hex. socket ignition lock M8x40 1 25 Nm (18.44 lb ft) -
fastening screw
2 Ignition lock fastening shear head - 1 Manual -
screw
3 Flanged, hex. head screws used to M6x25 2 10 Nm (7.38 lb ft) -
fasten the saddle lock to the saddle
6 Cyl. head, hex. socket for fastening M5x16 4 4 Nm (2.95 lb ft) -
the saddle to the tail fairing
FUEL TANK COVER

used to fasten the radiator guard to
the radiator
2 Button head, hex. socket block lid/ M5x9 2 10 Nm (7.38 lb ft) -
fuel tank cover fastening screws
3 Button head, hex. socket fuel tank M5x9 8 4 Nm (2.95 lb ft) -
cover fastening screws
4 Cyl. head, hex. socket rear fuel tank M6x90 1 12 Nm (8.85 lb ft) -
cover fastening screw
5 Self-locking rear fuel tank cover fas- M6 1 12 Nm (8.85 lb ft) -
tening nut
BODYW - 420
SHIVER 900 Bodywork
TANK
fastening screws
BODYW - 421
Bodywork SHIVER 900
SIDE FAIRINGS
screws used for fastening the grilles
to the duct covers
screws used for fastening the duct
covers to the ducts
used to fasten the duct covers to the
radiator
fastening the conveyors to the tank
fastening the conveyors to the brack-
et
6 Self-tapping screws used for fasten- 2.9x20 2 2 Nm (1.48 lb ft) -
ing the tank/fuel tank cover/ducts
7 Self-tapping, cyl. head, slot drive 2.9x20 4 2 Nm (1.48 lb ft) -
screws used for fastening the side/
tail fairings
• Remove the saddle.

• Remove from both sides the fixing
screws of the ignition switch assembly
dashboard.
• Lift the front of the ignition switch as-

sembly dashboard and remove the
rear from the tank cover.
• Operating from both sides of the mo-

torcycle, remove the fixing screws of
the duct covers.
BODYW - 422
SHIVER 900 Bodywork
• Remove the side panel fixing screws

before the radiator.
• Remove the four screws fixing the side

panels to the tank covers.
• Release the side panels from the

ducts.
• Remove the duct front screws.
BODYW - 423
Bodywork SHIVER 900
• Remove the duct rear screws.
• Raise the tank partially and remove the

duct central fixing screws.
• Remove the ducts.
• Disconnect the vent pipes from the fuel

collection tank and remove it.
• Operating from the right side of the mo-

torcycle, disconnect the vent pipe.
BODYW - 424
SHIVER 900 Bodywork
• Disconnect the fuel pump connector.
• Remove the fuel pump connector be-

low the chassis crosspiece so that the
tank can be removed later.
• Remove the nut and remove the cen-

tral fixing screw of the tank.
• Remove the tank.
BODYW - 425
Bodywork SHIVER 900
• Remove the front screws of the tank

cover.
• Remove the rear screws of the tank

cover.
• Remove the central screws of the tank

cover.
• Remove the three outer screws indica-

ted on the tank cap.
BODYW - 426
SHIVER 900 Bodywork
• Carefully remove the inner screw of the

tank cap so that it does not fall into the
tank.
• Remove the complete cap.
• Remove the tank cover.
Front mudguard
BODYW - 427
Bodywork SHIVER 900

support
• Working on both sides of the vehicle, undo and remove the four screws that secure the
mudguard.
• Remove the mudguard
Rear grab rail
• Unscrew and remove the screws (1)

used for fastening the rear wiring har-
ness protection cover.
BODYW - 428
SHIVER 900 Bodywork
• Remove the protection cover (2).
• Remove the clamps (3).

NOTE
DURING REASSEMBLY, ENSURE THAT ALL THE CLAMPS
AND THE WIRING HARNESS ARE IN THE CORRECT PO-
SITION.
• Disconnect the license plate light (4)

and rear light assembly (5) connector.
• Remove the two self-tapping screws

(6).
BODYW - 429
Bodywork SHIVER 900
• Remove the two screws (7), complete

with "T" bushings (8).
• Remove the four front screws (9)
• Remove the grab bar (10), taking care

to retrieve the "T" bushings (11).
BODYW - 430
SHIVER 900 Bodywork
INSTRUMENTS
1 Button head, hex. socket instrument M5x12 4 3 Nm (2.21 lb ft) -
panel adapter fastening screws
2 Self-tapping, SWP screws used to 5x14 3 3 Nm (2.21 lb ft) -
fasten the instrument cluster and
cover to the support plate
fastening the steering plate to the in-
strument panel plate
steering plate to the instrument panel
support plate
fastening nuts
• Remove the two instrument panel cov-

er (2) fastening screws (1).
BODYW - 431
Bodywork SHIVER 900
• Remove the instrument panel cover

(2).
• Remove the two instrument panel sup-

port fastening screws (3).
• Loosen the nuts used for fastening the

special screws (4) so that it is possible
to remove them.
• Raise the instrument panel in order to

remove the three screws (5) used for
fastening metal instrument panel sup-
port to the instrument panel.
BODYW - 432
SHIVER 900 Bodywork
• Disconnect the connector (6) and re-

move the instrument panel (7).
• Remove the four screws (8) in order to

separate the instrument panel (7) from
the plastic support (9)
Tail guard
REAR BODYWORK
used for fastening the covers to the
terminal
BODYW - 433
Bodywork SHIVER 900

2 Self-tapping screws used for fasten- M5x19 4 4 Nm (2.95 lb ft) -
ing the tail fairings to the battery com-
partment
3 Self-tapping, cyl. head Pozidriv 4.2x16 2 3 Nm (2.21 lb ft) -
screws used for fastening the grab-
bar to the tail fairings
used for fastening the number plate
holder to the number plate holder
support
fastening the grab-bar support to the
grab bar and the saddle support
• Remove the rear grab bar and the two

upper screws used for fastening the tail
fairing
• Extract the pin (1) from the side fairing,

and raise the fairing so as to unhook it
at point (2).
• Remove the two ignition switch assem-

bly fastening screws, remembering to
retrieve the metallic cable clamp
See also
Rear grab rail
BODYW - 434
SHIVER 900 Bodywork
• Remove the external screw used for

fastening the tail fairing to the side fair-
ing.
• Remove the two internal screws used

fro fastening tail fairing to the side fair-
ing and separate them.
• If necessary, in order to remove the ig-

nition switch assembly, disconnect the
saddle opening cable and remove it.
Copertura terminale
• Remove the saddle, the rear grab-bar,

the rear light assembly and the number
plate support in order to remove the
terminal covers.
The following operations refer to a single cover,

but are valid for both:
• Remove the lower fastening screw (1)

and retrieve the "T" bushing with the
rubber grommet.
BODYW - 435
Bodywork SHIVER 900
• Remove the upper fastening screw (2)

and retrieve the "T" bushing with the
rubber grommet.
• If the number plate support has not

been removed, remove the screw (3)
and the respective washer and grom-
met.
• Slide the cover (4) off from the rear.
See also
Seat
License plate holder

Rear grab rail
Taillight assy.
• Unscrew and remove the protective

rubber grommets (5)
BODYW - 436
SHIVER 900 Bodywork
BODYW - 437
INDEX OF TOPICS
PRE-DELIVERY PRE DE
SHIVER 900 Pre-delivery
Carry out the listed checks before delivering the motorcycle.

WARNING
HANDLE FUEL WITH CARE.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection
- Safety fasteners:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 439
Pre-delivery SHIVER 900
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
PRE DE - 440
SHIVER 900 Pre-delivery
- Response to throttle control

- Stability when accelerating and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
Static test
Static check after test drive:

- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system

- Stroke of brake and clutch levers (if present)
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 441
A
ABS: 191, 356, 364
Accessories:
Air filter: 71
Air temperature sensor: 148, 180
B
Battery: 119, 131
Brake: 370–372, 374, 375, 377
Brake calliper: 370, 371
Brake disc: 372, 374
Brake pads: 375, 377
Bulbs:
C
CAN line: 191
Chain: 13, 245–248, 252, 331
Chain tensioner: 245–248
Clutch: 176, 221, 223, 225, 228–231, 385–387
Coil: 161
Connecting rods:
Connectors: 184
coolant: 391
Coolant: 391
Crankcase: 52, 263, 265, 270, 271, 274
Crankshaft: 52, 263, 270, 272, 274
Cylinder: 51, 236, 237, 242, 251–254, 258, 260, 266, 386, 387
D
Diagnostics: 288, 364
Drive chain: 13, 331
E
ECU: 185, 364
Electric fan: 181, 391
Electrical system: 13, 77, 80, 439
Engine oil: 69
Engine temperature sensor: 146
Exhaust: 198, 349, 351
Exhaust manifold: 198, 351
F
Fairings:
Fork: 294–296, 303
Front wheel: 320
Fuel: 159, 198, 285, 419
Fuel pump: 159, 285
Fuses: 124
G
Gearbox selector: 213
H
Handlebar: 290
Head cover: 236, 247, 261
Headlight: 314, 402
I
Identification: 11
Instrument panel: 180
Intake pressure sensor: 141
K
Keys: 117
L
License plate holder: 405, 436
M
Magneto flywheel: 217, 247, 266
Maintenance: 8, 65
Mudguard: 321, 427
O
Oil filter: 70
Oil pressure sensor: 173
R
Radiator: 198, 391, 396
Rear wheel: 323, 330, 331
Recommended products: 67
Run/Stop switch: 183
S
Scheduled maintenance: 65
Shock absorber:
Shock absorbers: 316
Side fairings:
Side stand: 178, 347
Side stand sensor: 178
Spark plug: 67
Spark plugs:
Speed sensor: 133
Stand: 178, 347
Start-up: 122
Starter motor: 214, 215
T
Tank: 198, 398, 419
Throttle body: 163, 286
Transmission: 12
Tyres: 14
U
Use: 288, 364
W
Water pump: 393
Wiring diagram: 111

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SERVICE STATION MANUAL

THE VALUE OF SERVICE

SPECIAL TOOLS S-TOOLS

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

POWER SUPPLY P SUPP

BRAKING SYSTEM BRAK SYS

CLUTCH SYSTEM CLU SYS

COOLING SYSTEM COOL SYS

KEEP OUT OF THE REACH OF CHILDREN.

WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC-

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

BEFORE DISASSEMBLING COMPONENTS

MAINTENANCE PROGRAMME SECTION CARRIED OUT AT THE SPECIFIED MILEAGE INTER-

THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.

Dimensions and mass

WEIGHT AND DIMENSIONS

(*) Alternative solution

Frame and suspensions

Wheels and tyres

FUEL SUPPLY SYSTEM

GENERAL TIGHTENING TORQUES

GENERAL TIGHTENING TORQUES FOR SELF TAPPING SCREWS FOR PLASTIC

FRONT BRAKE MASTER CYLINDER

FRONT MUDGUARD - ENGINE FAIRING

FRONT BRAKE CALLIPERS

FRONT ELECTRICAL SYSTEM

FUEL TANK COVER

AIR FILTER CASING

ABS BRAKING SYSTEM

ENGINE - ACCESSORIES - LEVER MECHANISMS

PETROL VAPOUR RECOVERY SYSTEM

REAR BRAKE MASTER CYLINDER

REAR BRAKE CALLIPER

REAR ELECTRICAL SYSTEM

Pos. Description Type Quantity Torque Notes

Pos. Description Type Quantity Torque Notes

Cylinder - piston assy.

The pistons are available in four size types (A, B,

PISTON - CYLINDER COUPLING

Crankcase - crankshaft - connecting rod

MARKINGS ON THE INSIDE OF THE CRANKCASES

• In the area of the starter gears on the flywheel side crankcase.

CRANKCASE SELECTION CLASSES

• 4 - 5 - 6 for the flywheel side;

The category type is stamped on the outside of the

CRANKSHAFT SELECTION CLASSES

After having determined the categories of:

PRIMARY GEAR CATEGORY

CRANKCASE-PRIMARY GEAR SELECTION CLASSES

CRANKSHAFT CATEGORY (CRANK PIN)

** Crank pin selection class.

SPECIAL TOOLS S-TOOLS

020710Y Engine plate

AP8140187 U-bolt for motor support

020850Y Primary gear lock

020712Y Handle for removing the flywheel cover