2023 Ducati Desert X

Symbols - Abbreviations - References
To allow quick and easy consultation, this manual uses graphic symbols to highlight situations in which maximum care
is required, as well as practical advice or information. Pay attention to the meaning of the symbols since they serve to
avoid repeating technical concepts or safety warnings throughout the text. The symbols should therefore be seen as
real "reminders". Please refer to this page whenever in doubt as to their meaning.
The terms right-hand and left-hand refer to the motorcycle viewed from the riding position.
Warning
Failure to comply with these instructions may put you at risk, and could lead to severe injury or even death.
Important
Failure to follow the instructions in text marked with this symbol can lead to serious damage to the motorcycle and its
components.
Note
This symbol indicates additional useful information for the current operation.
Disposal
This symbol supplies information on the disposal of a substance/material.
Product specifications
Symbols in the diagram show the type of threadlocker, sealant or lubricant to be used at the points indicated. The table
below shows the symbols used and the specifications of the various products.

Symbol Specifications Recommended product

LOCTITE

LOCK 1 Low-strength threadlocker. Loctite 222

LOCK 2 Medium-strength threadlocker, compatible with oil. Loctite 243 (or THREE
BOND TB1324)

LOCK 3 High-strength threadlocker for threaded parts. Loctite 270

LOCK 4 Surface sealant resistant to high mechanical stress and solvents. Resists Loctite 510
high temperatures (up to 200 °C) and pressures up to 350 bar; fills gaps
up to 0.4 mm.

LOCK 5 Permanent adhesive for free sliding cylindrical couplings or threaded Loctite 648
couplings on mechanical parts, coaxial parts. High resistance to Loctite 128455
mechanical stress and solvents. Temperature range: ‑55 to 175 °C. (ex. 648 BV)


LOCK 6 Pipe sealant for pipes and medium to large fittings. For water and gases Loctite 577
(except oxygen). Maximum filling capacity: 0.40 mm (diameter
clearance).

LOCK 7 Instant adhesive for rubber and plastics with elastomer charged ethyl Loctite 480
base.

LOCK 9 Medium-strength threadlocker. Loctite 406

LOCK 10 Product for metal parts to seal and lock freely sliding cylindrical couplings Loctite 128443 (former
or threaded couplings. Resistant to high mechanical stress and high 648 AV)
temperature, excellent resistance to solvents and chemical attack.

LOCK 11 Medium-strength threadlocker. Loctite 401

LOCK 12 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel

OTHER SEALING AGENTS

DUCATI sealing compound. THREE BOND 1215

Sealing compound THREE BOND 1207B

One-component sealing compound SIKAFLEX 221

Exhaust pipe sealing paste. Self-sealing paste hardens when heated and Holts Firegum
resists temperatures exceeding 1000 °C.

Sealing compound. BOSTIK clear universal
silicone

Sealing compound. Ser Sil Silver

VEHICLE/ENGINE GREASE

GREASE Multipurpose, medium fibre, lithium grease. SHELL Alvania R3
A

GREASE Molybdenum disulphide grease, high mechanical stress and high SHELL Retinax HDX2 or
B temperature resistant. SHELL Gadius S2 V220 AD
2

GREASE Bearing/joint grease for parts subject to prolonged mechanical stress. SHELL Retinax LX2
C Temperature range: -10 to 110 °C.

GREASE Protective grease, with anti-corrosive and waterproofing properties. SHELL Retinax HD2
D

GREASE Grease PANKL - PLB 05
E

GREASE Grease (Vehicle): OPTIMOL -
F PASTE WHITE T
(Engine): PANKL — PLB03

GREASE Grease PANKL - PLB07
G

GREASE Grease KLÜBER STABURAGS NBU
H 30 PTM

GREASE Copper grease CUPRUM 320
I

GREASE Grease FLUOROCARBON GEL 880
L

GREASE Grease ROCOL — DRY MOLY
M PASTE

GREASE Grease AKRAPOVIC — CERAMIC
N ANTI SEIZE PASTE

PROTECTIVE AGENTS


Spray used to protect electric systems. Eliminates moisture and SHELL Advance Contact
condensation and provides excellent corrosion resistance. Water repellent. Cleaner

Spray used to protect electric systems. Eliminates moisture and SHELL Advance Contact
condensation and provides excellent corrosion resistance. Water repellent. Cleaner

Spray used to protect electric systems. Eliminates moisture and Arexons TL246
condensation and provides excellent corrosion resistance. Water repellent.

Spray used to protect electric systems. Eliminates moisture and Nyogel 760G
condensation and provides excellent corrosion resistance. Water repellent.

LUBRICANT FOR RUBBER PARTS

Emulsion for lubrication of rubber. P 80

Concentrated lubricant for tyre installation. Michelin

Denatured alcohol. Denatured alcohol

Protection lubricant emulsion. KLUBERPLUS S 06/100

THERMAL COMPOUND

Thermal compound. HTC Electrolube

LUBRICANTS FOR MECHANICAL ELEMENTS

Engine oil (for characteristics see "Fuel, lubricants and other fluids"). SHELL Advance 4T Ultra

SAE 80-90 gear oil or special products for chains with O‑rings. SHELL Advance Chain

Dry lubricant, polymerising on contact with air. Molykote D321R
Molykote M55 Plus

Lubricant for mechanical elements. Rothen extra - Additive

Lubricant for mechanical elements. Castor oil

DEGREASING AGENTS

All-purpose degreaser and cleaner. Arexons Fulcron

Degreaser for Pankl connecting rods (if any). Meta Clean 366

Degreasing agent. Lochim Solfast

Degreasing agent. Deta Blu

Degreasing agent. Saga Special

OTHER

DOT4 special hydraulic brake fluid. SHELL Advance Brake
DOT4

Anti-freeze (nitride, amine and phosphate free) 30 to 40% + water. SHELL Advance coolant or
Glycoshell
General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, make sure that the working area is well-
ventilated. Never run the engine indoors.
Warning
Exhaust gases contain carbon monoxide, which is a poisonous gas that can cause unconsciousness or even death if
inhaled.
Run the engine outdoors or, if working indoors, use an exhaust gas extraction system.
Fuel
Always make sure the working area is well ventilated. Keep any sources of ignition, such as cigarettes, open flames or
sparks, well away from working area and fuel storage area.
Warning
Fuel is highly flammable and can explode under certain conditions. Keep away from children.
Hot parts
Warning
The engine and exhaust parts become hot when the motorcycle engine is running and will stay hot for some time after
the engine has been stopped. Wear heat-resistant gloves before handling these components or allow the engine and
exhaust system to cool down before proceeding.
Warning
The exhaust system might be hot, even after engine is switched off; take special care not to touch the exhaust system
with any body part and do not park the vehicle next to flammable material (wood, leaves etc.).
Used engine oil
Warning
Wear suitable gloves to work with engine oil. Keep away from children.
Brake dust
Warning
Never clean the brake assembly using compressed air or a dry brush.
Brake fluid
Warning
Spilling brake fluid onto plastic, rubber or painted parts of the motorcycle may cause damages. Protect these parts
with a clean shop cloth before proceeding to service the system. Keep away from children.
Coolant
Engine coolant contains ethylene glycol, which may ignite under particular conditions, producing invisible flames.
Although the flames from burning ethylene glycol are not visible, they are still capable of causing severe burns.
Warning
Take care not to spill engine coolant on the exhaust system or engine parts. These parts may be hot and ignite the
coolant, which will subsequently burn with invisible flames. Coolant (ethylene glycol) is irritant and poisonous when
ingested. Keep away from children. Never remove the radiator cap when the engine is hot. The coolant is under
pressure and will cause severe burns.
The cooling fan operates automatically: keep hands well clear and make sure your clothing does not snag on the fan.
Battery
Warning
The battery gives off explosive gases; never cause sparks or allow naked flames and cigarettes near the battery. When
charging the battery, ensure that the working area is properly ventilated.
General maintenance instructions
Useful tips
Ducati recommends you to follow the instructions below in order to prevent problems and obtain the best result:
- when diagnosing faults, primary consideration should always be given to what the customer reports about
motorcycle operation since this information can highlight faults; your questions to the customer concerning
symptoms of the fault should be aimed at clarifying the problem;
- diagnose the problem systematically and accurately before proceeding further. This manual provides the
theoretical background for troubleshooting; this basis must be combined with personal experience and attendance
at periodic training courses held by Ducati;
- repair work should be planned carefully in advance to prevent any unnecessary downtime, for example obtaining
the required spare parts or preparing the necessary tools, etc.;
- limit the number of operations needed to access the part to be repaired.
General advice on repair work
- Always use top quality tools. When lifting the motorcycle, only use devices that fully comply with the relevant
European directives.
- When working on the motorcycle, always keep the tools within reach, ideally in the order required, and never put
them on the motorcycle or in hard-to-reach or inaccessible places.
- The workplace must be kept clean and tidy at all times.
- Always replace gaskets, sealing rings and split pins with new parts.
- When loosening or tightening nuts or screws, always start with the largest or start from the centre; tighten nuts
and screws to the specified torque working in a cross pattern.
- Always mark any parts and positions which might easily be confused upon reassembly.
- Use exclusively Ducati original spare parts and the recommended brands of lubricants.
- Use special tools where specified.
- Ducati Technical Bulletins often contain updated versions of the service procedures described in this manual.
Check the latest Bulletins for details.
Identification data
Each Ducati motorcycle is identified by two numbers, one for the frame and one for the engine.
Note
Please quote these numbers, which identify the motorcycle model, when ordering spare parts.

DATA STAMPED ON THE FRAME
DMH

EEC FRA/BEL
USA JAP AUS TWN KOR P.GULF 35 KW 70 KW

ZDMXANDT? ZDM1X00T? ZDM1X00T?
ZDM1X00AA#B ZDM1X00AA#B ZDM1X00AA#B ZDM1X00AA#B ZDM1X00AA#B ZDM3X35AA#B ZDM2X70AA#B
#B #B #B
DMT

EEC THA JAP AUS CHN

ML01X00AA#T ML01X00AA#T ML01X00AA#T ML01X00AA#T ML01ZBFS#T
Note
The ZDM stamping indicates the manufacturer Ducati Motor Holding whereas the MLO stamping indicates the manufacturer Ducati Motor Thailand.
DAFRA

BRA

95V1X00AA#M
Key
Example:

1 2 3 4 5 6

ZDM or ML0 1X 00AA P B ??????
1 Manufacturer: Ducati Motor Holding

2 Type - identical for all models
3 Variant
4 Year of manufacture
5 Manufacturing facility
6 Progressive serial no.

DATA STAMPED ON ENGINE
DMH

EEC BEL USA JAP AUS TWN KOR P.GULF 35 KW 70 KW

ZDM937W4V ZDM937W4V ZDM937W4V ZDM937W4V ZDM937W4V ZDM937W4V ZDM937W4V ZDM937W4Z ZDM937W4Z
AND#
DPT937W4V DPT937W4V DPT937W4V DPT937W4V DPT937W4V DPT937W4V DPT937W4V DPT937W4Z DPT937W4Z
DMT

EEC THA JAP AUS CHN

ZDM937W4V ZDM937W4V ZDM937W4V ZDM937W4V
DPTZBF
DPT937W4V DPT937W4V DPT937W4V DPT937W4V
DAFRA

BRA

95V937W4V
Key
Example:

1 2 3

ZDM or DPT 937W4T *??????*
1 Manufacturer: Ducati Motor Holding

2 Engine type
3 Progressive production no.
General

Reference Technical specifications

VEHICLE DIMENSIONS

Total length 2390 mm (94.09 in)

Total width (at hand guard) 960 mm (37.80 in)

Total width (at rear-view mirrors) 907 mm (38.98 in)

Headlight fairing height 1425 mm (56.10 in)

Handlebar height 1178 mm (46.38 in)

Seat height 880 mm (34.65 in)

Minimum ground clearance 250 mm (9.8 in)

Front footpeg height 362 mm (14.25 in)

Rear footpeg height 483 mm (19.01 in)

Wheelbase 1615 mm (63.58 in)

FRAME

Type Steel tubular trellis

Front subframe Plastic front subframe

Rear subframe Steel tubular trellis

Swinging arm Aluminium double-sided swinging arm

Steering head angle 27.6°

Steering angle 43° RH/LH

Trail 122 mm (4.80 in)

FRONT FORK

Specifications KAYABA fully adjustable upside-down fork

Stanchion diameter 46 mm (1.81 in)

Front wheel travel 230 mm (9.05 in)

REAR SUSPENSION

Specifications KAYABA fully adjustable monoshock, remote adjustment of
spring preload

Rear shock absorber travel 92 mm (3.62 in)

Rear wheel travel 220 mm (8.66 in)

FRONT WHEEL

Rim Tubeless tangentially spoked rim

Wheel rim size 2.15"x21"

Tyre size 90/90 - 21 M/C 54V M+S TL (A)

Type of tyres Radial tubeless tyres

REAR WHEEL

Rim Tubeless tangentially spoked rim

Wheel rim size 4.5"x18"

Tyre size 150/70 R18 M/C 70V M+S TL

Type of tyres Radial tubeless tyres

FRONT BRAKE SYSTEM

Front brake Semi-floating drilled twin-disc

Disc braking surface material Stainless steel

Disc carrier material Aluminium

Disc diameter 320 mm (12.60 in)

Disc thickness 6 mm (0.24 in)

Disc thickness (max. wear) 4 mm (0.16 in)

Brake calliper make Brembo

Calliper piston diameter 30 mm (1.18 in)

Number of calliper pistons 4

Friction material TT2182 FF

Brake lever master cylinder diameter 16 mm (0.62 in)

Brake master cylinder type PR 18/19

REAR BRAKE SYSTEM

Rear brake With fixed drilled steel disc


Disc thickness 6 mm (0.24 in)

Disc thickness (max. wear) 5.4 mm (0.21 in)


Brake calliper make Brembo

Calliper piston diameter 11 mm (0.43 in)


Friction material S-40-GF

Brake master cylinder type PR 16/22

CHAIN

Make REGINA 525/137ZRDB

Number of chain links (World Wide) 114

Number of chain links (China) 112

ENGINE

Type Ducati Testastretta, twin cylinder, “L” type, Desmodromic
timing system, 4 valves per cylinder, liquid-cooled

Bore 94 mm (3.7 in)

Stroke 67.5 mm (2.66 in)

Displacement 937 cu. cm(57.18 cu. in)

Compression ratio 13.3 : 1

Maximum power at crankshaft (EU) Regulation no. 81 kW / 110 CV at 9.250 rpm (*)
134/2014 Annex X, kW/HP

Maximum torque at crankshaft (EU) Regulation no. 92 Nm / 9.4 kgm at 6,500 rpm (*)
134/2014 Annex X, kW/HP

Maximum torque at crankshaft (EU) Regulation no. 92 Nm / 9.4 kgm at 6,500 rpm (*)
134/2014 Annex X, kW/HP (BELGIUM/FRANCE)

Max. rotation speed 10200 rpm

Timing system Toothed belt type with two overhead camshafts, 4 valves
per cylinder

Lubrication system Lobe oil pump with integrated by-pass valve and oil cooler

Oil pump type Lobe oil pump with integrated by-pass valve

Cooling system Liquid cooling with thermostat

Air filter One filtering element in the air-box

Crankshaft type One-piece

EXHAUST


Type Stainless steel tailpipe and mono-silencer

Lambda sensors number: 2

Catalytic converters number: 1

Emissions and consumption CO2 emissions 133 g/km, Consumption 5.6 l/100Km

GENERAL

Type Vertically-oriented 5” colour TFT display

Standard equipment Turn indicators automatic switching off

Number of seats 2
Important
(*) The indicated power/torque values have been measured with a static test bench in accordance with the type-
approval regulations and match with the data detected during type-approval and stated in the vehicle registration
document.
Colours

MATT STAR WHITE SILK
FAIRING
(Side fairings, front mudguard, tank):
• Primer: 2K White, code 873AC001, Manufacturer Palinal.

• Base coat: Star White, code 873AC001, Manufacturer Palinal.
• Clear coat: Acriplast Clear Semiopaca, code 96598, Manufacturer Lechler.
REAR SUBFRAME/FRAME
VPIC Polished Black (Powder Coating), code NJN3819AV, Manufacturer Azko Nobel.
WHEEL RIMS
Black.

MATT SATURN GREY
FAIRING
(Side fairings, front mudguard, tank):

• Base coat: Saturn Grey, code 928.F559, Manufacturer Palinal.
FUEL TANK
• EPD with PPG product.

• Base coat: Saturn Grey, code 928.F559, Manufacturer Palinal.
REAR SUBFRAME/FRAME
VPIC Polished Black (Powder Coating), code NJN3819AV, Manufacturer Azko Nobel.
WHEEL RIMS
Anodised.
Transmission


Clutch Hydraulically-controlled servo-assisted slipper and self-servo wet
multiplate clutch

Clutch control Hydraulic

Gearbox 6 speed

Gearbox type 6-speed gearbox with constant mesh gear, pedal control on the left
Transmission with Ducati Quick Shift (DQS) up/down EVO

Primary drive: sprocket/rear 33/61
sprocket ratio

Final drive: gearbox output 15/49
sprocket/rear sprocket ratio

Drive ratio (1.85:1)

1st 14/38

2nd 17/31

3rd 20/28
Gear ratios
4th 22/26

5th 23/24

6th 24/23

Make REGINA

Drive chain Number of links (World Wide) 114

Number of links (China) 112
Timing system/valves

Timing diagram with valve clearance of 1 mm (0.039 in)

Opening 4°±3° B.T.D.C.
Intake
Closing 52°±3° A.B.D.C.

Opening 63° ± 3° B.B.D.C.
Exhaust
Closing 7° ± 3° A.T.D.C.

Valve lift with valve clearance of 0 mm

Intake 11.3 mm (0.44 in)

Exhaust 10.1 mm (0.39 in)

Valve diameters

Intake valve diameter 35.5 mm (1.40 in)

Exhaust valve diameter 28.8 mm (1.13 in)

Valve clearance adjustment values

Assembly value Check value

Opening rocker arm - intake 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)

Opening rocker arm - exhaust 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)

Closing rocker arm - intake 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)

Closing rocker arm - exhaust 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)

Belt Cold tensioning Notes
status value

110 ± 5 Hz With new belt we mean a belt never fitted before.
New (Min. 105 - Max.
115)

75 ± 5 Hz Even a new belt just installed on an engine that has been started for the first time up to
Used
(Min. 70 - Max. 80) fan turning on has to be considered as used.
Crankshaft

Reference Standard value Service limit

Oval 0.005 mm (0.00019 in) n.a.

Crankshaft Taper – n.a.

Main journals alignment Ø 0.02 mm (Ø 0.00079 in) (of oscillation) n.a.

MAIN JOURNAL FOR SANSERA CON-RODS

CRANKSHAFT
CRANKCASE
CRANKCASE HOLE SIZE SHELL SHELL THICKNESS
CRANK PIN SIZE [mm]
MARKING CLASS
[mm] COLOUR [mm]

48.980÷48.988 (1.9283 1.990÷1.995 (0.0783
C PURPLE
÷ 1.9680 in) ÷ 0.0785 in)
44.992÷45.000 (1.7713
A
÷ 1.7716 in)
48.988÷48.996 (1.9286 1.990÷1.995 (0.0783
D PURPLE
÷ 1.9289 in) ÷ 0.0785 in)

48.980÷48.988 (1.9283 1.994÷1.999 (0.0785
C RED
÷ 1.9680 in) ÷ 0.0787 in)
44.984÷44.992 (1.7710
B
÷ 1.7713 in)
48.988÷48.996 (1.9286 1.994÷1.999 (0.0785
D RED
÷ 1.9289 in) ÷ 0.0787 in)

48.980÷48.988 (1.9283 1.998÷2.003 (0.0786
C BLUE
÷ 1.9286 in) ÷ 0.0788 in)
44.976÷44.984 (1.7707
C
÷ 1.7710 in)
48.988÷48.996 (1.9286 1.998÷2.003 (0.0786
D BLUE
÷ 1.9289 in) ÷ 0.0788 in)

48.980÷48.988 (1.9283 2.002÷2.007 (0.0788
C YELLOW
÷ 1.9286 in) ÷ 0.0790 in)
44.968÷44.976 (1.7703
D
÷ 1.7707 in)
48.988÷48.996 (1.9286 2.002÷2.007 (0.0788
D YELLOW
÷ 1.9289 in) ÷ 0.0790 in)

COUPLING CLEARANCE (min÷max): 0.030÷0.068 (0.0011 ÷ 0.0026 in)

AVERAGE FAILURE VALUE OF MAIN JOURNALS: 0.040 (0.0015 in)

SANSERA CON-ROD

CON-

CRANKSHAFT CRANK PIN SIZE CON-ROD BIG END
ROD SHELL COLOUR SHELL THICKNESS [mm]
MARKING [mm] SIZE [mm]
CLASS

A 41.996÷42.004 45.019÷45.025
1.478÷1.483/1.482÷1.487 (0.0581
(1.6533 ÷ 1.6537 A (1.7724 ÷ 1.7726 RED/BLUE
÷ 0.0583 / 0.0583 ÷ 0.0585)
in) in)

B 45.013÷45.019 RED 1.478÷1.483 (0.0581 ÷ 0.0583 in)
(1.7721 ÷ 1.7724

SANSERA CON-ROD

CON-

CLASS
in)

45.019÷45.025
1.482÷1.487/1.486÷1.491 (0.0583
A (1.7724 ÷ 1.7726 BLUE/YELLOW
÷ 0.0585 / 0.0585 ÷ 0.0587 in)
41.988÷41.996 in)
B (1.6530 ÷ 1.6537
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 BLUE 1.482÷1.487 (0.0583 ÷ 0.0585 in)
in)

45.019÷45.025
1.486÷1.491/1.490÷1.495 (0.0585
A (1.7724 ÷ 1.7726 YELLOW/BLACK
÷ 0.0587 / 0.0586 ÷ 0.0588 in)
41.980÷41.988 in)
C (1.6527 ÷ 1.6530
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 YELLOW 1.486÷1.491 (0.0585 ÷ 0.0587 in)
in)

45.019÷45.025
1.490÷1.495/1.494÷1.499 (0.0586
A (1.7724 ÷ 1.7726 BLACK/GREEN
÷ 0.0588 / 0.0588 ÷ 0.0590 in)
41.972÷41.980 in)
D (1.6524 ÷ 1.6527
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 BLACK 1.490÷1.495 (0.0586 ÷ 0.0588 in)
in)


AVERAGE FAILURE VALUE OF CON-RODS: 0.007 (0.0002 in)

OIL PRESSURE

RUNNING-IN PERIOD at 2500 rpm

Pressure at crankshaft recess [bar] Head pressure [bar]

Min Max Min Max

5.00 (72 PSI) 9.00 (130 PSI) 0.20 (2.9 PSI) 2.00 (29 PSI)
Cylinder/piston

CYLINDER


Cylinder nominal 94 mm (3.70 in)
diameter

Max. oval 0.005

Max. taper Measure diameter (X) compared to Check with respect to upper
liner upper edge. edge:
X(A)=10 mm (0.39 in)
X(B)=50 mm (1.97 in)
X(C)=100 mm (3.94 in)
øXA≤øXB≤øXC
øXC-øXA≤0.015 mm (0.0006
in)

Diameter Section A 94.000 ÷ 94.010 mm (3.7008 in ÷
Section B 3.7012 in)
Section C 94.010 ÷ 94.020 mm (3.7012 in ÷
3.7016 in)
94.020 ÷ 94.030 mm (3.7016 in ÷
3.7020 in)

Piston-to-bore clearance 0.025 ÷ 0.045 mm (0.0010 in ÷
0.0018 in)

PISTON


Nominal diameter 94 mm (3,701 in)

Diameter Section A 93.965 mm ÷ 93.975 mm
Section B (3.6994÷3.6998 in)
Section C 93.975 mm ÷ 93.985 mm
(3.6998÷3.7002 in)
93.985 mm ÷ 93.995 mm
(3.7002÷3.7006 in)

Gudgeon pin–to-piston 0.014 mm (0.0006 in) 0.010 ÷ 0.018 mm (0.0004 in
clearance ÷ 0.0007 in)

Nominal diameter Ø 20 mm (0,787 in)

Piston Ø 20(+ 0.015; + 0.010) mm
Ø 0.787(+ 0.0006; + 0.0004) in

Gudgeon pin Ø 20(0; - 0.003) mm
Ø 0.787(0; - 0.0001) in

Gudgeon pin-to-connecting rod 0.041 ÷ 0.042 mm (0.00161 in ÷ 0.035 ÷ 0.048 mm (0.0014 in
clearance 0.00165 in) ÷ 0.0019 in)

Engine cylinder compression (16 ± 1) bar 10 bar (MIN)
measured with DDS
Gearbox


Gearbox shafts End float – /*

Selector drum End float – /*

Central slider thickness 3.90 ÷ 4.00 mm (0.1535 in ÷ 0.1575 in) –
Gear selector fork
Fork–to-gear clearance 0.070 ÷ 0.284 mm (0.002756 in ÷ 0.0112 in) 0.4 mm (0.02 in)
* gearbox and drum shafts are tensioned, hence they have no clearance.
Cooling system


Type Fluid closed circuit with bent radiator (twin fan) and
mixing thermostat

Coolant 2.05 litres (0.45 UK gal)
capacity

Type of fluid ENI Agip Permanent Spezial (do not dilute,
use pure)

Thermostat Starts opening at 75 °C

Electric fan enabling 98 °C

Electric fan disabling 93 °C
Front wheel


Minimum tread depth In the most worn part 2 mm (0,079 in)

Tyre pressure (on the road) Cold 2.0 bar (rider only)
2.2 bar (with rider and passenger)

Tyre pressure (offroad) Cold 1.8 bar (rider only)
2.0 bar (with rider, passenger and bags)
Tubeless tyres
Tyre pressure is subject to changes due to outer temperature and altitude; check and adjust it every time you travel in
areas with wide temperature variations or at high altitudes.
Important
Check and set tyre pressure when tyres are cold. To avoid front wheel rim distortion, when riding on bumpy roads,
increase tyre pressure by 0.2 ÷ 0.3 bar.
Tyre repair or replacement (Tubeless)

In case of minor punctures, tubeless tyres take a long time to deflate as they feature a degree of self-sealing. If a tyre
is slightly deflated, carefully check that there are no leaks.
Warning
Punctured tires must be replaced. Replace tires with recommended standard tires only. Be sure to tighten the valve
caps securely to avoid leaks when riding. Never use tube type tires. Failure to heed this warning may lead to sudden
tire bursting and to serious danger to rider.
After the replacement of a tyre, wheel balancing is required.
Warning
Do not remove or move the counterweights for wheel balancing.
Important
Tyres must be fitted only on rims by using the proper standard tyre changer.
Do not use levers or similar tools as they damage the rims.

Front suspension


Type Kayaba fully adjustable upside-down fork

Oil quantity, per 681 cu. cm(41.55 cu. in)
leg

Fluid level 105 mm (4.13 in) (measured without spring and preload tube, with leg at the end of stroke from
plug)

Stanchion 46 mm (1.81 in)
diameter

Wheel travel 230 mm (9.05 in)
Rear wheel


Minimum tread depth In the most worn part 2 mm (0,079 in)

Cold 2.2 bar (rider only)
Tyre pressure (on the road)
2.5 bar (with rider and passenger)

Cold 1.8 bar (rider only)
Tyre pressure (offroad)
2.2 bar (with rider, passenger and bags)

Make REGINA

Type 525/137ZRDB
Drive chain
Number of links (World Wide) 114

Number of links (China) 112
Tubeless tyres
Tyre pressure is subject to changes due to outer temperature and altitude; check and adjust it every time you travel in
areas with wide temperature variations or at high altitudes.
Important
Check and set tyre pressure when tyres are cold. To avoid front wheel rim distortion, when riding on bumpy roads,
increase tyre pressure by 0.2 ÷ 0.3 bar.
Tyre repair or replacement (Tubeless)

In case of minor punctures, tubeless tyres take a long time to deflate as they feature a degree of self-sealing. If a tyre
is slightly deflated, carefully check that there are no leaks.
Warning
Punctured tires must be replaced. Replace tires with recommended standard tires only. Be sure to tighten the valve
caps securely to avoid leaks when riding. Never use tube type tires. Failure to heed this warning may lead to sudden
tire bursting and to serious danger to rider.
After the replacement of a tyre, wheel balancing is required.
Warning
Do not remove or move the counterweights for wheel balancing.
Important
Tyres must be fitted only on rims by using the proper standard tyre changer.
Do not use levers or similar tools as they damage the rims.

Rear suspension


Type KAYABA Fully adjustable Kayaba monoshock. Spring preload remote adjustment

Shock absorber Stroke 92 mm (3.62 in)

Wheel travel 220 mm (8.66 in)
Hydraulic brakes

FRONT SIDE


Type Semi-floating drilled dual disc

Thickness 6 mm (0.24 in)
Limit value 4 mm (0.15 in)

Brake disc
Flange material Aluminium

Braking surface material Steel


Make Brembo

Type 4-piston monoblock (M50) radial mount calliper, ABS Bosch Cornering

Brake calliper Calliper cylinder diameter 30 mm (1.18 in)


Pad friction material TT2182 FF

Type PR 16/22
Brake master cylinder
Master cylinder diameter 16 mm (0.63 in)

REAR SIDE


Type With fixed drilled steel disc.

Thickness 6 mm (0.24 in)
Brake disc
Limit value 5.4 mm (0.21 in)

Diameter 265 mm (10.43 in)

Make Brembo

Type 2-piston floating calliper [ ABS Cornering ]

Brake calliper Number of calliper pistons 2

Calliper cylinder diameter 28 mm (1.10 in)

Pad friction material S-40-GF

Type 2-piston calliper [ABS Bosch Cornering]
Brake master cylinder
Master cylinder diameter 11 mm (0.43 in)
Charging system/generator


Battery Voltage 12 V

Charge 4 Ah

Type Lithium Battery SKYRICH HJT7B-FPZ-SCR 4AH LX5

Generator Capacity 14V - 490W - 35A

Fuse-protected electronic regulator 30A

Starter motor 12V - 0.7 kW
Injection-ignition system


Starting Type Electric starter motor 12 V - 0.7 kW

Spark plugs Make and type NGK MAR9A-J

Electrode gap 0.8 ± 0.1 mm (0.0315 ± 0.0039 in)
Fuel system
Important
Do not use any additives in fuel or lubricants. Using them could result in severe damage of the engine and motorcycle
components.
Warning
The motorcycle is only compatible with fuel having a maximum content of ethanol of 10% (E10). Using fuel with
ethanol content over 10% is forbidden. Using it could result in severe damage to the engine and motorcycle
components. Using fuel with ethanol content over 10% will make the warranty null and void.

Reference Type

Unleaded fuel 95-98 RON
Fuel specifications for the US market Unleaded fuel with a minimum octane rating of 90 (RON+MON)/2

System Bosch electronic injection, throttle body with full Ride by Wire system

Throttle body diameter Ø 53 mm (2.09 in)

Injectors per cylinder - throttle body 1

Firing points per injector - throttle body 4
Lights/Instrument panel

Dashboard Vertically-oriented 5” colour TFT display

Reference Type Technical specifications

LED low beam No.2 LEDs OSRAM KW HLL531.TE

Headlight
LED high beam No.2 LEDs OSRAM KW HJL531.TE
No.4 LEDs OSRAM KW HHL532.TK

Parking light LED parking light/DRL No.4 LEDs OSRAM KW CELNM2.TK

Rear parking light with LED No.12 LEDs OSRAM LAE6SF

Rear stop light with LED No.12 LEDs OSRAM LAE6SF
No.6 LEDs OSRAM LAG6SP

Front turn indicators Europe version with LED No.1 LED LUMILEDS LXM2-PL01

Front turn indicators US version with LED No.3 LEDs OSRAM KY DMLN31.FY

Rear turn indicators Europe version with LED No.1 LED LUMILEDS LXM2-PL01

Rear turn indicators USA version with LED No.3 LEDs OSRAM KY DMLN31.FY

Number plate light with LED No. 3 LEDs CREE CLA1A-WKW

FUSE BOXES
Refer to the table below to identify the circuits protected by the various fuses and their ratings.
Important
Switch the ignition key to OFF before replacing the fuse to avoid possible short-circuits.
Warning
Never use a fuse with a rating other than specified. Failure to observe this rule may damage the electric system or
even cause fire.

Fuse box (A) key

Position El. item Value

1 – –

2 – –

3 Fuel pump relay 10 A

4 Diagnostics 7.5 A

5 Key 3 (accessories) 10 A

6 Key 2 (Dashboard / BBS) 15 A

7 Key 1 (ECU / ABS / IMU) 5A

8 Spare 10 A

9 Spare 20A

10 Spare 15A

Fuse box (B) key


1 ABS 10 A

2 ABS 25 A

3 BBS 15 A

4 Dashboard 20 A

5 Starter relay 7.5 A

6 Load relay 25 A

7 – –

8 Spare 10 A

9 Spare 20 A

10 Spare 15 A
Dimensions
A) Total length: 2390 mm (94.09 in)

B) Wheelbase: 1615 mm (63.58 in)
C) Minimum Ground clearance: 250 mm (9.8 in)
D) Seat height: 880 mm (34.65 in)
E) Handlebar height: 1178 mm (46.38 in)
F) Headlight fairing height: 1425 mm (56.10 in)
H) Total width (at hand guard): 960 mm (37.80 in)

I) Max. width (at rear-view mirrors): 907 mm (38.98 in)
L) Front footpeg height: 362 mm (14.25 in)
M) Rear footpeg height: 483 mm (19.01 in)
Fuel, lubricants and other fluids
Warning
Failure to observe weight limits could result in poor handling and impair the performance of your motorcycle, and you
may lose control of the motorcycle.

Fuel, lubricants and other Type Technical specifications
fluids

Fuel tank, including a – Ducati recommends the use of SHELL V-Power super unleaded 21 litres (4.62 UK gal)
reserve of 4 litres (0.88 fuel with a minimum octane rating of 95 RON
UK gal) – For the US market, SHELL V-Power with 90 (RON+MON)/2 fuel
octane rating (at least)

Lubrication circuit: USA, Ducati recommends the use of only SAE 15W-50/JASO MA2 oil 3.1 litres (0.68 UK gal)
CANADA, ITALY and suggests the use of Shell Advance DUCATI 15W-50 Fully
Synthetic Oil

Lubrication circuit: other Ducati recommends the use of only SAE 15W-50/JASO MA2 oil 3.1 litres (0.68 UK gal)
countries and suggests the use of Shell Advance 4T Ultra 15W-50 oil
(JASO: MA2 and API: SN)

Front/rear brake and DOT 4 -
clutch circuits

Protectant for electric Protective spray for electric systems -
contacts

Front fork SHELL Donax TA Oil level per leg: 105
mm (4.13 in).
Oil volume per leg: 681
cu. cm(41.56 cu. in).

Cooling circuit ENI Agip Permanent Spezial antifreeze (do not dilute, use pure) 2.05 litres (0.45 UK gal)
Important
Do not use any additives in fuel or lubricants. Using them could result in severe damage of the engine and motorcycle
components.
Warning
The motorcycle is only compatible with fuel having a maximum content of ethanol of 10% (E10). Using fuel with
ethanol content over 10% is forbidden. Using it could result in severe damage to the engine and motorcycle
components. Using fuel with ethanol content over 10% will make the warranty null and void.
Important
These references identify the fuel recommended for this vehicle, as specified by the European Regulation EN228.
Engine oil
A good quality engine oil has special properties. Use only a highly detergent engine oil with certified SE, SF or SG or
higher service ratings as marked on the container.
Recommendations concerning oil

It is recommended to use oil complying with the following specifications:
• Viscosity grade SAE 15W-50.

• Standard API: SN.
• Standard JASO: MA2.
SAE 15W-50 is an alphanumerical code identifying oil class based on viscosity: two figures with a W ("winter") in-
between; the first figure indicates oil viscosity at low temperature; the second figure indicates its viscosity at high
temperature. API (American standard) and JASO (Japanese standard) standards specify oil characteristics.
Torques

Thread Torque (Nm) ±
Application Notes
(mm) 10%

ACCESSORIES

LH rear-view mirror fastener M10x1.25 40

RH rear-view mirror fastener M10x1.25 40

STAND

Side stand rotation pin lock nut fastener M10x1.25 35* LOCK 3

Stand sensor fastener M6x1 5

Side stand rotation pin fastener M10x1.25 35* GREASE A + LOCK 3

Sliding shoe to side stand M6x1 10 PRE-APPLIED THREADLOCKER

Stand plate to engine retainer M10x1.25 45* GREASE B

CHAIN - SPROCKET

Sprocket fastener M25x1.25 186* GREASE B

Sprocket cover fastener M6x1 6 PRE-APPLIED THREADLOCKER

LIGHTS

Headlight to front subframe retainer M6x1 10

Tail light fastener M5x0.8 5

Front turn indicators to spacers fastener M5x0.8 5

Rear turn indicators to spacers fastener M5x0.8 5

Tail light to number plate holder fastener AF3.5 0.85

INSTRUMENT PANEL

Instrument panel fastener M5x0.8 MANUAL

Instrument panel to mount fastener M5x0.8 3

FRONT FORK

Steering head clamp retainer M6X1 10* GREASE B

Steering head central fastener M8X1.25 18* GREASE B

LOCK 2 + GREASE B on underhead
Handlebar stud bolt to head fastener M10X1.25 45*
Seq. 1-2-1

Bearing preload ring nut M35X1 35* GREASE D

Application Notes
(mm) 10%

Steering stop adjuster lock nut fastener M8X1.25 18 LOCK 2

Bottom yoke terminal fastener M8X1.25 16* GREASE B

Handlebar U-bolt fastener M8X1.25 25* GREASE B Seq. 1-2-1

Front brake hose guide to bottom yoke fastener M6X1 8 PRE-APPLIED THREADLOCKER

Splash guard to bottom yoke fastener M6X1 8 PRE-APPLIED THREADLOCKER

KAYABA fork bottom end clamp fastener M8X1.25 19* GREASE B Seq. 1-2-1

Cable guide to steering head fastener M5x0.8 5 LOCK 2

ABS sensor to LH fork axle lug fastener M6x1 8

Steering damper support to steering head
M6x1 10
fastener

Steering damper clamp retainer M6x1 10

ELECTRIC SYSTEM

BBS support bracket to electrical sys. upp.
ST5 2
support fastener

El. sys. upper support to el. sys. upper support
AF3.5 0.85
screw

Battery cable to terminal fastener M6x1 10

Solenoid starter cable to starter motor fastener M6x1 5

Solenoid starter cable on solenoid starter
M6x1 5
fastener

Ground cable on engine fastener M6x1 10

Ignition switch to steering head fastener M8x1.25 24 LOCK 2

Regulator support to frame fastener M5x0.8 6

Voltage rectifier to support fastener M6x1 5

ECU support to airbox upper shell retainer ST5 2

IMU to bracket retainer M6x1 6

IMU support bracket to frame fastener M5x0.8 6

Horn to frame fastener M8x1.25 18

IE support to subframe fastener M6x1 10

ABS sensor to brake calliper plate fastener M6x1 8


Application Notes
(mm) 10%

USB to headlight support fastener ST3 0.7

Power socket fastener 4

Latch fastener M22x1.5 3

12V socket support fastener ST3 3

BBS buffer fastener ST3 3

USB socket transformer to front subframe
ST3 0.8
retainer

FRONT BRAKE

Front brake master cylinder to handlebar
M6x1 10 Seq.: 1-(UP)-2-1
fastener

Front brake calliper fastener (LH+RH) M10x1.25 45* GREASE B

Front brake calliper pre-tightening for settling
M10x1.25 2 GREASE B
(RH)

Front brake calliper pre-tightening for settling
M10x1.25 2 GREASE B
(LH)

REAR SWINGING ARM

Lower chain sliding shoe retainer M5x0.8 5 PRE-APPLIED THREADLOCKER

Upper chain sliding shoe fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

Upper chain sliding shoe fastener 5 2

Chain guard to swinging arm fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

Chain guard fin fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

GREASE B (torque to have when
Chain tensioning slider adjuster fastener M8x1.25 8
loosening)

Hose clip to swinging arm fastener M6x1 7

Front brake retaining clip to bottom yoke
M6x1 10
fastener

REAR BRAKE

Rear brake fluid reservoir to frame fastener M5x0.8 3 PRE-APPLIED THREADLOCKER

Rear brake master cylinder to support fastener M6x1 10

Rear brake calliper holder plate to swinging arm
M5x0.8 5 PRE-APPLIED THREADLOCKER
retainer

M6x1 8

Application Notes
(mm) 10%
Mushroom-head lock nut to rear brake lever
fastener

ABS SYSTEM

ABS control unit to canister support fastener M6x1 6.8 LOCK 2

Canister support to frame fastener M6x1 10

ABS support to frame fastener M6x1 7

27

Filler plug on ABS control unit retainer M10X1 (Min. 25.5 -
Max. 28.5)

Bleed on union M8x1 5

Front calliper bleed screws M8x1 7

Rear calliper bleed M8x1 12

Bleed on front brake master cylinder M8x1 7

27

Union to RH front brake calliper fastener M10X1 (Min. 25.5 -
Max. 28.5)

27

Union on front brake master cylinder fastener M10X1 (Min. 25.5 -
Max. 28.5)

27

Double union to LH front calliper fastener M10X1 (Min. 25.5 -
Max. 28.5)

27

Union to rear brake calliper fastener M10X1 (Min. 25.5 -
Max. 28.5)

27

Union to rear brake master cylinder fastener M10X1 (Min. 25.5 -
Max. 28.5)

NUMBER PLATE HOLDER

Number plate holder plate to number plate
M6x1 5
holder subframe arm fastener

Reflector fastener M4x0.7 0.7

Number plate holder to frame front fastener M6x1 10 LOCK 2

Number plate holder to frame rear fastener M8x1.25 24

Number plate light puffer M4x0.7 fully home

Number plate light fastener M4x0.7 1.5

Application Notes
(mm) 10%

Rear mudguard to number plate holder fastener M5x0.8 5

Lower mudguard to number plate holder fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

HANDLEBAR - CLUTCH CONTROL

Clutch lever fastener M6x1 10 Seq.: 1-(UP)-2-1

RBW throttle to handlebar fastener 3.5 Seq.: 1-(UP)-2-1

Clutch actuator to engine fastener M6x1 10

Clutch master cylinder to handlebar fastener M6x1 10

LH switch fastener M5x0.8 2

RH switch fastener M4x0.7 1.5

Counterweight to handlebar tube retainer M6x1 10

RH and LH hand guard to clutch and brake
M6x1 10
master cylinder fastener

Hand guard arm to RH and LH hand guard
ST4 0.7
fastener

27

Filler plug to clutch slave cylinder retainer M10X1 (Min. 25.5 -
Max. 28.5)

27

Union to clutch master cylinder fastener M10X1 (Min. 25.5 -
Max. 28.5)

bleed on clutch master cylinder M8x1 7

bleed on clutch slave cylinder M8x1 7

REAR SUSPENSION

Shock-absorber to subframe fastener M10x1.25 70* LOCK 3 on threading

LOCK 3 on threading GREASE B on
Shock absorber to swinging arm fastener M10x1.25 70*
cylindrical head

FRONT MUDGUARD

Front mudguard to brackets fastener M6x1 10 PRE-APPLIED THREADLOCKER

Mudguard brackets to fork axle lug fastener M5x0.8 5 LOCK 2

Screw securing front brake line clip to mudguard 0.5

WATER RADIATOR

Application Notes
(mm) 10%
Radiator to RH and LH frame upper retainer M6x1 10

Expansion reservoir fastener M5x0.8 5 LOCK 2

Water hose clamps fastener on horizontal and
3
vertical cylinder

Water hose clamps fastener on thermostatic
3
valve

Water hose clamp fastener on radiator and water
3
pump

Horizontal cylinder bleed tie 0.6

Water bleeder cap on left casing 15

Water hose clamps fastener on thermostatic
3
valve

Lower bracket to engine fastener M5x0.8 8 LOCK 2

Fan support to radiator fastener M6x1 10 PRE-APPLIED THREADLOCKER

Fans to support fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

Fans to support fastener M5x0.8 5

Expansion reservoir fastener M6x1 8 LOCK 2

FOOTPEGS AND LEVERS ON BRAKE SIDE

Brake master cylinder control rod fastener M6x1 7.5

Footpeg to engine fastener M10x1.5 42* GREASE B

Footpeg to frame fastener M10x1.5 42* GREASE B

Brake lever pin to footpeg fastener M8x1.25 24 PRE-APPLIED THREADLOCKER

Passenger footpeg holder plate to subframe
M8x1.25 35 LOCK 2
fastener

RH heel guard to plate fastener M6x1 8

Brake switch cover fastener M5x0.8 5

Brake master cylinder support bracket fastener M6x1 6

Heat guard support screw fastener M6x1 10

FOOTPEGS AND LEVERS - BRAKE SIDE AND GEARBOX SIDE

Gearchange lever pin to footpeg fastener M8x1.25 24 PRE-APPLIED THREADLOCKER

Footpeg to engine fastener M10x1.5 42* GREASE B

Application Notes
(mm) 10%

Footpeg to frame fastener M10x1.5 42* GREASE B

Passenger footpeg holder plate to subframe
M8x1.25 35 LOCK 2
fastener

LH heel guard to plate fastener M6x1 8

DQS joint to con-rod fastener M6x1 10

Gearchange lever (connecting rod) to pawl
M6x1 10 PRE-APPLIED THREADLOCKER
fastener

DQS joint fastener M6x1 5 LOCK 1

DQS to gear change pedal fastener M6x1 10

Mushroom-head part to brake lever fastener M6x1 8

FRONT WHEEL

PRE-APPLIED THREADLOCKER
Brake discs and phonic wheel fastener M8x1.25 30*
(alternatively LOCK 2)

Front wheel nut fastener M25x1.25 63* GREASE B

Tyre (angle) valve tightening M8x1.25 9

REAR WHEEL

PRE-APPLIED THREADLOCKER
Brake disc / phonic wheel fastener M8x1.25 25*
(alternatively LOCK 2)

Rear sprocket fastener M10x1.25 55* LOCK 2 (On thread and underhead)

Pin on rear sprocket flange fastener M14x1.5 44* LOCK 5 (On thread and underhead)

Rear wheel shaft nut fastener M30x1.5 180* GREASE B

Tyre (angle) valve tightening M8x1.25 9

FUEL TANK

GAC flange to tank fastener M5x0.8 5

Tank plug fastener M5x0.8 5

Level sensor fastening screws M5x0.8 4 X-type sequence

Tank to frame front fastener M6x1 10

Tank to frame rear fastener M6x1 10

Cock to tank retainer M5x0.8 5

Fuel hose to cock fastener 1

Application Notes
(mm) 10%

Fuel hose retaining plate to engine fastener M6x1 10

EXHAUST SYSTEM

Exhaust pipe flange to hor./vert. head nut M6x1 10

Pre-silencer retaining clip M6x1 4 GREASE I

Lambda sensor fastener (HOR.+VER.) M18x1.5 24.5

RH-LH connecting rod to pre-silencer fastener M6x1 10

RH connecting rod to exhaust support bracket
M6x1 10
fastener

LH connecting rod to footpeg holder plate
M6x1 10
fastener

Clamp to fix Silencer M6x1 10.5 GREASE I

Heat guard on silencer fastener M5x0.8 5

Screw securing Silencer to bracket M8x1.25 20

Heat protection support bracket to engine
M6x1 10
fastener (rear)

Heat protection support bracket to engine
M5x0.8 5
fastener (front)

Heat guard on exhaust pipe fastener (VER.) M6x1 10

Rear heat guard to front heat guard fastener M5x0.8 5

Endcap to silencer fastener M5x0.8 5

Silencer bracket to subframe fastener M8x1.25 25

SEAT

Passenger seat to subframe retainer M6x1 10

FRAME

GREASE B (on thread and
Screws securing frame to engine M12x1.25 60*
underhead)

Frame/subframe fastener M10x1.5 70* LOCK 3

Seat bracket to subframe fastener M6x1 10

Tank bracket to frame fastener M6x1 10 PRE-APPLIED THREADLOCKER

Latch to tank bracket fastener M6x1 5


Application Notes
(mm) 10%
Headlight support to frame fastener M8x1.25 30 PRE-APPLIED THREADLOCKER

RH+LH adjuster ring nut for fastening swinging
M30x1.5 5 GREASE B
arm to frame and engine

Lock ring nut for fastening swinging arm to frame
M30x1.5 60* GREASE B
and engine

Nut securing swinging arm shaft to frame and
M18x1.5 70* GREASE B
engine

Plaxiglas support to headlight support fastener M6x1 10

Steering damper support to frame fastener M6x1 10

Tank pads to frame fastener M6x1 10

OIL COOLER

Pressure switch to remote oil pipe fastener M10x1 24

Pressure switch oil pipe to engine retainer M14x1.5 32

Pressure switch support to engine fastener M6x1 10

AIR INLET/OIL BREATHER

Filter cover to Airbox upper shell fastener ST5 2

Duct to Airbox upper shell fastener ST5 2

Cable ring to Airbox upper shell fastener ST5 2

Temperature sensor to Airbox upper shell
ST3 0.3
fastener

Connector bracket to Airbox upper shell fastener ST5 2

Upper shell to Airbox lower shell fastener ST5 2.25

Blow-by hose clips on blow-by valve fastener 1.5

FUEL SUPPLY SYSTEM

Injector cap to throttle body fastener M5x0.8 5

Intake funnel to throttle body fastener M5x0.8 5

Throttle body to airbox lower shell fastener M6x1 8

Throttle body to intake manifold retainer 2.5

FAIRING

Fastener securing tank central cover to tank M5x0.8 5

Application Notes
(mm) 10%
RH conveyor to tank fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

LH conveyor to tank fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

Headlight cover fastener M6x1 10 PRE-APPLIED THREADLOCKER

Rad duct fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

Radiator grille fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

RH fairing fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

LH fairing fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

Plexiglas fastener M5x0.8 5

Clutch casing cover fastener M5x0.8 3 PRE-APPLIED THREADLOCKER

Splash guard to frame fastener M5x0.8 5 PRE-APPLIED THREADLOCKER

V.H. wiring support to engine fastener M5x0.8 5

RH/LH sump guard support bracket to engine
M5x0.8 5
fastener

Sump guard support front bracket to HOR. head
M6x1 10
fastener

Sump guard to brackets fastener M5x0.8 5

Sump guard to engine lower fastener M6x1 10

Stand protection to sump guard retainer M6x1 10 LOCK 2

Shock absorber protection to swinging arm
M5x0.8 5
fastener
* dynamic safety-critical point; tightening torque tolerance must be Nm ± 5%.

Engine tightening torque values

Torque (Nm)
Application Thread / pitch Notes
Min Nominal Max

GEAR SELECTOR CONTROL

Selector drum cam retaining screw M8x1.25 22 25 28 LOCK 2

PRE-APPLIED
Gearbox pawl screw M8x1.25 34 36 38
THREADLOCKER

PRE-APPLIED
Gearbox pawl screw M6x1 15 16 17
THREADLOCKER

GEARBOX / CLUTCH

Clutch drum nut M25x1.5 180 190 200 GREASE B

FCC - wet clutch spring screw M6x1 9 10 11

TIMING SYSTEM

Timing layshaft belt roller ring nut M15x1 64 71 78 GREASE A

Camshaft gear nut M14x1 50 55 60 GREASE B

FIXED and MOBILE tensioner retaining nut M8x1.25 22 25 28 GREASE A

PRE-APPLIED
PLASTIC cover retaining screw M6x1 9 10 11
THREADLOCKER

PLASTIC cover filter support self-tapping
3.5 1.5 1.75 2
screw

IGNITION

Spark plug M10x1 11 12 13

PRE-APPLIED
Screw securing rotor to flywheel M6x1 11 13 15
THREADLOCKER

PRE-APPLIED
Starter clutch retaining screw M6x1 9 10 11 THREADLOCKER
LOCK 5

Flywheel retaining nut M24x1 313 330 346 LOCK 5

Primary sprocket retaining ring nut M22x1 171 190 209 GREASE B

Steel oil recess blanking plug - NITRIDED M20x1 45 50 55 LOCK 5

PRE-APPLIED
Balancing plug M12x1.25 26 28 30
THREADLOCKER

Connecting rod bolt (Class 14.9) M10x1 Apply the indicated product GREASE C on thread and
underhead
Snug to 20 Nm

Tighten to 35 Nm

Tighten with a rotation of
100° ± 1°

Torque check 80 ÷ 110 Nm

Crankshaft dowel M8x1.25 11 13 15 LOCK 5

Crankshaft drilled dowel M8x1.25 11 13 15 LOCK 5

COVERS

Wet clutch fluid filler cap M20x2.5 4.5 5 5.5

Water pump cover plug + washer M10x1 13.5 15 16.5

Clutch recess blanking plug + washer M10x1 10 11 12

Water pump bearing retaining screw +
M6x1 9 10 11 LOCK 2
washer

Timing inspection cover screw M6x1 4.5 5 5.5

First tightening: 3÷3.5

Generator cover, clutch and water pump
M6x1 Final tightening: 90º
cover closing screw (aluminium)

Torque check: 5÷10

Special screw securing clutch/generator
M6x1 12.5 13.5 14.5
cover to stud bolt

PRE-APPLIED
Generator stator retaining screw M6x1 12.1 13.5 14.9 THREADLOCKER
alternatively LOCK 5

PRE-APPLIED
Sound-deadening panel retaining screw M6x1 10 12 14
THREADLOCKER

Rotary gear sensor retaining screw M4x0.7 2 2.5 3 LOCK 2

CRANKCASE

Oil mesh filter plug M32x1.5 38 42 46

Plastic oil mesh filter M24x1.5 9 10 11 GREASE A

Oil intake service hole plug - steel/aluminium M22x1.5 38 42 46 LOCK 5

Oil cartridge M16x1.5 12 13 14 ENGINE OIL

Nipple for oil cartridge M16x1.5 38 42 46 LOCK 2

Stud bolt special screw for heat protection
M16x1.5 27 30 33
support

M15x1 22 25 28 LOCK 5
Clutch crankcase oil delivery channel plug
(lobe pump)

Stud bolt special screw for heat protection
M12x1.5 18 20 22
support

SEALING COMPOUND on
Oil drain plug with magnet M12x1.5 18 20 22
thread

Cylinder/head stud bolt M10x1.5 28 30 32 LOCK 2

M8x1.25

Apply product

Casing jointing screw in cylinder area GREASE B
Preload torque 17 19 21

Tightening
22 25 28
torque

M8x1.25

Apply product

Central jointing screw + swinging arm
GREASE B
connection area Preload torque 17 19 21

Tightening
22 25 28
torque

Gear stopper lever retaining screw M8x1.25 16 18 20 LOCK 2

Gearbox pawl inertial retaining screw M8x1.25 20 22 24 LOCK 2

Nut retaining oil adjustment screw to clutch M8x1 10 11 12

Blow-by valve retaining screw M6x1 9 10 11

Secondary bearing, chain side, stop screw M6x1 9 10 11 LOCK 2

Primary bearing, clutch side, stop screw M6x1 9 10 11 LOCK 2

Casing jointing screw in idle gear shaft area M6x1 9 10 11

Casing outer jointing screw M6x1 9 10 11

PRE-APPLIED
Selector drum bearing retaining screw M6x1 9 10 11
THREADLOCKER

Radial pick-up retaining screw M6x1 9 10 11

Oil squirter under piston retaining screw M5x0.8 7 8 9 LOCK 2

Blow-by valve upper shell screw M3x0.5 1 1.2 1.4 LOCK 5

ELECTRIC STARTER

Starter motor inner retaining screw M6x1 12.5 13.5 14.5 LOCK 2

Starter motor inner retaining screw M6x1 12.5 13.5 14.5 LOCK 2

PRE-APPLIED
Starter motor rear retaining screw M6x1 9 10 11
THREADLOCKER

COOLING CIRCUIT

Water circuit ties - 2 2.5 3

OIL PUMP

By-pass pump plug M15x1 15 17 19 LOCK 5

Oil lobe pump assembling screw M6x1 9 10 11

CYLINDER HEADS

FIXED and MOBILE tensioner pin M20x1 45 50 55 LOCK 2

Camshaft belt roller ring nut M17x1 64 71 78 GREASE A

Temperature sensor on water union M12x1.5 20 23 26 LOCK 4

PRE-APPLIED
Rocker arm shaft blanking plug + washer M12x1.25 14 15 16
THREADLOCKER

M10x1.5

Apply product

Snug torque to
GREASE C (On thread and
Nut for head/cylinder stud bolt 20 Nm
underhead)


Tightening
57 60 63
torque

M8x1.25

Apply product

Camshaft cap retaining screw ENGINE OIL

Tightening
21 22.5 25
torque

PRE-APPLIED
Coil retaining screws M6x1 9 10 11 THREADLOCKER
alternatively LOCK 2

Pulley flange retaining screws 10.9 M6x1 12.5 14 15.5

Intake manifold retaining nut M6x1 9 10 11

Head cover retaining screw M6x1 9 10 11

Head cover retaining special screw M6-M5 M6x1 9 10 11

Exhaust manifold stud bolt M6x1 9 10 11 LOCK 5

Vacuometer retaining screw + washer M6x1 4 5 6

Horizontal head air breather union + washer M6x1 2 2.5 3 LOCK 2

MAP sensor special screw M6x1 4 5 6

Vertical head air breather screw + washer M6x1 7 8 9 LOCK 2

Intake manifold retaining screw M6x1 9 10 11

Secondary air cover retaining screw M5x0.8 5 6 7

Head cover retaining special stud bolt screw M6x1 9 10 11

Stud bolt special screw securing water PRE-APPLIED
M5x0.8 5 6 7
unions to head THREADLOCKER

PRE-APPLIED
Screw securing water unions to head M5x0.8 5 6 7
THREADLOCKER

CANISTER USA-CAL VERSIONS

Union for canister + washer M6x1 4 5 6
Engine special tools

PART NO. DESCRIPTION IMAGE

88713.0137 Crankshaft gear stopping key

88713.2676 Wrench to block head nuts (M10)

88713.2103 Bearing surface for head installation

88713.1994 Rocker arm shaft puller

88765.1635 Graduated disk bearing tool for spark advance check with disk

88713.2906 Oil cartridge wrench

88765.1623 Timing pulley positioning tool


88713.3219 Reaction tool for pulley tightening

88713.2442 Oil seal driving tool (Ø7)

88700.5644 Timing pulley stop wrench

88713.3408 Clutch drum carrier locking tool

88713.2877 Spark plug wrench

88713.2870 Con-rod guiding tool


88713.0031 Primary drive gear puller

88713.1309 Fork feeler gauges

88713.1806 Camshaft pulley (Z=20) tightening tool

88713.2011 Tool to block crankshaft at Top Dead Centre (TDC)

88765.1298 Valve lower, upper shim check gauge

88713.1821 Fixed and mobile tensioner pin wrench

88713.3367 Flywheel wrench


88713.3334 Fork positioning plate

88713.0022 Gear selector tool

88713.1749 Puller for driving pulley and cover

88713.4411 Insert

88713.2695 Tool for measuring oil pressure at the clutch
Frame special tools


80007.0139 Front wheel shaft wrench

88713.0025 Tool for removing/refitting fork plug

88713.0030 Tool for bushing/shim insertion

88713.2775 Spoked wheel centring tool

88713.1058 Wrench to fit steering tube plug

88713.1062 Steering tube bearing installation tool

88713.0957 Tool for removing/refitting fork leg


88713.0958 Rotation bar for fork overhaul

88713.1072 Big end bearing driving tool

88713.3220 Engine repair work bench

88713.2777 Nipple torque wrench

88713.2776 Nipple tightening torque wrench

88713.4302 Tool for retaining forks in the vice
Diagnosis special tools


97900.0281 "HASP DDS3.0" wrench

97900.0279 DDS 3 (Ducati Diagnosis System 3.0)

97900.0253 Belt tensioning

97900.0282 Diagnostic cable

97900.0283 Connection cable

97900.0284 USB cable
Vehicle pre-delivery
This document contains important information for:
• Preparing the vehicle and setting it ready for the road.

• Information for motorcycle delivery to Customer.
• Instructions for vehicle maintenance.
Check of the supplied kit completeness
All bikes come with two keys associated to four lock nipples on side panniers and top case, all in the underseat
equipment kit.
Fitting the handlebar and controls

FITTING THE HANDLEBAR (where required)
Remove handlebar service support.
Centre the handlebar (A) on the bottom U-bolt (1) so that the silk-screen prints (2) coincide with the side edges of the
bottom U-bolt (1).
Note
In the following picture, with alignment to the lower reference mark, the handlebar is installed in “OFF” mode.
Apply the specified product to screws (3) thread and underhead.
Refit the two upper U-bolts (4) and start the screws (3) without fully tightening them.
Centre the handlebar on the lower U-bolt so that the silk-screen printed points (A) coincide with the upper surface of
the lower U-bolt, as shown in the figure.
Tighten the screws (3) to a torque of 25 Nm ± 5% applying a 1-2-3-4-1-2 sequence, as indicated.

FITTING HANDLEBAR BALANCING WEIGHTS AND RH AND LH HAND GUARDS
Below is the procedure for the installation of the LH hand guard. Proceed in the same way for the RH hand guard.
Insert bushing (2) on screw (1) and position them on the LH hand guard (3).
Insert in sequence the balancing weight (4), the spacer (5) and the bushing (6) on the threading of the screw (1) and
screw the bushing striker plate (7) without tightening.
Position the retaining bushing (10) on the hand guard.
Insert washer (9) and screw (9) on the LH hand guard.
Position the LH hand guard assembly on the handlebar by inserting the washer (12) and the self-locking nut (8).
Tighten the screw (11) to a torque of 10 Nm ± 10%.
Keep the hand guard fully home against the handlebar and tighten the screw (1) to a torque of 10 Nm ± 10%.
Warning
Check that by turning the handlebar fully to the right and to the left there are no interferences. If there is some
interference, work on handlebar position between the stud bolts and U-bolt.
Fitting the rear-view mirrors
Take the rear-view mirrors from the supplied kit and check their conditions.
Screw the left rear-view mirror (1) clockwise and the right rear-view mirror (2) counter clockwise, respectively.
Tighten the lock nuts (3) to a torque of 40 Nm ± 10%.
Note
It is possible to manually adjust the left (1) and right (2) rear-view mirrors in the possible directions indicated by the
arrows; this type of adjustment must be carried out with care to avoid forcing the position of the rear-view mirror, thus
damaging it.
Fitting the battery
Warning
We remind you that the LITHIUM-ION battery installed on the Desert X is of the sealed-type and completely
maintenance-free; therefore, it does not need to be filled with acid or other types of fluids.
Insert the key in the seat lock (1), turn it clockwise and simultaneously press down on the front side of the rider seat
(2) to help release the latch.
Remove the rider seat (2) by lifting it and moving it towards the front of the motorbike.
Place the battery inside its compartment.

Fix the battery using strap (6).
Connect the vehicle positive cable (1) and the ABS positive cable (2) to the battery positive terminal, then connect the
vehicle negative cable (3) and the ABS negative cable (4) to the negative terminal, as shown in the figure.
Tighten two screws (5) to a torque of 2 Nm ± 10% and position the protective rubber block (A) on the battery positive
terminal.
Apply the indicated product to pin (D) of rider seat (2).

Fit the rider seat (2) to the motorcycle by engaging tab (B) under the housing (C) present in the seat holder plate.
Shift rider seat (2) down to lock pin (D) in seat lock (E).
Make sure the rider seat (2) is properly fastened by moderately pulling it up.
Take key out of the lock (1).
Assemble windscreen
Pre-fit the four rubber blocks (3) inside the holes of Plexiglas windscreen (2).
Note
Orient the rubber blocks with the most rounded part facing the outside of the windscreen.
Apply the specified product to the shank (A) of screws (1);
Fit Plexiglas windscreen (2) on front fairings and start screws (1);
Tighten the screws (1) to a torque of 5 Nm ± 10%.
Fitting the number plate holder and cat’s eye
Remove the self-locking tie (A) and undo the screw (1).
Position number plate holder plate (2) as shown in the figure.
Apply the indicated product to the threading of three fixing screws (1).
Start screws (1) on the number plate holder plate (2).
Tighten the three screws (1) to a torque of 5 Nm ±10%.
Insert cat’s eye pins (1) inside bracket (2).
Insert two washers (3) and tighten two nuts (4) to a torque of 0.7 Nm ± 10%.
Position the bracket with the cat’s eye on the number plate holder plate (2) and secure it with two screws (5) and two
nuts (6) after fitting the number plate.
For European version number plate holder plate, number plate holder brackets (A) must be installed as shown in the
figure.
Left-hand switch
Switch (1) controls displaying and setting of instrument panel parameters.
Switch (2) controls displaying and setting of instrument panel parameters.
Switch (3) has 3 positions:
• Position (3a) = turn indicator off.

• Position (3b) = it activates the turn indicators to the left.
• Position (3c) = it activates right turn indicators.
Switch (4) controls the lights and has 3 positions:
• High beam, pushed up.

• Low beam, in the middle.
• High-beam flasher and “Start/Stop Lap” function, pushed down.
Switch (5) controls the Riding Mode change control and ENTER function.
Red switch (6) controls the warning horn.
Switch (7) controls enabling/disabling of the 4 turn indicators (Hazard).
Switch (8) controls enabling/disabling of the Cruise Control function.
Switch (9) controls an increase in the cruise speed set by the Cruise Control function, or controls to follow the
previously set speed as the cruise speed.
Switch (10) controls a decrease in the cruise speed set by the Cruise Control function, or controls to set the current
speed as the cruise speed.
Switch (11) controls enabling/disabling of the ABS function.
Right-hand switch
Switch (12) controls heated handgrips switch-on/off (if provided).
Switch (13) controls the following:
• Enabling/disabling of the DRL function.

• Enabling/disabling of the fog lights, if provided.
Switch (14) controls the engine starting.
Switch (15) controls the engine killing and has 2 positions:
• Pushed up: RUN ON. Only in this position can the engine be started by pressing the button (14).
• Pushed down: engine kill (RUN OFF).
Transport Mode function
The “Transport Mode” function limits instrument panel operation, in particular:
• "Transport Mode" is displayed in the instrument panel section devoted to interactivity; it is thus not possible to
display information and/or edit the different parameters.
• The Riding Mode changeover quick menu can only be accessed, but the relevant parameters cannot be edited.
Warning
The "Transport Mode" function is activated at Ducati at the end of line (EOL) and must be deactivated before
motorcycle delivery to the final customer, during the pre-delivery phase.
Note
For further details on the "Transport Mode" function, refer to the dedicated bulletin SRV-ESB-18-005.
Setting menu function
This function allows you to enable, disable and set certain vehicle functions; for safety reasons, this function is only
accessible when the vehicle is stationary. If you are in the Setting menu and the vehicle is moving, the instrument
panel will automatically exit the menu and set the display to the previously selected Riding Mode page.
Select the Interactive Menu (A) by holding button (1) pressed. Use buttons (1) and (2) to select "Settings" (B) and
press ENTER (3).
The following functions are displayed in the setting menu:
• Indication of scheduled maintenance service due dates (SERVICE).

• RIDING MODES.
• Setting of the displayed riding information sequence in Drive Mode (INFO DISPLAY).
• Fuel level display (FUEL INDICATOR).
• Auto/Manual DRL light mode (DRL CONTROL).
• Setting the brightness and theme of the instrument panel (DISPLAY SETUP).
• PIN CODE activation and modification (PIN CODE).
• Date and time setting (DATE AND TIME).
• Tyre calibration and drive ratio (TYRE CALIBRATION).
• Deletion of associated and paired devices (BLUETOOTH) - if present.
• Turn indicator automatic power-off management (TURN INDICATORS).
• Language setting (LANGUAGE).
• Unit of measurement setting (UNITS).
• Calculation of the partial distance travelled by the vehicle (TRIP MASTER PRECISION).
• INFO: Battery voltage indication (BATTERY); Digital engine rpm indication (RPM).
Riding Mode change function
This function allows you to change the motorbike riding modes in static and dynamic conditions.
To select the RIDING MODE press and hold button (3) “ENTER”, use buttons (1) and (2) to scroll through the list
and briefly press button (3) “ENTER” to select the riding mode.
Six riding modes are available:
• RALLY.
• ENDURO.
• WET.
• TOURING.
• URBAN.
• SPORT.
Each riding mode is associated with a different colour for the name and frame of the rev counter. The parameters
associated with each riding modes are customisable and are:
• Power (Engine power).

• DWC (Ducati Wheelie Control).
• DTC (Ducati Traction Control).
• DQS (Ducati Quick Shift).
• ABS (Antilock Braking System).
• EBC (Engine Brake Control).
PIN CODE function
This function allows you to activate or modify your PIN code, which is useful in the event of malfunctioning of the key
recognition system or key malfunctioning.
To activate and/or modify the PIN CODE, enter the setting menu, select the “Pin Code” indication by pressing
buttons (1) or (2) and press button (3) “ENTER” to confirm.
Use buttons (2) and (1) to select "New Pin" and then press button (3) to confirm. The indication "PIN code > New
Pin" is then displayed on the top with four spaces for entering the digits of the secret code: "0 0 0 0".
The two arrows on the digit indicate the possibility of setting it:
• Every time button (1) is pressed, the digit will increase by one unit (+1).
• Every time button (2) is pressed, the digit will decrease by one unit (-1).
• To confirm the digit and shift to the following one, press button (3).
• Repeat the procedure until you confirm all the 4 digits of the PIN CODE.
Once the “fourth” digit is set, upon pressing button (5) the instrument panel activates the following indications:
• Back: to exit the menu and return to the previous display.

• Save: to save the entered code.
After saving the entered code, the instrument panel displays “Saved”. After 2 seconds, the instrument panel will go
back to the previous screen, showing the additional indication "Modify Pin". After having stored the first PIN CODE,
then "New Pin" menu item is no longer available, but replaced by the function to be used to modify the secret code.
Note
To change the Pin Code, from the Setting Menu - Pin Code function, enter the old Pin Code and, if correctly entered
and recognised, enter the new Pin Code. If the Pin Code is forgotten, it must be reset using the DDS 3.0, and using the
motorcycle ignition key.
Date and time setting

DATE SETTING
.This function allows user to display and/or set/change the date and time. To set the date, select “Date and time”
from the setting menu by pressing button (1) or (2); once the function is highlighted, press button (3) to confirm.
Select “Set date” and press button (3) to confirm; when this indication is highlighted, the instrument panel displays
the date set in the format: YEAR, MONTH, DAY.
Note
Every time the battery is disconnected, the date and time are reset and must be set again.
Note
If the date has never been set, the year, month and day will be “- -”.
If the date is not correct, the instrument panel shows "Wrong" for 3 seconds and then automatically highlights the
year value (with the two arrows) to set again another date.
To set the time, select “DATE AND TIME” from the setting menu by pressing button (1) or (2); once the function is
highlighted, press button (3). Select “Set time” and press button (3) to confirm; when this indication is highlighted,
the instrument panel displays the time set in the format: HOUR, MINUTE, AM/PM.
Warning
Every time the battery is disconnected, the date and time are reset and must be set again.
Language setting
This function allows setting the instrument panel language.
• Use buttons (1) and (2) to select “Settings” from the Interactive Menu and press ENTER (3).
• Select the “Language” item and press ENTER (3).
The following items are displayed: “English, Italiano, Deutsch, Francais, Netherlands, Espanol”.
The currently set language is indicated at the bottom of the page.
Use buttons (1) and (2) to scroll and select the desired language. Press ENTER (3) to confirm; the “Back” item is
selected, then press ENTER (3) again to quit.
Setting the units of measurement
This function allows changing the units of measurement of the displayed values. Enter the setting menu, use buttons
(1) or (2) to select “Units” and press button (3) to confirm.
When opening this function, the instrument panel displays the following indications:
• Speed.
• Temperature.
• Consumption.
• Default (visible only if one or more parameters have been modified).
The quantities for which it is possible to set the units of measurement are:

Speed Temperature Fuel consumption

km/h - mph °C - °F L/100km - km/L - mpg(UK) - mpg(USA)
Vehicle maintenance schedule

The maintenance schedule described in this bulletin is the one that will be communicated to Customers through all
Ducati communication channels. We are confident that you will cooperate in respecting the times and operations
indicated for the various scheduled maintenance services. The types of service provided for this model are:

OIL SERVICE To be carried out after the first 1,000 km (600 mi) and in any case within 6 months of the motorcycle
1000 delivery to the Customer.

ANNUAL To be carried out for the first time 12 months after the previous service coupon and then every 12
SERVICE months.

OIL SERVICE To be carried out for the first time at 15,000 km / 9,000 mi and then every 15,000 km / 9,000 mi or
15000 every 24 months.

To be carried out for the first time at 30,000 km / 18,000 mi and then every 30,000 km / 18,000 mi.
DESMO
The Desmo Service does not include the operations already performed in the Oil Service 15000 /
SERVICE
Annual Service. The Desmo Service could be due and therefore carried out at the same time of the Oil
operations
Service/Annual Service.
Below are the specified time intervals for the different types of service:

Type of scheduled maintenance Time

OIL SERVICE 1000 1h:06 min (11 LU)


ANNUAL SERVICE 30 min (5 LU)

DESMO SERVICE operations 3h:00 min (30 LU)

OIL SERVICE + DESMO SERVICE operations 4h:12 min (42 LU)

ANNUAL SERVICE + DESMO SERVICE operations 3h:30 min (35 LU)
In addition to the prescribed times, we also indicate the time expected to be required for the main additional
operations that can be performed during the services:

Type of operation Time

Brake and clutch fluid (every 24 months) 36 min (6 LU)

Front fork fluid (every 45,000 Km / 27,000 mi) 1h:12 min (12 LU)

Timing belts (every 30,000km/18,000mi or 60 months) 30 min (5 LU)*
* time not to be summed to the Desmo Service.
Prescribed time to carry out the operations of the Oil Service 1000:


Note
When turning off the Oil Service/Annual Service indication on the instrument panel through the DDS 3.0, the new
deadlines, in time and mileage, will be stored at +15,000 km / 9,000 mi and +24 months, respectively.
Following are all the operations to be performed during the Oil Service 1000:
• Read fault memory with the DDS 3.0 and check technical updates and recall campaigns on DCS.
• Change engine oil and oil filter.
• Visually check the front fork and rear shock absorber seals.
• Check brake and clutch fluid level.
• Check chain, chain sliding shoes, front and rear sprocket wear, check final drive chain tension, lubrication and
stretching. Measured stretching value: ___________ (cm) (in).
• Check spoked wheels as specified in the workshop manual.
• Check the freedom of movement and tightening of the side stand.
• Check that all rubber gaiters and visible hoses (i.e. fuel, brake and clutch, cooling system, bleed hoses, etc.) are
not cracked, are tight and correctly seated.
• Check rear brake lever free play and handlebar lever and pedal control lubrication.
• Check tyre pressure and wear.
• Check the operation of all electric safety devices (side stand and clutch sensor, front and rear brake switches,
engine kill switch, gear/neutral sensor).
• Check lights, turn indicators, horn and controls.
• Final test and road test of the motorcycle, testing safety devices (e.g. ABS and DTC) electric fans and idling.
• Visually check the coolant level and sealing of the circuit.
• Softly clean the motorcycle.
• Registration of the service coupon with Service warning light turning off on instrument panel with DDS 3.0 and
filling in of the service coupon in the Service Booklet.
Prescribed times to carry out the operations of the Oil Service/Annual Service:


OIL SERVICE 1h:42 min (17 LU)

ANNUAL SERVICE 30 min (5 LU)
We remind you that the date from which the counting starts to calculate the Annual Service threshold is written in the
instrument panel by the DDS 3.0 upon the turning off of the Oil Service 1000 warning light.
Following are all the operations to be performed during the Oil Service/Annual Service:
• Change engine oil and oil filter.
• Check and clean air filter.
• Visually check the front fork and rear shock absorber seals.
• Check brake and clutch fluid level.
• Check front and rear brake disc and pad wear. Change, if necessary.
• Check front and rear brake calliper screw and front brake disc screw tightening.
• Check the proper tightening of front and rear wheel nuts and rear sprocket nut.
• Check the proper tightening of engine to frame, swinging arm and rear shock absorber fasteners.
• Check wheel hub bearings.
stretching.
• Check steering tube bearing clearance.
stretching. Measured stretching value: ___________ (cm) (in).
• Check steering tube bearing clearance.
• Check spoked wheels as specified in the workshop manual.
• Check the freedom of movement and tightening of the side stand.
• Check that all rubber gaiters and visible hoses (i.e. fuel, brake and clutch, cooling system, bleed hoses, etc.) are
not cracked, are tight and correctly seated.
• Check rear brake lever free play and handlebar lever and pedal control lubrication.
• Check tyre pressure and wear.
• Check the operation of all electric safety devices (side stand and clutch sensor, front and rear brake switches,
engine kill switch, gear/neutral sensor).
• Check lights, turn indicators, horn and controls.
Prescribed time to carry out the operations of the Desmo Service:


DESMO SERVICE (does not include the operations to be performed in the Oil Service/Annual 3h:00 min (30
Service) LU)
Following are all the operations to be performed during the Desmo Service:
• Check and/or adjust valve clearance.
• Change timing belts.
• Change spark plugs.
• Change air filter.
• Change coolant.
• Check silentblocs on rear sprocket and lubricate the rear wheel shaft.
Note
When turning off the Desmo Service Operations indication on the instrument panel through the DDS 3.0, the new
deadline will be stored as mileage + 30,000 km/18,000 mi.
Service Information
This function allows displaying information on the mileage and time deadlines for OIL SERVICE, ANNUAL SERVICE
and DESMO SERVICE scheduled maintenance.
To view the deadlines, access the setting menu and use buttons (1) and (2) to select “Service”, then press button (3)
to confirm.
Available information:
• OIL SERVICE: it indicates the countdown of the km/mi left to the specified threshold (15,000km/9,000mi).
• DESMO SERVICE interventions: it indicates the countdown of the km/mi left to the specified threshold
(30,000km/18,000mi).
• ANNUAL SERVICE: it indicates the due date of the annual maintenance.
When the set service deadlines are getting closer, the warning light (A) is activated and each time the bike is switched
on, the instrument panel activates the grey indication (B) for 5 seconds, with the remaining distance or days. For the
OIL SERVICE and DESMO SERVICE it is activated before the last 1000 km, while for the ANNUAL SERVICE it is
activated when 30 days are left. Once the service deadline has been reached and exceeded and each time the
instrument panel is switched on, the yellow indication (B) is displayed for 5 seconds, with the distance or days
exceeded in relation to the pre-set threshold for the relevant service.
We remind you that the date from which the counting starts to calculate the Annual Service threshold is written in the
instrument panel by the DDS 3.0 upon the turning off of the Oil Service 1000 warning light.
Useful information for scheduled maintenance

Fuel, lubricants and
Type Quantity
other fluids

SAE 15W-50/JASO MA2 or SHELL Advance DUCATI
Engine oil 3.1 cu. dm(litres) (0.68 UK gal)
15W-50 Fully Synthetic Oil

Oil level per leg: 105 mm (4.13 in) Oil
KAYABA front fork SHELL Donax TA
volume per leg: 681 cu.cm

Cooling circuit ENI Agip Permanent Spezial 2.05 cu. dm(litres) (0.45 UK gal)

TIGHTENING TORQUES FOR SAFETY TIGHTENING CHECK

Front brake disc screws 30 Nm±5% + pre-applied threadlocker

Rear brake disc screws 25 Nm±5% + pre-applied threadlocker

Front brake calliper screws 45 Nm±5% + Shell GADUS S2 V220 AD 2 (pre-tightening 2Nm)

Rear wheel shaft fastener 180 Nm±5% + Shell GADUS S2 V220 AD 2

Rear sprocket retaining nuts 55 Nm±5% + LOCTITE 243

Front wheel nut 63 Nm±5% + Shell GADUS S2 V220 AD 2

Sprocket fastener 186 Nm±5% + Shell GADUS S2 V220 AD 2

Frame to horizontal and vertical head
60 Nm±5% + Shell GADUS S2 V220 AD 2 on thread and underhead
retaining screws

Rear shock absorber to frame upper
70 Nm ± 5%; LOCTITE 270 application on threading
fastener

Rear subframe to frame fastener 70 Nm ± 5%; LOCTITE 270

Rear shock absorber to swinging arm 70 ± 5%; LOCTITE 270 application on threading and GADUS S2 V220 AD 2
fastener application on round head

CHECK OF ENGINE OIL LEVEL AND TOP-UP, IF NECESSARY
Check the engine oil level through the inspection sight glass (1) on the clutch cover. To check the engine oil level, the
bike must be placed with both tyres resting on a flat surface, in a vertical position and with the engine warm,
approximately 15 minutes after the engine has been switched off; the level must be between “MIN” and “MAX”
reference marks. If the engine oil level is low, unscrew the plug (2) and top up.
Refit the plug (2).

CHECK OF COOLANT LEVEL AND TOP-UP, IF NECESSARY
Check the coolant level in the expansion reservoir, observing it from the right side of the vehicle, after turning the
handlebar fully to the left. Set the vehicle on a flat surface on the centre stand (if possible) or on service stand. Check
that the level is between the “MIN” and “MAX” marks located on the expansion reservoir.
If the level is low, loosen the plug (1) and add new specified liquid until the correct level is reached.
Refit the plug (1).

FINAL DRIVE CHAIN TENSIONING AND LUBRICATION
To tension the final drive chain it is necessary to:
• Make the rear wheel turn until you find the position where chain is tightest.
• Set the motorcycle on the side stand.
• With a finger, push down the chain at the point of measurement and release.
• Measure the distance (A) between the swinging arm and the centre of a chain pin by placing the measuring tape
at the rear end of the chain sliding shoe. The distance should be as follows:
• World Wide version A = 47 ÷ 49 mm (1.85÷ 1.93 in).

• China version A = 44 ÷ 46 mm (1.73÷ 1.81 in).
Note
This only applies to the motorcycle standard settings, available upon delivery. For chain washing, lubrication and
inspection, please refer to Service Bulletin SRV-SRB-19-046 “Final drive chain maintenance precautions”.

TYRE INFORMATION
The Desert X Year 2023 is equipped with Pirelli Scorpion Rally STR tyres.

Pirelli Scorpion Rally STR tyre pressure

ON ROAD 2.0 bar (rider only)

ON ROAD 2.2 bar (rider with passenger)
Front wheel
90/90 - 21 M/C 54V M+S TL (A)
OFF-ROAD 1.8 bar (rider only)

OFF-ROAD 2.0 bar (rider with passenger and bags)

ON ROAD 2.2 bar (rider only)

ON ROAD 2.5 bar (rider with passenger)
Rear wheel
150/70 - R18 M/C 70V M+S TL
OFF-ROAD 1.8 bar (rider only)

OFF-ROAD 2.2 bar (rider with passenger and bags)

FUSE BOX KEY
The fuse boxes are located under the rider seat and are laid out as follows:
• Fuse box (A) and (B) in front of the battery.

• Main fuse (C) on the RH side.
• Fuses (D) on the solenoid starter on the RH side.
As far as boxes (A) and (B) are concerned, to expose the fuses, lift the box protective covers. Mounting position and
ampere capacity are marked on box cover, as shown in the following tables.

Fuse box (A) key


1 – –

2 – –


4 Diagnostics 7.5 A




8 Spare 10 A

9 Spare 20A

10 Spare 15A

Fuse box (B) key


1 ABS 10 A

2 ABS 25 A

3 BBS 15 A

4 Dashboard 20 A


6 Load relay 25 A

7 – –

8 Spare 10 A

9 Spare 20 A

10 Spare 15 A
Operations to be carried out by the dealer
Warning
This scheduled maintenance chart is designed for a road use of the Multistrada. If it is used on the track, even if not
during sport competitions, all parts of the motorcycle are more stressed so the routine maintenance operations must
be carried out more frequently than indicated.

Annual Service*

Desmo Service*

Oil Service*

Oil Service 1000*

Reading of the error memory with DDS 3.0 and check of technical updates and recall campaigns
• • • 12
on DCS

Change engine oil and filter • • 24

Check and clean air filter • 24

Change air filter •

Change timing belts • 60

Check and/or adjust valve clearance •

Change spark plugs •

Change coolant • 48

every 45,000 km /
Change front fork fluid
27,000 mi

Visually check the front fork and rear shock absorber seals • • 12

Check brake and clutch fluid level • • 12

Change brake and clutch fluid 24

Check front and rear brake disc and pad wear • 12

Check the proper tightening of brake calliper screws and front and rear brake disc screws • 12

Check rear brake disc screw tightening (by removing the rear wheel shaft if brake disc fastening
•
screws with hexagon wrench flat are present)

Check spoked wheels as specified in the workshop manual • • • 12

Check front and rear wheel nuts and rear sprocket nut tightening • 12

Check for proper tightening of engine to frame, swinging arm and rear shock absorber fasteners • 12

Check wheel hub bearings • 12

Check silentblocs on rear sprocket and lubricate the rear wheel shaft •

Check chain, front and rear sprocket wear, check final drive chain tension, lubrication and
stretching. Measured stretching value:______________ (cm) (in)

• • 12
Warning
We recommend replacing the final drive chain kit within 12,000 mi/20,000 km.

Check steering tube bearing clearance • 12

Check the freedom of movement and tightening of the side stand • • 12

Check that all rubber gaiters and visible hoses (i.e. fuel, brake and clutch, cooling system, bleed,
• • 12
drain hoses, etc.) are not cracked, are tight and correctly seated

Check rear brake lever free play and handlebar lever and pedal control lubrication • • 12

Check tyre pressure and wear • • 12

Check the operation of all electric safety devices (side stand and clutch sensor, front and rear
• • 12
brake switches, engine kill switch, gear/neutral sensor)

Check lights, turn indicators, horn and controls • • 12

Final test and road test of the motorcycle, testing safety devices (e.g. ABS and DTC), electric fans
• • • 12
and idling

Visually check the coolant level and sealing of the circuit • • • 12

Softly clean the motorcycle • • • 12

Registration of the service coupon with Service warning light turning off on instrument panel with
• • • 12
DDS 3.0 and filling in of the service coupon in the Service Booklet
* The First Service 1000 must be carried out after the first 1,000 km/600 mi or within six months from bike delivery
to the customer.
* The Oil Service
must be carried out every 15,000 km/9,000 mi.

* The Desmo Service
must be carried out every 30,000 km/18,000 mi.
* The Annual Service
must be carried out every 12 months.
In case of off-road use, it is necessary to perform the maintenance operations more frequently than scheduled.
Scheduled maintenance chart: operations to be carried out by the customer
Important
Using the motorcycle under extreme conditions, such as very damp and muddy roads or dusty and dry environment,
could cause above-average wear of components like the drive system, the brakes or the air filter. If the air filter is
dirty, the engine could get damaged. Therefore, this might translate in required service or replacement of the wear
parts earlier than specified in the scheduled maintenance chart.

List of operations and type of intervention km. x1,000 1
(set mileage (km/mi) or time interval*)
mi. x1,000 0.6

Months 6

Check engine oil level •

Check brake and clutch fluid level •

Check tyre pressure and wear •

Check the drive chain tension and lubrication. •

Check brake pads. If necessary, contact your dealer to replace pads •
* Service operation to be carried out in accordance with the specified distance or time intervals (km, miles or months),
whichever occurs first.
Check engine oil level
Check the engine oil level through the inspection sight glass (1) on the clutch cover side.
To check the oil level correctly, carefully follow the instructions below:
• The level should be checked at warm engine, about 15 minutes after the engine has been stopped.
• Turn off the engine and wait 10\15 minutes to allow the oil to flow completely inside the sump.
• Position the bike with both wheels on a flat ground and in straight position.
• Then, check the engine oil level through the sight glass (1).
• If the oil level is below the centreline between the MIN and MAX notches, it is necessary to add oil.
• To do this, remove the filler plug (2) and top up with the recommended oil until the oil reaches the MAX notch.
USA, CANADA, ITALY version

Ducati recommends the use of only SAE 15W-50/JASO MA2 oil and suggests the use of Shell Advance DUCATI 15W-50
Fully Synthetic Oil.
Other country version

Ducati recommends the use of only SAE 15W-50/JASO MA2 oil and suggests the use of Shell Advance 4T Ultra 15W-50
oil (JASO: MA2 and API: SN).
Refit the filler plug (2).

Recommendations concerning oil
It is recommended to use oil complying with the following specifications:
• Viscosity grade SAE 15W-50.

• Standard API: SN.
• Standard JASO: MA2.
SAE 15W-50 is an alphanumerical code identifying oil class based on viscosity: two figures with a W ("winter") in-
between; the first figure indicates oil viscosity at low temperature; the second figure indicates its viscosity at high
temperature. API (American standard) and JASO (Japanese standard) standards specify oil characteristics.
Changing the engine oil and filter cartridge

Service operation

First Service 1000

Change engine oil and filter Oil Service

Annual Service (24)

Special tools



CHANGING THE ENGINE OIL
Note
This operation has to be carried out with hot engine (but turned off) because the oil in these conditions is more fluid
and comes out faster and completely.
Warning
Dispose of oil and/or filter cartridges in compliance with environmental protection regulations.
Disposal
Do not dispose of the waste into the environment; do not pour the product, either new or exhausted, inside drains,
water courses or the soil. Collect and deliver waste to authorized collecting centres. Dispose of waste in compliance
with the prevailing local and national standards. European Waste Catalogue Codes recommended for waste disposal as
indicated by Decision No 2001/118/EC: EWC 13 02 05* (Mineral-based non-chlorinated engine, gear and lubricating
oils): EWC 16 01 07* (Oil filters).
Note
It should be noted that the above-mentioned EWC code is a general and non-binding provision, provided based on
product original composition and intended use. The user is thus responsible for selecting the EWC code most suitable
to the concerned product, based on product real use and taking into account any alterations and/or contaminations of
the product, as well as any amendments to the prevailing standard on waste disposal.
Remove the complete sump guard (Removing the sump guard).

Remove the horizontal exhaust manifold (Removing the exhaust system).
Position a specific container under the sump.
Loosen plug (1) with seal (A) and let the oil completely flow out.
Clean plug thread (1), check that there are no metal deposits on end of the magnetic drain plug.
Apply the indicated product to plug (1) thread, and refit it with seal (A) to the sump.
Tighten drain plug (1) to a torque of 20 Nm (Min. 18 Nm – Max. 22 Nm).

OIL CARTRIDGE FILTER REMOVAL
Remove the oil sump filter cartridge (2) using service tool part no. 88713.2906.
Important
Dispose of the used filter, do not re-use it.

REFITTING THE OIL CARTRIDGE FILTER
Fit a new cartridge (2) using the specific tool available on the market and having care to lubricate the seal with engine
oil.
Screw cartridge (2) into relevant seat and tighten it to a torque of 13 Nm (Min. 12 Nm - Max. 14 Nm).
Every two oil changes, clean the oil intake mesh filter.
Note
It is advisable to refill the filter cartridge with engine oil before fitting it: this enables the recommended oil level to be
maintained without topping up.

REMOVING THE MESH INTAKE OIL FILTER
Loosen outer plug (3) and collect seal (4).

Loosen the filtering element (5) and slide it out of casing.
Loosen drain plug (6) and collect seal (7).
Clean the mesh filter with fuel and compressed air. Take care not to damage the mesh.

REFITTING THE MESH INTAKE OIL FILTER
Apply the indicated product to the thread of mesh filter (5).

Start mesh filter (5) on casing.
Tighten mesh filter (5) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).
Insert seal (4) in plug (3) with the cutting edge facing the crankcase.
Start plug (3) on casing.
Tighten plug (3) to a torque of 42 Nm (Min. 38 Nm – max. 46 Nm).
Fit the seal (7) on the drain plug (6).

Apply the indicated product to the thread of drain plug (6).
Start drain plug (6) on casing.
Tighten drain plug (6) to a torque of 42 Nm (Min. 38 Nm – Max. 46 Nm).
Fill the lubrication circuit, until topping up to the proper engine oil level.
Remove the filler plug (8) and carry out refilling with the specified oil type up to reaching the notch that identifies the
MAX level in the sight glass (9).
Refit the filler plug (8). Run the engine at idle speed for a few minutes.
Check that there are no oil leaks and that the warning light on the instrument panel switches off a few seconds after
starting up the engine.
If not, stop the engine and trace the fault.
Check that the oil level is the specified one; if necessary, restore the MAX. level.
Refit the horizontal exhaust manifold (Refitting the exhaust system).

Refit the complete sump guard (Refitting the sump guard).
Checking valve clearance

Service operation

Check and adjust valve clearance Desmo Service

Specific tool for the procedure



88765.1635 Engine timing and timing check tool
Remove the rider and passenger seats (Removing the seat).

Remove the fuel tank (Removing the fuel tank).
Remove the airbox (Removing the airbox and throttle body).
Remove the timing belt covers (Removing the timing belt external covers).
Remove the sump guard unit (Removing the sump guard).
Remove the water radiator lower retainer from the engine leaving the radiator connected to the cooling system
(Removing the water radiator).
Disconnect the caps from the spark plugs of horizontal and vertical heads (Replacing the spark plugs).
Disconnect the secondary air units of the head covers (Removing the secondary air system).
Remove the horizontal and vertical head covers (Removing the camshafts).
Undo the screws (1) to remove the timing inspection cover (2) in correspondence of the crankshaft and collect the
gasket.
Bring the vertical cylinder piston to the TDC (combustion stage) and proceed as described in chapter "Removing the
mobile tensioner/timing belt".
Then, all valves are closed and the camshafts are in rest position, i.e. free to rotate.
Note
The figures show an engine block removed from the frame, but the operation can also be performed with engine on the
frame.

CHECKING THE CLOSING CLEARANCE
Using a feeler gauge, check the clearance between the closing rocker arm (A) sliding shoe and the highest point of the
camshaft lobe (B).
The value must be within the prescribed ones.

VALVES ASSEMBLY VALUE CONTROL VALUE

INTAKE 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)

EXHAUST 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)
Should the values be other than those indicated in the table, remove the opening shim (4), as described in chapter
"Removing the valves", and replace it with one of suitable thickness to obtain the prescribed clearance.
Note
Closing rocker arm shims measuring 2 to 3.45 are available as spare parts: the size is punched on the shim.

CHECKING THE OPENING CLEARANCE
Using a feeler gauge, check the clearance between the opening rocker arm (C) and the lowest point of the camshaft
lobe (D).


INTAKE 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)

EXHAUST 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)
Note
Reach the same condition with the horizontal head by rotating the crankshaft in order to have the piston in the TDC in
combustion stage. Repeat the above-mentioned operations.
Make sure that the O-ring (5) is installed on the timing inspection cover (2).
Refit timing inspection cover (2) on generator cover and start screws (1).
Tighten the screws (1) to a torque of 5 Nm (Min. 4.5 Nm. - Max. 5.5 Nm).
Refit the horizontal and vertical head covers (Refitting the camshafts).
Connect the secondary air units of the head covers (Refitting the secondary air system).
Reconnect the caps on the spark plugs of horizontal and vertical heads (Replacing the spark plugs).
Refit the water radiator (Refitting the water radiator).
Refit the sump guard unit (Refitting the sump guard).
Refit the timing belt covers (Refitting the timing belt external covers).
Refit the airbox (Refitting the airbox and throttle body).
Refit the fuel tank (Refitting the fuel tank).
Refit the rider and passenger seats (Refitting the seat).
Change timing belts

Service operation

Desmo Service
Change timing belts
Annual Service (60)



88765.1635 Graduated disk bearing tool for spark advance check with disk

88765.1623 Timing pulley positioning tool

97900.0253 Belt tensioning

To replace the timing belts follow the procedures described under paragraph (Removing the mobile tensioner/timing belt)
and (Refitting the mobile tensioner/timing belt).
Change spark plugs

Service operation

Change spark plugs Desmo Service



88713.2877 Spark plug wrench
Warning
Do not dispose of waste components into the environment.
Disposal
Do not dispose of waste into the environment. Collect and deliver waste to authorized collecting centres. Dispose of
waste in compliance with the prevailing local and national standards. European Waste Catalogue Codes recommended
for waste disposal as indicated by Decision No 2001/118/EC: EWC 16 01 22 (components not otherwise specified).
Note
Spark plug type

Make: NGK
Type: MAR9A-J

CHECKING THE SPARK PLUG CONDITION
Check the colour of the ceramic insulation around the central electrode: an even, light brown colour indicates the
engine is in good condition and running at the right temperature.
Inspect the centre electrode for wear and check spark plug gap, which should be (X) = 0.8 ÷ 0.1 mm (0.0315 ÷
0.0039 in).
Important
Check the gap between the central and side electrodes. Replace the spark plug if measured value is different from the
specified one or the spark plug shows clear signs of carbon deposits.
Warning
Do not use spark plugs with inadequate heat rating or incorrect thread length.
The spark plug must be securely installed.
If a spark plug is loose, it can overheat and damage the engine.

VERTICAL HEAD
Remove the spark plug
Remove the rider seat (Removing the seat).

Loosen screws (1) and remove tank bracket (2).

Loosen screw (3) with washer (4) and remove vertical coil (5).
Remove the spark plug (6) from vertical head using tool part no. 88713.2877.
Fitting the spark plug
Fit a new spark plug (6) and use tool part no.88713.2877 to screw it on vertical head.
Tighten the spark plug (6) to a torque of 12 Nm (Min. 11 Nm - Max. 13 Nm).
Warning
Check that the pre-applied threadlocker is still present on screw thread (3). Otherwise, use the indicated product.
Insert the vertical coil (5) and start screw (3) with washer (4).
Tighten screw (3) to a torque of 10 Nm (Min. 9 Nm – Max. 11 Nm).
Check that the pre-applied threadlocker is still present on screw threads (1). A maximum of three removal/refitting
operations is recommended.
Position tank bracket (2) on the frame and start screws (1).
Refit the rider seat (Refitting the seat).

HORIZONTAL HEAD
Remove the spark plug
Loosen screws (1) securing at the bottom the water radiator assembly (2) to the horizontal head.
Working on either sides of the motorcycle, loosen screws (3) and release the RAD-DUCT pins (A) from the rubber
blocks (B) of the headlight lower cover.
Lift the water radiator assembly (2) to access the coil.
Loosen screw (4) with washer (5) and remove horizontal coil (6).
Remove the spark plug (7) from horizontal head using tool part no. 88713.2877.
Fitting the spark plug
Fit a new spark plug (7) and use tool part no.88713.2877 to screw it on horizontal head.
Tighten the spark plug (7) to a torque of 12 Nm (Min. 11 Nm - Max. 13 Nm).
Warning
Insert the horizontal coil (6) and start screw (4) with washer (5).
Position water radiator assembly (2).

Fit the pins (A) of RAD-DUCT into rubber blocks (B) of the lower headlight cover and start screws (3).
Apply the specified product to the thread of screws (1).
Start screws (1) securing at the bottom the water radiator assembly (2) to the horizontal head.
Changing and cleaning the air filters

Service operation

Oil Service
Check and clean air filter
Annual Service (24)

Change air filter Desmo Service

REMOVING THE AIR FILTER
Remove the seat (Removing the seat).

Important
A clogged air filter will reduce air intake and engine power, increase fuel consumption and cause a build up of deposits
on the spark plugs. Do not use the motorcycle without a filter as impurities in the air could get into the engine and
cause damage.
Note
Do not dispose of replaced filters into the environment.
Disposal
If filtering element is replaced, do not dispose of waste into the environment. Collect and deliver waste to authorized
collecting centres. Dispose of waste in compliance with the prevailing local and national standards.
European Waste Catalogue Codes recommended for waste disposal as indicated by Decision No 2001/118/EC: EWC 15
02 02* (Absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing
contaminated by dangerous substances).
Note
Important
If the motorcycle is used in very damp or dusty conditions, the air filter cartridge must be changed more frequently.
Remove the sound-deadening cover (1).

Disconnect connectors (5) from the control unit.
Disconnect the voltage regulator connector (6) and the generator connector (7).
Loosen screws (10) with washers (11) and remove the control unit with rubber support (12).
Loosen the six screws (2) securing air filter cover (3) to the airbox upper shell (4).
Slide out the air filter (8).
Clean the air filter (8) with a jet of compressed air or replace it.

REFITTING THE AIR FILTER
Fit the air sensor (8) on the airbox upper cover (4), aiming it as shown in the figure.
Position the air filter cover (3) on the airbox upper cover (4) and start the screws (2) in the positions shown in the
figure.
Tighten the six screws (2) to a torque of 2 Nm ± 10%, following the sequence shown in the figure.
Position the control unit complete with rubber support (12) and start screws (10) with washers (11).
Connect the voltage regulator connector (6) and the generator connector (7).
Connect connectors (5) to control unit assembly.

Refit the soundproofing cover (1) on airbox, aiming it as shown in the figure.
Warning
When positioning the fuel tank, make sure that the soundproofing material (1) does not obstruct the inlet of the airbox
(B).
Position soundproofing material (1) as shown in the figure.
Refit the seat (Refitting the seat).

REMOVING THE HORIZONTAL HEAD BELT COVER AIR FILTER
Important
Working on the RH side of the motorcycle, loosen screws (14) and remove horizontal head belt cover (13).
Loosen screws (15) and remove the air filter (16) from the horizontal head belt timing cover (13).
The filter can be cleaned with a jet of compressed air or replaced, if necessary.

REFITTING THE HORIZONTAL HEAD BELT COVER AIR FILTER
Refit filter (16) on the horizontal head belt cover (13) and start screws (15).
Tighten the screws (15) to a torque of 1.75 Nm (Min. 1.5 Nm. - Max. 2 Nm).
Check that the pre-applied threadlocker is still present on the screws (14). A maximum of three removal/refitting
Working on the motorcycle RH side, position the horizontal head belt cover (13) and start the screws (14).
Tighten the screws (14) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm), following the sequence shown in the figure.
Checking coolant level

Service operation

First Service 1000

Oil Service
Checking coolant level
Desmo Service

Annual Service (12)
Check the coolant level contained in the expansion reservoir, on the right-hand side of the vehicle at the intervals
specified in the “Scheduled maintenance chart”.
Check that the coolant level in the expansion reservoir is between the MIN and MAX marks on the reservoir.
Refit the plug (1).
Warning
Do not dispose of coolant into the environment.
Disposal
water courses or the soil. Collect and deliver waste to authorized collecting centres.
Dispose of waste in compliance with the prevailing local and national standards.
01 14* (Antifreeze fluids containing dangerous substances).
Note
Change coolant

Service operation

Desmo Service
Change coolant
Annual Service (48)
Warning
Make sure the engine is cold before proceeding. Attempting to change the coolant with the engine hot could lead to
burns from hot coolant or scalding steam.
Warning
Do not dispose of coolant into the environment.
Disposal
water courses or the soil. Collect and deliver waste to authorized collecting centres.
Dispose of waste in compliance with the prevailing local and national standards.
01 14* (Antifreeze fluids containing dangerous substances).
Note
Remove the front half-fairing (Removing the front half-fairing).
Working on the LH side of the motorcycle, position a container close to plug (1) and set motorcycle on side stand.
Loosen plug (1) located on the water pump cover and recover the relevant gasket (2).
Working on the right side of the motorcycle, loosen the water radiator plug (3) without removing it, making sure that
no coolant flows out.
Allow the coolant to drain off completely.

Screw plug (1) with a new gasket (2) on the water pump cover.
Tighten plug (1) to a torque of 15 Nm (Min. 13.5 Nm – max. 16.5 Nm).
Fill the circuit by pouring new specified coolant inside water radiator, until it is completely full.
Screw the water radiator plug (3).
Loosen plug (1) and complete the filling of the expansion reservoir, taking the fluid level to the MAX top mark.
Screw the plug (1).
Wait several minutes for the coolant to fill all the internal passages.
Start the engine and wait for two complete fan cycles.
Switch off the engine and allow it to cool down.
Warning
Keep your hands, clothing and tools well clear of the radiator fan at all times; this fan starts automatically without
warning and could cause serious injury or damage.
Important
Check the circuit for possible leaks.

CHECKING COOLANT LEVEL
Remove the RH conveyor (Removing the front half fairing).
Apply commercial pliers (A) on the expansion reservoir/water radiator.

Loosen the water radiator cap (3) and check the coolant level.
If the level is low, top up with the recommended coolant until reaching the MAX level.
Screw the water radiator plug (3).
Remove the commercial pliers (A).
Check that the coolant level in the expansion reservoir is between the MIN and MAX marks on the reservoir.
Refit the plug (1).
Refit the RH conveyor and the front half-fairing (Refitting the front half-fairing).
Changing the fluid in the front brake system

Service operation

First Service 1000

Check brake fluid level Oil Service

Annual Service (12)

Change brake fluid Annual Service (24)
Guided diagnosis for front brake system bleeding (Guided diagnosis for front brake system bleeding).
Note
Some of the figures shown in the following procedure are indicative only with reference to the type of material, shape
or colour, but are important for assembly, disassembly and adjustment procedures.
Warning
Brake fluid is corrosive and will damage paint. Avoid contact with eyes and skin. In case of accidental contact, wash
thoroughly with water.
Warning
Note
Disposal
Do not dispose of the exhausted fluid into the environment; do not pour the product, either new or exhausted, inside
drains, water courses or the soil. Collect and deliver waste to authorized collecting centres. Dispose of waste in
compliance with the prevailing local and national standards.
02 05* (Mineral-based non-chlorinated engine, gear and lubricating oils).
Loosen screws (3) and remove cover (1) with the membrane from the front brake fluid reservoir (2).
Siphon the fluid from the reservoir (2).
Important
Refit the membrane (without the plug) on the reservoir to avoid brake fluid splashes during the following operations.
Working on either sides of the motorcycle, loosen screws (4) and remove front brake callipers.
Take calliper pads apart and during this operation be careful with the fluid level, which must always be sucked out each
time it flows back in the reservoir.
Make sure that all pistons of both callipers are fully moved back.
Working on either sides of the motorcycle, position front brake callipers on fork axle lugs and start screws (4).
Pre-tighten screws (4) to a torque of 2 Nm ± 10%.
Attach a transparent plastic tubing to the RH calliper bleed union (5) and insert the other end of the tubing in a
container placed on the floor.
Loosen the bleed union (5).
Fill the front brake fluid reservoir with new fluid up to the MAX level.
Pull the lever to make a 20 - 30 mm (0.79 - 1.18 in) stroke and keep the lever in this position using a non-elastic
clamp until clear (new) brake fluid flows out.
Tighten the RH calliper bleed union (5) to a torque of 4 Nm ± 10%.

Remove the transparent tubing and use a piece of paper towel to clean the hole of bleeder cap and remove any
residues of fluid, then then refit the rubber cap.
Attach a transparent plastic tubing to the LH calliper bleed union (5) and insert the other end of the tubing in a
Loosen the bleed union of the LH calliper (5) and then take the lever through the whole stroke to allow fluid to flow
out.
Keep the lever against the handgrip.
Tighten the LH calliper bleed union (5) to a torque of 4 Nm ± 10%, then release the lever.
Remove the transparent tubing and use a piece of paper towel to clean the hole of bleeder cap and remove any
residues of fluid, then then refit the rubber cap.
Repeat the above operation until the old fluid flows out completely.
Then, with the bleed union definitely closed, repeatedly pull the lever until a pressure is detected in the brake system.
Warning
After draining the old fluid from the reservoir and while filling the system, always keep the fluid level above the MIN
mark to avoid any air bubbles in the circuit.
Hold the lever pulled towards the handgrip and simultaneously tighten the screws (4) to a torque of 45 Nm ± 5%.
To complete the ABS system bleeding, after performing the standard bleeding of the just-described front braking
system and after "Changing the rear brake circuit fluid", perform the procedure described in "Bleeding of the ABS hydraulic
system".
Changing the fluid in the rear brake system

Service operation

First Service 1000

Check brake fluid level Oil Service

Annual Service (12)

Change brake fluid Annual Service (24)
Warning
Warning
Note
Disposal
Attach a transparent plastic tubing to the rear calliper bleed union (1) and insert the other end of the tubing in a
Unscrew the cover (2) of the rear brake fluid reservoir (3).
Fill the reservoir (3) with new oil up to the MAX mark.
Operate the rear brake pedal (4) to pressurise the circuit.

Keep pedal pushed down.
Loosen rear calliper bleed union (1) by 1/4 of a turn so as to drain all fluid and fully push the rear brake pedal until
pedal stops.
Make sure the fluid reservoir (3) does not become empty.
Warning
After draining the old fluid from the reservoir and while filling the system, always keep the fluid level above the MIN
mark to avoid any air bubbles in the circuit.
Note
If bleeding tool is not available, move back calliper pistons as well.
Repeat the above operations until finishing all the fluid contained inside package (approx. 250 cc – 15.26 cu. in).
Tighten the rear calliper bleed fitting (1) to a torque of 5.5 Nm ± 10% and remove the transparent tubing.
Top up with fluid until the MAX mark is reached.

Tighten the cover (2) on the rear brake fluid reservoir (3).
Make sure that the bleed union (1) is properly tightened to a torque of 5.5 Nm ± 10%.
Make sure that, with bleed union duly closed, pressure is correctly developed through brake pedal.
Use a piece of paper towel and clean the hole of bleeder cap to remove any residues of fluid and then refit the rubber
cap.
Adjusting the steering head bearing play

Service operation

Oil Service
Check steering tube bearing clearance
Annual Service (12)



88713.1058 Wrench to fit steering tube plug
Excessive handlebar play or shaking fork in the steering head indicate that the play of the steering head bearings will
require adjustment as follows:
Remove the handlebar (Removing the handlebar).
Loosen the clamp screw (1) that holds the steering tube to the steering head.
Slacken the clamp screws (2) securing the steering head to both fork legs.
Using the special tool (A) part no. 88713.1058 tighten the ring nut (3) to a torque of 35 Nm ±5%.
Push the steering head against the ring nut (3) and tighten the screw (1) to a torque of 18 Nm ± 5% and screws (2)
following a (1-2-3) sequence to a torque of 10 Nm ± 5%.
Refit the handlebar (Refitting the handlebar).
Adjusting the chain tension

Service operation

First Service 1000

Oil Service
Check brake fluid level
Desmo Service

Annual Service (12)

FINAL DRIVE CHAIN MAINTENANCE PRECAUTIONS
The chains that are installed on the Ducati models are roller chains made according to ISO/DIN/BS standards and are
made up of internal links alternated with external links, connected to one another by pins.
The internal links (3) are made up of two plates connected to one another by means of a pair of bushes (2); a roller
(1) is inserted in each bush.
The external links (4) instead are made up of two external plates connected to one another by means of a pair of pins
(5) and four O-rings (6).
The O-rings have the double function to retain the incorporated lubricant and avoid infiltrations of foreign bodies in the
pin-bush area.
This type of chains is characterised by two fundamental parameters:
• The pitch length.

• The link internal width.
These two values are expressed with a standardised numeric code consisting of three digits (example: 415, 420, 428,
520, 525, 530).
Note
In case of Regina chains, references other than the traditional ones are used.
According to the international reference, the first of the three numbers represents the pitch of chain (P), defined as the
distance between the centres of two consecutive pins.
Chain pitch is calculated by multiplying 1/8 of an inch by the first of the three digits engraved on the link (520):
P = 1/8” x 5 = 5/8”, hence chain pitch is 5/8”.
To obtain the pitch value in centimetres, it is necessary to multiply the value obtained in inches by the conversion
factor 2.54: P = 5/8” x 2.54 = 1.5875 cm ➔ 1.59 cm.
Following is the summary table of the chain pitch values.

Regina reference International reference Chain pitch

54 - 90 - 124 - 125 - 126 415 - 420 - 425 - 428 1/2” = 1.2700 cm

135 - 136 - 136.2 - 137 520 - 525 - 530 - 532 5/8” = 1.5875 cm

138 – 138.2 630 – 632 3/4” = 1.9050 cm
According to the international reference, the second and third digits represent instead the internal width (W) of the
chain; the higher this number and the greater the distance between the two internal plates.
The internal width is calculated by multiplying 1/8 of an inch by the second and third digits (520) adding a point
between the two digits (2.0 - 2.5 - 3.0).
W = 1/8” x 2.0 = 1/4” = 1/4” x 2.54 = 0.635 cm.
In case of chain 530, the pitch is the same but the width is different: W = 1/8” x 3.0 = 3/8” = 3/8” x 2.54 = 0.952
cm.
Warning
By changing the internal distance between the links the space available for the gear teeth will change. Therefore, there
must always be a front sprocket and rear sprocket chain coupling with the same characteristics.
We remind you that it is not possible to install a chain 520 on a rear sprocket and front sprocket with pitch 530 or vice
versa.
Statistically, it has been found out that the average useful life of a final drive chain is of approx. 20,000 km, if
periodically maintained following the indications stated inside the Owner's Manual.
To ensure the best performance and a long duration of the chain over time, you are required to follow the information
relevant to chain washing, lubrication, check and tensioning, indicated in the following sub-sections:
• Washing the chain.

• Lubricating the chain.

CHECKING THE CHAIN
It is necessary to frequently inspect the chain checking that there are no stiff joints, missing or damaged O-rings or
other worn out components (in particular the closing link).
Chain wear can be easily checked by measuring its elongation. If the chain exceeds the provided stretching limits, the
kinematic mechanism becomes unreliable, the pitch is no longer complied with and the chain could skip to the
following teeth of the gear causing its breakage, as a consequence.
To perform the final drive chain check follow the procedure below:
Note
Before performing the measurement clean and lubricate the drive chain correctly.
1) If the chain is installed on the motorbike, tension the upper and lower branch engaging a low gear and turning the
rear wheel clockwise or counter clockwise, respectively; if instead the chain is not installed on the motorbike, it is
necessary to position it on a horizontal surface fastening it at one end and tensioning it using a weight of approx. 20
Kg (44 lb) applied to the opposite end, as shown in the figure.
2) Using a gauge or a precision millimetre rule, measure the distance between the centres of two pins distant to one
another of a number “N” of links.
Note
The number “N” of links is obtained by counting the pins. The “N” number of pins to be taken into account for the
measurement depends on the chain type.
Check that the detected measurement does not exceed the maximum admissible length value indicated in the
following table:

Regina reference International N (number of Maximum admissible length (chain with O-
reference pins) rings)

54 - 90 - 124 - 125 - 415 - 420 - 425 - 428 23 29.5000 cm (11.614 in)
126

135 - 136 - 136.2 - 520 - 525 - 530 - 532 16 25.6500 cm (10.098 in)
137

138 – 138.2 630 – 632 16 30.0780 cm (11.841 in)
The chain must be replaced if a higher value is detected.
Besides measuring the length, to perform a chain wear check it is possible to visually inspect the plates, pins, O-rings
and bushes. In case of:
• Cracks on plates.
• Cracks on pins.
• Pin rotation.
• Damaged O-rings.
• Scoring on the surface of the rollers.
Replace the drive chain.

ADJUSTING THE CHAIN TENSION
The correct tensioning of the chain is an extremely important factor for its duration and efficiency. Chain tension must
be checked and restored in case of use:
• on the road, after the first 100 km (62 mi) and then every 400 km (248 mi);
• off-road, after every use.
For the tensioning we remind you that the chain must be placed in its maximum tensioning condition. Then, it is
possible to adjust the chain by acting on the tensioning system.
An excessive chain tensioning could cause an increase of work load between the pins and the bushes, an overheating
of the chain with premature consumption of the lubricant and therefore its possible rapid wear.
Following are some events that may occur in case of wrong tensioning of the chain:
1) Formation of micro-cracks in the chain rollers that are not visible to the naked eye; by inspecting the chain it is
possible to identify some deep signs of scoring on the surface of the rollers.
2) Longitudinal breakage of the link due to an excessive stress.
3) Pin rotation.
Important
If drive chain is too tight or slack, adjust tension so as to bring values back to the specified range.
Make the rear wheel turn until you find the position where chain is tightest.
Set the motorcycle on the side stand.
With a finger, push down the chain at the point of measurement and release.
Measure the distance (A) between the swinging arm and the centre of a chain pin by placing the measuring tape at the
rear end of the chain sliding shoe. The distance should be as follows:
• World Wide version A = 47 ÷ 49 mm (1.85÷ 1.93 in).

• China version A = 44 ÷ 46 mm (1.73÷ 1.81 in).
Note
Note
The described procedures apply to all vehicle versions, regardless of the standard setting
Working on the motorcycle RH side, loosen nut (1).

Working on both sides of the motorcycle, completely loosen the lock nuts (2) and bring them fully home on adjuster
screws (3).
Work on adjuster screws (3) to adjust chain tensioning.
Check that chain sliding shoes are in the same position, checking it on reference notch (4).
Important
An incorrectly tensioned chain will lead to early wear of the transmission components.
Check the correct chain tensioning, apply the indicated product on the adjuster screw (3) threads.
Bring lock nuts (2) fully home on swingarm and tighten them at the torque of 8 Nm ± 10% while holding adjuster
screws (3).
Tighten nut (1) to a torque of 180 Nm ± 5%.

REPLACING THE CHAIN
To replace the final drive chain it is possible to use any dedicated generic tool, since it is not a specific tool sold directly
by Ducati.
After removing the junction link of the chain follow the procedure below:
1) Using the fork of the old external link or joint link connect one end of the chain to be replaced with the new chain.
2) Slowly pull the other end of the old chain until winding the new chain around the front sprocket; carry on until the
end of the new chain is on the rear sprocket.
3) Remove the old fork together with the old chain and then:
• Wind also the other end of the new chain around the rear sprocket so that the two ends are placed one after the
other on two consecutive teeth.
• Take the new link to be bent and check that the two O-rings resting on the plate are installed on the fork.
Note
In the specific case of Regina chains, particular O-rings may be used that, besides retaining the lubricant in a better
way, have a definite direction to be followed during installation.
The two special O-rings that must be inserted on the junction link must have the protruding side facing towards the
inner link, as shown in the figure.
• Insert the fork of the new link to be bent from the rear side of the chain avoiding any contact with the pins to
avoid removing some of the lubricant.
4) Position the other two new O-rings, one on each bush, then insert the closing plate.
Note
With special O-rings for Regina chains, these must be installed on the side opposite the junction link with the
protruding side facing outwards, as shown in the figure:
5) Rotate the rear wheel so that the link to be bent is placed at the chain lower branch, in a position that allows
operating comfortably with the chain closing tools.
6) Using the generic chain closing tool, tighten the pack in different steps (applying a higher tightening torque, if
necessary) so as to check that the value of the distance X between the two external links is within the range indicated
in the table.

External plate distances (X) mm (in)

Min Max

Regina 530 ZRP B2 22.55 (8.88) 22.70 (8.94)

525 ZRPK 20.15 (7.93) 20.30 (7.99)

530 ZRPB 22.55 (8.88) 22.70 (8.94)

520 ZRDK 18.20 (7.16) 18.35 (7.22)

520 ORAW2 16.68 (6.57) 16.83 (6.62)

DID 525 HV3 19.50 (7.68) 19.70 (7.76)

525 HV2 19.50 (7.68) 19.70 (7.76)

520 V6 KAI 17.10 (6.73) 17.35 (6.83)

520 VP2-T 16.70 (6.57) 16.90 (6.65)

520 VF 16.46 (6.48) 16.66 (6.56)

525 HV3 19.50 (7.68) 19.70 (7.76)

525 VAZ 18.75 (7.38) 18.95 (7.46)
• If X is lower than the minimum value indicated in the table the link must be removed, the O-rings must be
checked for damage (replace them if necessary) and the operation must be repeated.
• If X is higher than the maximum value indicated in the table, tighten to a higher torque until obtaining the correct
value indicated in the table.
7) Still using the generic chain closing tool, bend the two pins in different steps (applying a higher tightening torque, if
necessary) so as to check that the value of the diameter Y of the two bent pins is within the range indicated in the
table.

Pin diameter (Y) mm (in)

Min Max

Regina 530 ZRP B2 5.45 (2.15) 5.65 (2.22)

525 ZRPK 5.45 (2.15) 5.65 (2.22)

530 ZRPB 5.45 (2.15) 5.65 (2.22)

520 ZRDK 5.45 (2.15) 5.65 (2.22)

520 ORAW2 5.50 (2.16) 5.65 (2.22)

DID 525 HV3 5.50 (2.16) 5.80 (2.28)

525 HV2 5.55 (2.18) 5.75 (2.26)

520 V6 KAI 5.40 (2.13) 5.60 (2.20)

520 VP2-T 5.40 (2.13) 5.80 (2.28)

520 VF 5.45 (2.15) 5.80 (2.28)

525 HV3 5.50 (2.16) 5.80 (2.28)

525 VAZ 5.70 (2.25) 6.00 (2.36)
• If the detected Y value is lower than the minimum value indicated in the table, continue bending the two pins
applying a higher tightening torque until reaching the correct value.
• If the detected Y value is higher than the maximum value indicated in the table, remove the link, order a new link
to be bent and repeat the entire operation.
8) If points 6) and 7) are complied with, certify the closing link as shown in the figure.
Note
Check with a magnifying glass that there are no cracks on the round surface of the bent area, as shown in the figure.

FAQ (FREQUENTLY ASKED QUESTIONS)
1) When is it necessary to replace the final drive kit?
In case of:
• Cracks on plates.
• Cracks on pins.
• Pin rotation.
• Damaged O-rings.
• Scoring on the surface of the rollers.
• Wear of the front sprocket teeth.
• Wear of the rear sprocket teeth.
• Stretching of the drive chain beyond the allowed limit.
2) Which are the causes for excessive noise of the drive chain?
• Wrong tensioning (chain too taut or too slack).

• Insufficient lubrication.
• Incorrect alignment between front sprocket and rear sprocket.
• Incorrect dimensional correspondence between chain, front sprocket and rear sprocket.
• Shocks or scraping of the chain on parts of the vehicle.
• Wear of the front sprocket or rear sprocket.
• Wear of the chain.
• Wear, breakage or misalignment of other drive components.
3) Which are the causes for excessive oscillation of the drive chain?
• Wrong tensioning (chain too taut or too slack).

• Uneven wear of chain, front sprocket or rear sprocket.
• Presence of stiff joints.
4) Which are the causes for a possible skipping of the chain on front/rear sprocket teeth?
• Excessive wear of the front sprocket or rear sprocket.

• Excessive stretching of the chain caused by wear.
• Insufficient chain tensioning.
• Incorrect positioning of sliding shoes, chain guide or tensioners.
• Bent, corrugated, damaged gear wheels or with wrong dimensions.
• Presence of foreign bodies between the chain and the gear wheels.
5) Which are the causes for wear of the front sprocket only on one side and of the rear sprocket on the
opposite side?
6) Which are the causes of possible stiffening of the joints of the drive chain?
• Excessive chain tensioning.

• Oxidation of chain joints.
• Undersized chain with respect to the loads to which it is subjected.
• Breakage or loss of O-rings.
• Incorrect assembly.
• Foreign material (sand, mud) on the chain joints.
7) Which are the causes of a possible breakage of chain pins, rollers or bushes?
• Excessive loads or loads applied too violently.

• Excessive wear of the front sprocket or rear sprocket.
• Excessive stretching of the chain caused by wear.
• Wrong chain tensioning.
• Incorrect dimensional ratio between chain, front sprocket and rear sprocket.
• Number of front sprocket teeth lower than the minimum recommended.
8) Which are the causes of a possible breakage of the drive chain links?
• Shocks or scraping of the chain on parts of the vehicle.

• Excessive chain tensioning.
• Significant misalignment between front sprocket and rear sprocket.
• Undersized chain with respect to the loads to which it is subjected.
• Corrosion caused by foreign agents (battery acid, fuel or other fluids).
Checking brake pad wear and replacing brake pads

Service operation

Oil Service
Check brake disc and pad wear
Annual Service (12)
Disposal
for waste disposal as indicated by Decision No 2001/118/EC: EWC 16 01 12 (Brake pads, other than those mentioned
under item 16 01 11).
Note
Warning
Important
On handing over the motorcycle after changing the brake pads, inform the Customer that the front brake must be used
gently for the first 100 km to allow the pads to bed in completely.
Check brake pads wear through the inspection hole in the callipers. Change both pads if friction material thickness of
even just one pad is about 1 mm (0.039 in).
Important
Change both pads even if just one of them is worn.
Note
Work in the same way on both front brake callipers.
Warning
Friction material wear beyond this limit would lead to metal support contact with the brake disc thus compromising
braking efficiency, disc integrity and rider safety.

REMOVAL
Note
Check through the calliper slot and make sure that the friction material on pads (1) is visible.
Loosen the screws (2) and remove the front right brake calliper (3).
Remove the front pads (1) from the front right brake calliper.
Note
Change pads that have a shiny or "vitrified" appearance.

REFITTING
Note
Fit the front pads (1) into the front right brake calliper.
Important

Position the front right brake calliper (3) on the fork axle lug and start the screws (2).
Pull the brake lever many times.
Note
Operate the brake lever repeatedly so that the pads firmly bed in against the disc thanks to the brake fluid pressure.
Check that the level in the master cylinder tank is not below the MIN mark.
If necessary, top up.
Top up with specified fluid (Fuel, lubricants and other fluids).
Checking rear brake pad wear and replacing brake pads

Service operation

Oil Service
Check brake disc and pad wear
Annual Service (12)
Note
Note
The described procedures apply to all vehicle versions, regardless of the standard setting
Warning
Do not dispose of brake pads into the environment.
Disposal
for waste disposal as indicated by Decision No 2001/118/EC: EWC 16 01 12 (Brake pads, other than those mentioned
under item 16 01 11).
Note
Warning
Check brake pads (1) wear through the inspection hole in the calliper halves.
Change both pads (1) if friction material thickness of even just one pad is about 1 mm (0.039 in).
Important
Warning
Friction material wear beyond this limit would lead to metal support contact with the brake disc thus compromising
braking efficiency, disc integrity and rider safety.

REMOVAL
Remove the safety split pins (2).

Push the retaining pin (3) until it comes out completely.
Remove the brake pads (1) by pushing the calliper pistons fully inside their seats.

REFITTING
Warning
Each time the rear pads are replaced due to wear, the pad retaining pin, which is supplied in the original pad
replacement kit, must also be replaced.
Fit new pads (1) inside the rear brake calliper, aiming them as shown in the figure.
Insert pin (3) and fix it by means of the safety split pins (2).
Operate the rear brake pedal (4) repeatedly so that the pads firmly bed in against the disc thanks to the brake fluid
pressure.
Check that the fluid level inside the rear reservoir (3) is between the MIN and MAX marks.
If this is not the case, loosen the plug (2) of the reservoir cover and top up the rear brake fluid reservoir (3).
Adjusting the front brake control lever and clutch lever
Lever (1) disengages the clutch. It features a dial adjuster (2) for lever distance from the handgrip on handlebar.
The lever distance can be adjusted through 33 clicks of the dial (2). Turn the dial (2) clockwise to increase lever
distance.
Turn the dial (2) counter clockwise to decrease lever distance.
When the clutch lever (1) is operated, drive from the engine to the gearbox and the drive wheel is disengaged. Using
the clutch properly is essential to smooth riding, especially when moving OFF.
The same adjustment can be made also for front brake control (3).
Warning
Any adjustment of clutch and brake levers must only be carried out when the vehicle is stationary.
Adjusting the position of the gearchange pedal and rear brake pedal
The position of the gearchange and rear brake pedals can be adjusted in relation to the footpeg to suit the
requirements of the rider.

PEDAL POSITION WITH QUICK-SHIFT CONTROL
Lock out the Quick-Shift control (1) using the suitable flat (A) and loosen nut (2), then bring it fully home against ball
joint (4).
Adjust the ball joint (4) on threaded rod, until obtaining centre distance (B) = 101.5 mm (4.00 in).
The gear change pedal height can be adjusted also by removing screw (3), nut (5) and spacer (6), thus disconnecting
ball joint (4) from gear change pedal. Select the hooking point (C) or (D), based on pedal desired height.
Refit screw (3), spacer (6) and secure everything to ball joint (4) through nut (5).
Warning
The joint on the Quick-Shift control and the ball joint must be aligned on the same level.
Apply the indicated product on the thread portion of ball joint (4) close to Quick-Shift control (1).
Screw nut (2) fully home on the Quick Shift control (1).
Tighten nut (2) to a torque of 5 Nm ± 10% while holding flat (A).

REAR BRAKE CONTROL PEDAL POSITION
To adjust the position of the rear brake pedal, proceed as follows.

Remove the rubber protection (1).
Loosen lock nut (2).
Turn pedal stroke adjuster screw (3) until pedal is in the desired position.
Tighten lock nut (2) to a torque of 5 Nm ± 10%.
Check that pedal has a free play (X) = 2 ÷ 5 mm (0.08 ÷ 0.19 in) before the brake bites.
Refit the rubber protection (1).
If not, modify the length of the cylinder push-rod in the following mode.
• Slacken off the check nut (4) on the cylinder pushrod.

• Screw the rod into the fork (5) to increase play, or unscrew it to reduce play.
• Tighten the lock nut (4) to a torque of 7.5 Nm ±10%, and check play again.
Adjusting the front fork
The motorcycle fork is completely manually adjustable in rebound and compression hydraulic damping and fork leg
internal spring preload.
This adjustment is done using the outer screw adjusters:
• (1) for rebound adjustment (right leg);

• (2) for internal spring preload adjustment (on both legs);
• (3) for compression adjustment (left leg).

REBOUND
Put the motorcycle on the side stand and make sure it is stable.
Turn adjuster (1) at the top end of the RH fork leg with a suitable screwdriver to adjust rebound damping.
Rotate adjuster (1) clockwise (H) to increase the hydraulic damping, while rotate adjuster (1) counter clockwise (S) to
decrease it.
The stiffest damping setting is obtained with the adjuster (1) turned fully clockwise to the "0" position.

PRELOAD
To change preload of the spring inside each fork leg, turn adjusters (2) with the suitable hexagon wrench, completely
counter clockwise, to obtain fully open position.
From this position, adjust the spring preload by turning the adjusters (2) clockwise.
Every turn corresponds to 1 mm (0.04 in) of spring preload.

COMPRESSION
Turn adjuster (3) at the top end of the LH fork leg with a suitable screwdriver to adjust compression damping.
Rotate adjuster (3) clockwise (H) to increase the hydraulic damping, while rotate adjuster (3) counter clockwise (S) to
decrease it.
The stiffest damping setting is obtained with the adjuster (3) turned fully clockwise to the "0" position.

STANDARD ADJUSTMENTS
Warning
Regulate the adjusters on both legs to the same positions.

Front fork adjustments

Type Rebound Compression Preload
(turns) (turns) (turns)

Road/Off Road Comfort -2 -2 2

Off Road Standard -1.5 -1.5 4

Off Road Sport -1.25 -1 8

Rider only -2 -2 2

Rider only (+ auxiliary tank, if present) -2 -2 2

Rider only + bags -2 -2 2

Rider + passenger -2 -2 2
Adjusting the rear shock absorber
The rear shock absorber has adjusters that enable you to suit the setting to the load on the motorcycle.
The adjuster (1), located on the lower mount which fastens the shock absorber to the swinging arm, adjusts the
damping during the rebound phase (return).
The knob (2), located on the RH of the motorcycle, adjusts the preload of the shock absorber external spring.
The adjuster (3), located on the expansion reservoir of the shock absorber, adjusts the damping during the
compression phase.
To carry out the adjustment, remove the rider seat (Removing the seat).
Access adjuster (3) with a screwdriver, from vehicle LH side, through the space between frame and electrical
components compartment.
Turn adjusters (1) and (3) or knob (2) clockwise or counter-clockwise respectively to stiffen or soften the damping or
the preload.
Warning
The shock absorber is filled with gas under pressure and may cause severe damage if taken apart by unskilled
persons.

Adjusting the rear shock absorber

Rebound Compression Preload
Type
(turns) (turns) (turns)

Road/Off Road Comfort -1.75 -3 6

Off Road Standard -1.25 -2 7

Off Road Sport -1.25 -1 8

Rider only -1.75 -3 6

Rider only (+ auxiliary tank, if present) -1.75 -2.5 10

Rider only + bags -1.75 -2.5 17

Rider + passenger -1.5 -2 26
Changing the clutch fluid

Service operation

First Service 1000

Check clutch fluid level Oil Service

Annual Service (12)

Change clutch fluid Annual Service (24)
Note
Warning
Clutch fluid is corrosive and will damage paint. Avoid contact with eyes and skin. In case of accidental contact, wash
Warning
Do not dispose of exhausted oil into the environment
Disposal
Note
Remove screws (1) and cover (2) with the membrane from the clutch fluid reservoir.
Fill the reservoir (3) with new specified oil up to the maximum level.
Operate the lever two or three times until the circuit is pressurised.
Hold the lever pulled towards the handgrip.
Attach a transparent plastic tubing to the bleed valve (4) and insert the other end of the tubing in a container placed
on the floor.
Open the bleed union (4) by 1/4 of a turn to allow fluid to flow out.
Fill the clutch fluid reservoir (3) with new specified oil up to the maximum level.
Warning
During the filling operation, always keep the fluid level above the MIN mark to avoid any air bubbles in the circuit.
By acting on the clutch lever, allow the fluid to flow from the bleed valve (4) until it changes colour and is free of air
bubbles.
Keeping the clutch lever pulled towards the handle, screw the bleed valve (4) back in, tightening it to a torque of 4 Nm
± 10%.
Important
Do not release the brake lever until the bleed valve has been fully tightened.
Restore fluid correct level inside reservoir (3).
Refit the cover (2) with the membrane and secure it with screws (2) to clutch fluid reservoir (3).
Cleaning the work surfaces
Important
If this operation is carried out by working directly on the engine installed on vehicle, thus not on the single overhauled
component on bench, make sure to duly protect all the cavities inside which residues of the removed sealant could fall.
Use a copper or plastic bristled brush (1) to remove sealant from the mating surface (2).
Refine cleaning by removing any sealant residues with an abrasive sponge (3) on the mating surface (2).
Complete cleaning of the mating surface (2) using a commercial degreasing detergent (4) for mechanical parts.
Applying the sealant
Important
Make sure that mating surfaces are perfectly clean and degreased to make sealant adhesion easier.
Apply an even and continuous bead (5) of the indicated product, using the dispenser and spreading as much sealant as
required along the profiles of mating surfaces (2), as shown in the figure.
Using a steel spatula (6), or alternatively a blade feeler gauge, make sure to clean it immediately after use, spread the
sealing paste (5) on the mating surface (2), covering the entire surface evenly without exceeding the quantity.
Any excess product could cause, during assembly, the formation of residues that could detach and fall inside engine.
Guided diagnosis for front brake system bleeding
Cust om er's complaint:
Long front brake leve r t ravel
Se t fro nt brake lever to t he most out ward pos itio n. What type of brake m aster
NO Is it possible to actually find a too long brak e lever t ravel? YES cylinder is ins t alled on the
Does t he front bra ke lever feel “spon gy”? m ot orcycle?
Se t t he ABS on th e instrum ent

panel at level 3 (if adjustable). Test
ride the bike and, at a s peed of Axial Radia l
ap prox. 50 km/ h, trig ger th e ABS at
least 10 times by only usi ng t he YES
front brake. Positio n th e mo t orcycle on th e Positio n th e mo t orcycle on th e
sid e stand and tur n t he sid e stand and tur n t he
handleb ar all t he way to t he left handleb ar all t he way to t he left
so that th e master cylinder is in so that th e master cylinder is in
t he high est positio n possible t he high est positio n possible
Does t he bra ke lever feel
“spon gy” an d wit h a longe r
travel?
NO Ope n th e fro nt br ake fluid Ble ed t he front bra ke mast er

rese rvoir cover and pull t he lever cylinde r by working on the
by ma king small m ove m ents blee ding conne ct ion and t opping
END (shor t t ravel with hig h freque ncy) up the brake fluid inside the
taki ng care not to sp ill th e fluid rese rvoir
Does t he front bra ke lever feel

NO “spon gy” an d wit h a longe r
travel?
YES
Ble ed t he fro nt br ake callipers
Ble ed t he fr ont right

brake calliper
(which is directly connected to
t he ABS con t rol unit)

trave l?
YES
Ble ed t he front left

brake calliper

trave l?
YES
Remov e t he fro nt brake callipers

from the fork, one at a time, in NOTE Carry out t his
order to operate the pistons operation at least 3 times
sep arate ly, ma king t he m re t ract so that all th e fluid in t he
to t he "fully backward" position brake circuit is replaced

trave l?
YES
Make sure t hat t here are no oil

leaks at the various connections
Fill in a YouTech re quest
on bra ke callip ers, brake maste r
cylinder and ABS control unit
Removing the headlight fairing
Working on either sides of the vehicle, loosen screws (1) and remove the Plexiglas windscreen (2).
Refitting the headlight fairing
Pre-fit the four H-shaped rubber elements (3) inside the holes of Plexiglas windscreen (2).
Note
Orient the rubber blocks with the most rounded part facing the outside of the windscreen.
Apply the specified product to the shank (A) of screws (1).

Fit Plexiglas windscreen (2) on front fairings and start screws (1).
Removing the side fairings

REMOVING THE SIDE FAIRINGS
Remove the headlight fairing (Removing the headlight fairing).
The procedure below describes how to remove one side fairing but it applies to both.
Extract the LH front turn indicator wiring placed behind the headlight, as shown in the figure, and remove the rubber
tie (A).
Disconnect LH front turn indicator connector (1).
Loosen the screw with short collar (2) and the nylon washer (3) retaining the LH side fairing (6) at the top.
Undo screw with short collar (2) retaining the LH side fairing (6) on the inside.
Loosen screw with long collar (4) fastening LH side fairing (6) at the bottom while holding threaded bushing (5) on the
opposite side.
Remove LH side fairing (6) from the motorbike by releasing pins (B) from rubber blocks (C), pin (D) from rubber block
(E) and special rubber block (7) from the slot (F).

REMOVING THE CONVEYORS
Remove the screw with collar (2) and the LH conveyor (1) by releasing it from the rubber blocks pre-fitted on the fuel
tank.
Remove the screw with collar (2) and the RH conveyor (3) by releasing it from the rubber blocks pre-fitted on the fuel
tank.
Refitting the side fairings

REFITTING THE CONVEYORS
Position the LH conveyor (1) by inserting it on rubber block (A) pre-fitted on the fuel tank.
Check that the pre-applied threadlocker is still present on the thread of the screw with collar (2). A maximum of three
removal/refitting operations is recommended.
Fasten the LH conveyor (1) by starting the screw with collar (2).
Important
During tightening of screw (2) the conveyor must be kept in a position so that the rear profile (green dotted line) is
aligned with the tank profile (red dotted line).
Position the RH conveyor (3) by inserting it on rubber block (B) pre-fitted on the fuel tank.
Check that the pre-applied threadlocker is still present on the thread of the screw with collar (2). A maximum of three
Fasten the RH conveyor (3) by starting the screw with collar (2).
Important
During tightening of screw (2) the conveyor must be kept in a position so that the rear profile (green dotted line) is
aligned with the tank profile (red dotted line).

REFITTING THE SIDE FAIRINGS
The procedure below describes how to refit one side fairing but it applies to both.
Fit the clip (8) in the indicated area of the left-hand fairing (9), orientating it as shown in the figures.
Fit Plexiglas fastening rubber block (10) at the indicated area of LH fairing (9), aiming it as shown in the figures.
Position LH side fairing (6) on the motorbike by engaging pins (B) on rubber blocks (C), pin (D) on rubber block (E)
and special rubber block (7) in the slot (F), as shown in the figure.
Check that the pre-applied threadlocker is still present on the threads of screws (2) and screw (4). A maximum of
three removal/refitting operations is recommended.
Fit nylon washer (3) onto screw with short collar (2).
Secure the LH side fairing (6) by starting the screw (2) with nylon washer (3) at the top and the screw (2) on the
inside.
Insert the threaded bushing (5) into the rear hole of the special rubber block (7) and start the screw with long collar
(4) on the threaded bushing (5).
Tighten screw (4) to a torque of 5 Nm ± 10% by holding threaded bushing (5) on the opposite side.
Connect the LH front turn indicator connector (1) to LH front turn indicator wiring branch.
Using the rubber tie (A) secure the LH front turn indicator cable and the LH front turn indicator wiring branch together.
Position the LH front turn indicator wiring behind the headlight, as shown in the figure.
Refit the headlight fairing (Refitting the headlight fairing).
Removing the tank fairings
Remove the headlight fairing (Removing the headlight fairing).

Remove the front half fairings (Removing the front half fairing).
Loosen the screws (1) and remove the central tank cover (2) by lifting it upwards, releasing the special rubber block
(A) from the cavity (B) and the pin (C) from the rubber block (D), as shown in the figure.
Refitting the tank cover
Fit two clips (3) in the indicated areas of the tank central cover (2), aiming them as shown in the figures.
Position the central tank cover (2) by inserting the special rubber block (A) into the cavity (B) and the pin (C) on the
rubber block (D), as shown in the figure.
Start the screws (1) on the tank central cover (2).
Refit the front half fairings (Refitting the front half fairing).
Refit the headlight fairing (Refitting the headlight fairing).
Removing the seat

REMOVING THE RIDER SEAT

REMOVING THE PASSENGER SEAT
Undo the screws (3), lift the front side of the passenger seat (4) and recover the spacers with collar (5).
Remove the passenger seat (4) by pulling it towards the front side of the motorcycle.
Removing the side body panels and the tail guard
Working on the motorcycle RH side, remove the tie (1), loosen screw (2) and remove the RH underseat cover (3).
Loosen screw (4) and remove the RH frame cover (5).
Working on the motorcycle LH side, remove tie (1), loosen screw (2) and remove the LH underseat cover (6).
Remove the LH frame cover (7).
Refitting side body panel and tail guard
Working on the motorcycle LH side, position the LH frame cover (7) engaging the tooth (A) into the cavity (B) in the LH
footpeg holder plate (8).
Check that the pre-applied threadlocker is still present on screw thread (2). A maximum of three removal/refitting
Fit the LH underseat cover (6) over the LH frame cover (7) and start the screw (2).
Fasten the upper part of the LH underseat cover (6) using the self-locking tie (7), with the closing device pointing
inwards.
Check that the pre-applied threadlocker is still present on screw threads (2) and (4). A maximum of three
Working on the RH side of the motorcycle, position RH frame cover (5) and start screw (4).
Fit the RH underseat cover (3) over the RH frame cover (5) and start the screw (2).
Tighten screw (2) and screw (4) to a torque of ± 5 Nm 10%.
Fasten the upper part of the RH underseat cover (3) using the self-locking tie (1), with the closing device pointing
inwards.
Refitting the seat

REFITTING THE PASSENGER SEAT
Refit passenger seat (4), inserting tabs (A) inside seats of rear subframe.
Position the spacers with collar (5) between the passenger seat (4) and the seat support plate, aiming them as shown
in the figure and start screws (3).

REFITTING THE RIDER SEAT

Removing the seat release mechanism

Undo the screws (3), holding the nuts (4) on the opposite side, then remove the latch (5) from the tank bracket (2)
and collect washers (6).
The seat lock (8) is located at the left-hand side of the motorcycle, inside the electrical components compartment.
Remove the nipple (7) from the seat lock (8).
Disconnect seat opening cable (9) from bracket (10).
Loosen ring nut (11), remove seat lock (8) from the electrical components compartment and collect the bracket (10).
Refitting the seat release mechanism
Insert seat lock (8) from electrical component support (A) outer side, aiming it as shown in the figure and inserting
teeth (B) and (C) inside the special recesses.
On support (A) inner side, insert bracket (10) on lock (8), aiming it as shown in the figure.
Secure lock (8) in place by starting and screwing ring nut (11).
Note
Aim ring nut (4) with the chamfered sides facing up.
Tighten ring nut (11) to a torque of 3 Nm ± 10%.
Fit seat lock latch cable (9) by inserting pawl (1) in its seat on the lock lever (8).
Fasten cable (9) by inserting it in the recess of bracket (10), where the relevant groove is (red in the figure).
Position latch (5) on the tank bracket (2), placing washers (6) in-between, and start screws (3) in the indicated side.
Start nuts (4) on the screw threads (3), as shown in the figure.
Tighten screws (3) to a torque of 5 Nm ± 10%, while holding nuts (4).
Remove the fuel tank (Refitting the fuel tank).
Remove the rider seat (Refitting the seat).
Removing the front mudguard
Working on both sides of the vehicle, loosen screws (1) with nylon washers (2) fastening front mudguard (3).
Loosen screw (5) so as to release calliper / calliper hose (6) from hose grommet (4).
Remove the front mudguard (3).
Refitting the front mudguard
Warning
Do not ride the motorcycle without the front mudguard fitted to avoid the risk of the brake hoses interfering with the
front wheel when braking.
Refit the front mudguard (3) and, working on both sides of the vehicle, start screws (1) with nylon washers (2).
Position the rubber block of calliper / calliper hose (6) in the appropriate seat of the hose grommet (4) on the rear side
of the front mudguard.
Close the upper flap of the hose grommet (4) and fasten it by starting the screw (5).
Tighten the screw (5) to a torque of 0.5 Nm ± 10%.
Removing the sump guard
Working on motorcycle LH side, loosen the screws (1), remove the stand protection (2) from the sump guard (5) and
collect the spacers with collar (A).
Working on either sides of the vehicle, loosen screws (3), lower screw (4) and remove the sump guard (5).
Refitting the sump guard

PRE-ASSEMBLING THE SUMP GUARD
If previously removed, position the RH bracket (6) on the clutch cover stud bolt, aiming it as shown in the figure and
start the screw (7).
Refit clip (8) on RH bracket (6).
If previously removed, position the LH bracket (9) on the generator cover, aiming it as shown in the figure and start
screw (10).
Tighten screw (10) to a torque of 13.5 Nm (Min. 12.5 Nm – Max. 14.5 Nm).
Refit clip (11) on LH bracket (9).
Fit the vibration dampers (11) on the sump guard (5) as shown in the figure. Insert spacers with collar (12) on
vibration dampers (11), on the inside.

REFITTING THE SUMP GUARD
Fit the sump guard (5) on motorbike, as shown in the figure.

Working on either sides of the motorcycle, start screws (3) and lower screw (4).
Pre-fit the spacers with collar (A) in the stand guard (2), aiming them as shown in the figure.
Working on the left side of the motorbike, position the stand guard (2) on the sump guard (5) and engage the screws
(1), ensuring that the spacers with collar (A) remain in place in the guard.
Removing the rear mudguard
Remove the screws (1) and the splash guard (2).

Refitting the rear mudguard
Position splash guard (2) and start the screws (1) in the positions shown.
Acronyms and abbreviations used in the manual
• ABS Antilock Braking System

• CC Cruise Control
• DQS Ducati Quick Shift
• DRL Daytime Running Lamp
• DTC Ducati Traction Control
• DWC Ducati Wheelie Control
• EBC Engine Brake Control
• GPS Global Positioning System
Key to wiring diagram

SHEET 1
Power line

Dotted line Component

1 Battery

2 Key switch

3 Fuse box 1

4 Fuse box 2

5 Rectifier

6 Generator

7 IMU

8 Relay / dip switch

9 Starter motor

10 Cold-start relay

11 Main fuse

SHEET 2
Engine line


12 Engine ECU

13 Throttle

14 Gear sensor

15 Quick Shift (DQS)

16 Horizontal TPS

17 Horizontal oxygen sensor

18 Map sensor 2

19 Map sensor 1

20 Coil 2

21 Coil 1

22 Ambient temperature

23 Front brake switch

24 Rear brake switch

25 Purge Valve

26 Secondary air valve

27 Engine Temperature

28 Pick- up

29 Side stand switch

30 Injection

31 Clutch switch

32 Vertical oxygen sensor

33 Main Relay

SHEET 3
BBS line


34 Black Box System (BBS)

35 RH fan

36 LH fan

37 Fuel pump

38 Fuel pump relay

39 Fuel level sensor

SHEET 4
ABS line


40 ABS control unit

41 Front speed sensor

42 Rear speed sensor

SHEET 5
Instrument panel line


43 Instrument panel

44 Immobilizer

45 Front left turn indicator

46 Front right turn indicator

47 Headlight

48 Rear left turn indicator

49 Rear right turn indicator

50 Tail light

51 Alarm

52 Oil temperature sensor

53 Number plate light

54 Instrument panel temperature sensor

55 Horn

56 Left-hand switch

57 Right-hand switch

58 LH heated handgrip

59 RH heated handgrip

SHEET 6
CAN line


60 Inertial platform (IMU)

61 ABS

62 Bluetooth

63 BBS CAN

64 BBS

65 Diagnostic socket

66 Instrument panel

67 ECU

68 ECU CAN

SHEET 7
Accessories


69 Bluetooth

70 Alarm

71 Auxiliary fuel pump

72 GPS navigation system

73 USB

74 Left additional spotlight

75 Right additional spotlight

76 12 V socket

77 LH heated handgrip

78 RH heated handgrip
Wire colour coding
B - Blue
W - White
V - Violet
Bk - Black
Y - Yellow
R - Red
Lb - Light blue
Gr - Grey
G - Green
Bn - Brown
O – Orange
P – Pink
Using the wiring diagram
The interactive wiring diagram includes:
• pages with wiring layout;

• key to wiring diagram.
The layout is divided into pages by macro-categories, which are shown in the bookmark panel:
• power lines;
• engine lines;
• BBS line;
• ABS line;
• instrument panel line;
• CAN line;
• Accessories.
Each page is identified by a number in the top left corner which is contained in a red box.
The pages can be navigated using Acrobat navigation buttons (A) or clicking on the bookmark section (B)
The page displays:
1 - electrical components
2 - the PIN information contained therein
3 - the orthographic representation of the components
4 - the electrical tracks connecting the components to each other
5 - the colour and thickness of the cables
6 - the numbering of the components contained in black circles
7 - the links connecting the components from one page to another represented by red boxes
Using links
The layout displays red boxes. When the cursor changes shape (see image) you can click to know what that specific
component is linked to.
Clicking on the box opens a popup window bearing target section (8) text, in which the component (9) and its PIN (10)
"-> page / pin X - part Y" are displayed.
While the pop-up window is open, click again to get to the required page. The target destination of the previous link is
displayed in the middle of the page.
At this point, you can choose to go back by clicking on the link in the destination PIN (11) or click on the page
bookmark or navigate using the page navigation buttons.
Links are also present in some branches and they can give access to other branches (C) or to numbered component
specific PINs (D). Some components are provided with links to other components (E).
Finally, on each numbered component an additional link is provided to get to the key page (F). Here a list is displayed
including the components present in the layouts and their description, you can click on each which links directly to the
relevant page (G).
Routing of wiring on frame

BRANCHES DESCRIPTION

Branch 1 Right-hand switch

Front right turn indicator

Front left turn indicator

RH heated handgrip (preset)

Ride by Wire

Front brake switch

Branch 2 Bluetooth (preset)

Instrument panel

Headlight

GPS Navigator (preset)

USB socket

Air temperature sensor

Branch 3 Key switch

Left-hand switch

Immobilizer

LH heated handgrip (preset)

Secondary tank pump (presetting)

Clutch switch

Branch 4 Secondary air actuator

Horizontal MAP sensor

Vertical MAP sensor

IMU Inertial platform

Voltage regulator

Airbox air temperature sensor

Branch 5 Horn

Right spotlight (preset)

Tank ground cable


Fuel pump

Purge valve

Fuel level sensor

RH fan

LH fan

Branch 6 Horizontal coil

Left spotlight (preset)

Quick-Shift

Front speed sensor

Side stand

Branch 7 Pick up

Oil pressure switch

Water temperature sensor

Horizontal oxygen sensor

Vertical oxygen sensor

Branch 8 Anti-theft system (preset)

Vertical coil

ABS control unit

ECU control unit

Injectors

Airbox potentiometer

Branch 9 Gear sensor

Rear brake switch

Rear speed sensor

Branch 10 Generator cable

Starter motor cable

Battery negative cable

Branch 11 Tail light

Rear right turn indicator

Rear left turn indicator

Number plate light
Removing the main wiring
To remove the entire main wiring harness from the motorbike, proceed as follows:
Remove the following parts:
• Headlight fairing (Removing the headlight fairing).

• Front half fairing (Removing the front half fairing).
• Fuel tank (Removing the fuel tank).
When removing the main wiring harness, remove any components that prevent removal.
Loosen the three screws (1) and remove the cover (2).
Remove tie (A).
Disconnect:
• (3) Instrument panel.

• (4) USB socket.
• (5) Air sensor.
Proceed with the removal of the main wiring harness.
Front branch
Disconnect:
• Headlight (Branch 2).

• Right and left turn indicators (Branch 1);.

POSITION TYPE INVOLVED BRANCHES NOTES

(A) L = 39 mm (1.53 in) button tie Instrument panel wiring branch

USB socket cable

Navigator wiring branch (preset)

Bluetooth wiring branch (preset)

(B) L = 39 mm (1.53 in) button tie Instrument panel wiring branch

Air temperature sensor wiring branch

(C) Big self-locking tie Instrument panel wiring branch

Headlight wiring branch


(D) Big self-locking tie Headlight support


USB socket wiring branch

Navigator wiring branch (preset)

Bluetooth wiring branch (preset)

Front RH turn indicator wiring branch


(E) Special Hellermann clamp Headlight lower cover

Front branch At the taping
RH front branch
Disconnect:
• Right-hand switch (Branch 1).

• RH heated handgrip (preset) (Branch 1).
• Ride by Wire (Branch 1).
• Front brake switch (Branch 1).
• Ignition switch (Branch 3).
• Left-hand switch (Branch 3).
• Immobilizer (Branch 3).
• LH heated handgrip (preset) (Branch 3).
• Secondary tank pump (preset) (Branch 3).
• Clutch switch (Branch 3).
• Secondary air system actuator (Branch 4).
• Horizontal and vertical map sensor (Branch 4).
• IMU inertial platform (Branch 4).
• Voltage regulator (Branch 4).
• Airbox air temperature sensor (Branch 4).
• Horn (Branch 5).


(A) Big self-locking tie Clip on airbox

Front airbox branch

(B) Big self-locking tie Front airbox branch

Horn wiring branch

(C) Big self-locking tie Clip on airbox

RH front branch

(D) Small self-locking tie Air temperature sensor wiring branch

Secondary air system actuator wiring branch
Central branch
Disconnect:
• RH spotlight (preset) (Branch 5).

• Tank ground cable (Branch 5).
• Fuel pump (Branch 5).
• Purge valve (Branch 5).
• Right and left fan (Branch 5).
• Anti-theft system (preset) (Branch 8).
• Vertical coil (Branch 8).
• ABS control unit (Branch 8).
• ECU (Branch 8).
• Injectors (Branch 8).


(A) Small self-locking tie Vertical head wiring support

Central branch

(B) Snap-on clip LH lower branch
Left central branch
Disconnect:
• Horizontal coil (Branch 6).

• LH spotlight (preset) (Branch 6).
• Quick-Shift (Branch 6).
• Front speed sensor (Branch 6).
• Side stand (Branch 6).
• Pick-up (Branch 7).
• Oil pressure switch (Branch 7).
• Water temperature sensor (Branch 7).
• Vertical and horizontal oxygen sensor (Branch 7).
• Gear sensor (Branch 9).
• Rear brake switch (Branch 9).
• Rear speed sensor (Branch 9).


(A) L = 62 mm (2.44 in) button tie Main branch

Gear sensor wiring branch

Gear sensor cable
Disconnect:
• Generator cable (Branch 10).

• Starter motor cable (Branch 10).
• Battery negative cable (Branch 10).
The main wiring harness can now be removed, marking the positions of any ties not previously removed.
Remove the main wiring harness together with the rear subframe, for disassembly please refer to chapter “Removing
the rear subframe”.
Refitting is the reverse of removal.

Branch 1


Branch 1 Right-hand switch

Front right turn indicator

Front left turn indicator

RH heated handgrip (preset)

Ride by Wire

Front brake switch
BRANCH 1A

POSITION DESCRIPTION

(1) Right-hand switch

(4) RH heated handgrip (preset)

(5) Ride by Wire

(6) Front brake switch
Warning
Insert connector by aiming it with the side shown in the figure facing up.


(A) L = 39 mm (1.53 in) button tie Control unit / front brake master cylinder hose

Throttle cable

Front brake switch cable

Right-hand switch wiring branch

(B) Hose clamp Steering head

Control unit / front brake master cylinder hose

Throttle cable



(C) L = 39 mm (1.53 in) button tie Throttle cable



(D) L = 62 mm (2.44 in) button tie Voltage regulator wiring branch

Throttle connector

Front speed sensor wiring branch

(E) Big self-locking tie Voltage regulator wiring branch

Inertial platform (IMU) wiring branch

Front brake switch wiring branch

Right heated handgrip wiring branch (preset)

Tank ground cable branch

Throttle control wiring branch

For further branches/components, refer to chapter “Routing of wiring on frame”.
BRANCH 1B


(2) RH turn indicator

(3) Left turn indicator


(A) L = 39 mm (1.53 in) button tie Right turn indicator cable

Right turn indicator wiring branch

(B) L = 39 mm (1.53 in) button tie Left turn indicator cable

Left turn indicator wiring branch

Branch 2


Branch 2 Bluetooth (preset)

Instrument panel

Headlight

GPS Navigator (preset)

USB socket

BRANCH 2A


(1) Bluetooth (preset)

(2) Instrument panel

(3) Headlight

(4) GPS Navigator (preset)

(5) USB socket

(6) Air temperature sensor
Note
Remove the film, wrap the protective sheath on wiring and ensure uniform adhesion.


(A) Small self-locking tie Front branch

Protective sheath

(B) Special Hellermann clamp Headlight lower cover

Front branch At the taping

(C) Big self-locking tie Headlight support

Instrument panel wiring branch


USB socket wiring branch

GPS navigation system presetting wiring branch

Bluetooth presetting wiring branch



(D) Big self-locking tie Instrument panel wiring branch



(E) L = 39 mm (1.53 in) button tie Instrument panel wiring branch


Branch 3


Branch 3 Key switch

Left-hand switch

Immobilizer

LH heated handgrip (preset)

Secondary tank pump (presetting)

Clutch switch
BRANCH 3A


(2) Left-hand switch

(4) LH heated handgrip (preset)

(6) Clutch switch
Warning
Insert connector by aiming it with the side shown in the figure facing up.


(A) L = 39 mm (1.53 in) button tie Clutch hose

Left-hand switch wiring branch

Clutch switch cable

(B) L = 39 mm (1.53 in) button tie Clutch hose

Ignition switch cable

Immobilizer antenna cable


Clutch switch cable

(C) L = 39 mm (1.53 in) button tie Clutch hose




Clutch switch cable

(D) L = 39 mm (1.53 in) button tie Clutch hose


Immobilizer antenna wiring branch


Clutch switch cable

(E) L = 82 mm (3.23 in) button tie ECU 1 wiring branch

Clutch switch connector and wiring branch

(F) L = 39 mm (1.53 in) button tie Ignition switch cable

LH heated handgrip presetting wiring branch

Clutch switch cable
BRANCH 3B


(1) Key switch

(3) Immobilizer

(5) Secondary tank pump (presetting)


(A) L = 39 mm (1.53 in) Clutch hose
button tie



Clutch switch cable

(B) L = 39 mm (1.53 in) Clutch hose Fasten the immobilizer antenna cable connector to
button tie the frame plate

Immobilizer antenna wiring
branch


Clutch switch cable

(C) L = 39 mm (1.53 in) Ignition switch cable connector
button tie
Fuel tank pump presetting Fasten the ignition switch connector to the frame
wiring branch plate

(D) Small self-locking tie ABS control unit / canister
support

Ignition switch wiring branch

Fuel tank pump presetting
wiring branch

Branch 4


Branch 4 Secondary air actuator

Horizontal MAP sensor

Vertical MAP sensor

IMU Inertial platform

Voltage regulator

Airbox air temperature sensor
BRANCH 4A


(1) Secondary air actuator

(2) Horizontal MAP sensor

(3) Vertical MAP sensor

(4) IMU Inertial platform

(5) Voltage regulator

(6) Airbox air temperature sensor


(A) Big self-locking tie Airbox

RH front branch

(B) Small self-locking tie Voltage regulator wiring branch

Inertial platform (IMU) wiring branch

Front brake switch wiring branch

Right heated handgrip wiring branch (preset)

Tank ground cable branch

(C) Small self-locking tie Air temperature sensor wiring branch

Secondary air system actuator wiring branch

(D) Big self-locking tie IMU support

RH front branch

Branch 5


Branch 5 Horn

Right spotlight (preset)

Tank ground cable

Fuel pump

Purge valve

Fuel level sensor

RH fan

LH fan
BRANCH 5A


(1) Horn

(7) RH fan

(8) LH fan
Note
Secure the left fan wiring branch connector to the frame.


(A) Big self-locking tie Clip on airbox

Front airbox branch

(B) Big self-locking tie Front airbox branch

Horn wiring branch

(C) Small self-locking tie Fan support

LH fan cable

(D) Small self-locking tie Fuel level sensor wiring branch

LH fan cable

(E) Small self-locking tie Fuel pipe

Fuel pump wiring branch

Right spotlight preset wiring branch

RH fan cable

(F) Small self-locking tie Fan support

RH fan cable
BRANCH 5B


(2) Right spotlight (preset)

(3) Tank ground cable

(4) Fuel pump

(6) Fuel level sensor


(A) Small self-locking tie Fuel pipe


Right spotlight wiring branch (preset)

RH fan cable

(B) Small self-locking tie Fuel pipe


Right spotlight wiring branch (preset)

(C) Small self-locking tie Fuel level sensor wiring branch

LH fan cable
BRANCH 5C


(5) Purge valve
Branch 6


Branch 6 Horizontal coil

Left spotlight (preset)

Quick-Shift

Front speed sensor

Side stand
BRANCH 6A


(1) Horizontal coil

(2) Left spotlight (preset)


(A) Big self-locking tie Horizontal coil cable

Left spotlight wiring branch (preset)

(B) L = 62 mm (2.44 in) button tie Secondary air system pipe

Horizontal coil cable

Left spotlight wiring branch (preset)
BRANCH 6B


(3) Quick-Shift

(5) Side stand
Warning
After having connected the Quick-Shift to the main wiring harness branch, make sure that the connection is fully
covered by the protective gaiter (X).

REFERENCE TYPE INVOLVED BRANCHES NOTES

(A) L = 82 mm (3.23 in) Starter motor / solenoid starter
button tie cable

Side stand wiring branch

Quick-Shift wiring branch

Horizontal oxygen sensor wiring
branch

Oil pressure switch wiring
branch

Airbox drain hose

Canister filter breather pipe

Expansion reservoir drain pipe

Fuel tank drain pipe

Generator cable

(B) L = 82 mm (3.23 in) Starter motor / solenoid starter Turn the side stand connection towards the
button tie cable inside of the bike

Side stand wiring branch and
connector


branch

branch

Airbox drain hose




Generator cable

(C) L = 82 mm (3.23 in) Starter motor / solenoid starter At sump guard bracket “purple” screw
button tie cable

Side stand cable


branch

branch

Airbox drain hose




(D) L = 82 mm (3.23 in) Airbox drain hose Turn the oxygen sensor connection towards the
button tie inside of the bike
Horizontal oxygen sensor cable
connector




(E) Small self-locking tie Quick-Shift wiring branch

Side stand cable

(F) Small self-locking tie Quick-Shift wiring cable

Side stand cable

(G) Special Hellermann Quick-Shift wiring cable Secure to the sump guard support (at cable
clamp marking)
Side stand cable

(H) Special Hellermann Quick-Shift wiring cable
clamp
Side stand cable

(J) Small self-locking tie
BRANCH 6C


(4) Front speed sensor


(A) Fast Point Control unit / front calliper
hose

Front speed sensor cable

(B) Hose clamp Mudguard support left bracket


(C) Small self- Mudguard support left bracket
locking tie cable ring
(C1) Secure to the mudguard support left bracket cable
Front speed sensor cable ring at the cable marking

(D) Small self- Voltage regulator wiring branch
locking tie
Front speed sensor wiring
branch

Branch 7


Branch 7 Pick-Up sensor

Oil pressure switch

Water temperature sensor

Horizontal oxygen sensor

Vertical oxygen sensor
BRANCH 7A


(1) Pick-Up sensor
BRANCH 7B


(2) Oil pressure switch

(4) Horizontal oxygen sensor


(A) Small self-locking tie Oil pressure switch support


(B) L = 82 mm (3.23 in) Starter motor / solenoid starter
button tie cable



branch

branch

Airbox drain hose




Generator cable


(C) L = 82 mm (3.23 in) Starter motor / solenoid starter Turn the side stand connection towards the

connector


branch

branch

Airbox drain hose




Generator cable

(D) L = 82 mm (3.23 in) Starter motor / solenoid starter At sump guard bracket “purple” screw
button tie cable

Side stand cable


branch

branch

Airbox drain hose




(E) L = 82 mm (3.23 in) Airbox drain hose Turn the oxygen sensor connection towards the
connector



BRANCH 7C


(3) Water temperature sensor
BRANCH 7D


(5) Vertical oxygen sensor


(A) L = 62 mm (2.44 in) button tie Vertical oxygen sensor wiring branch

Vertical oxygen sensor cable

(B) Big self-locking tie Clip prefitted on frame

Vertical oxygen sensor wiring branch

Vertical oxygen sensor cable

Branch 8


Branch 8 Anti-theft system (preset)

Vertical coil

ABS control unit

ECU control unit

Injectors

Airbox potentiometer
BRANCH 8A


(3) ABS control unit
BRANCH 8B


(4) ECU 1

(4A) ECU 2
BRANCH 8C


(1) Anti-theft system (preset)

(2) Vertical coil

(5) Injectors

(6) Airbox potentiometer
Warning
Fasten the vertical coil cable connector to the vertical head wiring support
Warning
Fasten the connectors of the potentiometer airbox wiring branch and of the injector airbox wiring branch to the
dedicated plate


(A) L = 39 mm (1.53 in) button tie Secondary air system pipe

Vertical coil cable

(B) L = 39 mm (1.53 in) button tie Anti-theft system wiring branch (preset)

Airbox rear branch

(C) Small self-locking tie Potentiometer airbox wiring branch

Injector airbox wiring branch

Branch 9


Branch 9 Gear sensor

Rear brake switch

Rear speed sensor
BRANCH 9A


(1) Gear sensor
Warning
Press the tab following the green arrow direction until you hear a “click” indicating that the connector has been
engaged correctly.


(A) L = 62 mm (2.44 in) button tie Main branch

Gear sensor wiring branch

Gear sensor cable
BRANCH 9B


(2) Rear brake switch


(A) Small self-locking tie ABS control unit / rear brake master cylinder hose

Rear stop sensor cable

(B) Small self-locking tie ABS control unit / rear brake master cylinder hose


Rear speed sensor cable and wiring branch

(C) L = 62 mm (2.44 in) button tie ABS control unit / rear brake master cylinder hose

Rear stop sensor connector, cable and wiring branch

BRANCH 9C


(3) Rear speed sensor


(A) Small self-locking tie ABS control unit / rear brake calliper
hose

Rear speed sensor cable

(B) Small self-locking tie ABS control unit / rear brake calliper
hose


Rear speed sensor cable and wiring
branch

(C) L = 62 mm (2.44 in) ABS control unit / rear brake calliper Fix the rear speed cable connector to the
button tie hose ABS/Canister support

Rear stop sensor connector, cable and
wiring branch

Rear speed sensor cable wiring
branch

Branch 10


Branch 10 Generator cable

Starter motor cable

Battery negative cable
BRANCH 10A


(1) Generator cable


(A) L = 82 mm (3.23 in) Starter motor / solenoid starter
button tie cable



branch

branch

Airbox drain hose




Generator cable

(B) L = 82 mm (3.23 in) Starter motor / solenoid starter Turn the side stand connection towards the

connector


branch

branch

Airbox drain hose




Generator cable
BRANCH 10B


(2) Starter motor / solenoid starter cable


(A) Big self-locking tie Vertical head wiring support

Starter motor / solenoid starter
cable

(B) Hose clamp Battery negative cable

Starter motor / solenoid starter
cable

(C) L = 82 mm (3.23 in) Starter motor / solenoid starter
button tie cable



branch

branch

Airbox drain hose




Generator cable

(D) L = 82 mm (3.23 in) Starter motor / solenoid starter Turn the side stand connection towards the

connector


branch

branch

Airbox drain hose




Generator cable

(E) L = 82 mm (3.23 in) Starter motor / solenoid starter At sump guard bracket “purple” screw
button tie cable

Side stand cable


branch

branch

Airbox drain hose



BRANCH 10C


(3) Battery negative cable


(A) Big self-locking tie Vertical head wiring support

Starter motor / solenoid starter cable

(B) Hose clamp Battery negative cable

Starter motor / solenoid starter cable

Branch 11


Branch 11 Tail light

Rear right turn indicator

Rear left turn indicator

Number plate light
BRANCH 11A


(1) Tail light

(2) Rear right turn indicator

(3) Rear left turn indicator

(4) Number plate light


(A) Big self-locking tie Number plate light wiring branch

Tail light cable and wiring branch


Rear fuel tank wiring branch

(B) Small self-locking tie Number plate holder cable retainer

RH turn indicator cable and wiring branch

LH turn indicator cable and wiring branch

Number plate light cable

Recharging the battery
The Desert X features a lithium-ion battery.
Before battery start-up, read carefully the following notes for this type of battery:
- LITHIUM batteries can get damaged, also permanently, if charged with high voltages or if excessively discharged.
For this reason, when the motorbike is not being used, it must be charged and/or maintained charged with the
specific battery charger/maintainer for lithium ion batteries. Never use battery chargers for lead batteries.
- 15 Volt must not be exceeded during battery recharge and 8 Volt must not be exceeded during discharge. In any
case, charging current must not exceed the rated value of 0.5 C = 2 Ampere (C = 4Ah is the rated capacity of the
battery). Do not use auxiliary starters (do not use the booster). Do not start the motorcycle by pushing it.
- The lithium battery with voltage lower than or equal to 8 Volt must never be recharged but replaced.
- The Desert X, being equipped with Lithium battery, has a strategy dedicated to prevent exceeding the battery
voltage minimum threshold; in this case when the voltage measured on the system is 9 Volt all bike electric loads
are deactivated by the system (automatic Key-Off). Then the battery self-discharge could lead to a further drop of
the voltage.
Check that no accessory is directly connected to the motorcycle battery, as after the triggering of the 9 Volt
undervoltage protection there will be a current absorption from the battery due to the accessory being connected,
followed by a rapid self-discharge.
- Always fully charge the battery before installing it if the measured voltage is lower than 12.8 Volt.
Removing the battery
Warning
Loosen screw (3).

Disconnect the vehicle negative cable (4) and the ABS negative cable (5) from the terminal.
Remove the protective rubber block from the positive battery terminal and loosen the screw (6).
Disconnect the vehicle positive cable (7) and ABS positive cable (8) from the positive terminal.
Remove the retaining strap (9) in order to release the battery.
Remove the battery.

If necessary remove the mat under the battery (10).
Refitting the battery
Warning
If the battery retaining strap is removed, reposition it by inserting the pin (11) into the seat (12).
Insert the mat under the battery (10).
Place the battery inside its compartment.

Fix the battery using strap (9).
Fasten the vehicle positive cable (7) and ABS positive cable (8) to the battery positive terminal.
Tighten screw (6) to a torque of 2 Nm ± 10% and position the protective rubber block on the battery positive terminal.
Connect the vehicle negative cable (4) and ABS negative cable (5) to battery negative terminal aiming them as shown
in the figure.
Connect the vehicle positive cable (1) and the ABS positive cable (2) to the battery positive terminal, then connect the
vehicle negative cable (3) and the ABS negative cable (4) to the negative terminal, as shown in the figure.
Tighten 2 screws (5) to a torque of 2 Nm ± 10% and position the protective rubber block (A) on the battery positive
pole.

Alternator / Generator
The generator used has a rated power of 490 W at 14V, and consists of a fixed element (stator/generator, A), located
in the generator cover and a mobile element (rotor/flywheel, B) fastened to the crankshaft.
Rotor (B) is manufactured with strong permanent magnets and features a lot of pin pairs for each stator phase. This
allows generating alternate voltage at a higher frequency compared to a standard generator. The result: at low rpm it
is possible to generate higher current.
Important
Check the charging current by using the "DDS" diagnosis instrument.
To check the generator, measure the voltage at each one of three ends of the generator cable and check if it is
compliant with the value indicated in the table (ambient temperature: 20°C).
Attention
Before testing, disconnect the generator wiring from the electrical system when the ignition key is set to OFF.

Rpm Active voltage Minimum voltage Maximum voltage

1500 rpm 20.8 V 18.9 V 24.5 V

2500 rpm 34.3 V 31.4 V 40.4 V
Values significantly lower than those indicated above can be due to:
- partially demagnetised rotor;
- short-circuited windings.
In the above cases the whole generator assembly (rotor and stator) should be replaced.
If checks have a favourable outcome, reconnect the generator to the regulator with ignition key on OFF. Make sure that
no cables are damaged or disconnected.
Removing the generator

Remove the belly pan (Removing the belly pan).
Drain the engine oil (Changing the engine oil and filter cartridge).
Remove the front sprocket cover (Removing the front sprocket cover).
Slide out the gearchange mechanism (Removing the gear shift).
Drain the cooling system and release the case from the pipes (Removing the cooling system hoses and unions).
Remove the generator cover (Removing the generator cover), the stator (A) (Disassembling the generator cover) and the rotor
(B) (Removing the flywheel/generator assembly).
Refitting the generator
Fit the rotor (B), the stator (A) (Fitting the flywheel/generator assembly) and the generator cover (Fitting the generator cover).
Refit the cooling system pipes (Refitting the cooling system hoses and unions) and restore the fluid level.
Refit the gearchange mechanism in its seat (Refitting the gear shift).
Refit the sprocket cover (Refitting the front sprocket cover).
Restore the engine oil level (Changing the engine oil and filter cartridge).
Refit the belly pan (Refitting the belly pan).
Rectifier-regulator
The rectifier-regulator (1) is placed on the front side of the frame, under the ignition switch.

REMOVAL

Remove the ECU (Removing the ECU).
Disconnect the two connectors (2).
Undo screws (3) and remove regulator (1).

REFITTING
Fit two vibration dampers (4) in the relevant holes of the voltage regulator support (6).
Fit the two spacers with collar (5).
Fit two spacers with collar (8) in the relevant holes of the voltage regulator support (6) positioning them as shown in
the figure.
Insert screws (9) in the regulator protection bracket (6).
Position the voltage regulator (1) on the voltage regulator support (6), and insert the two screws (9) with bracket on
the side of the support.
Start two nuts (7) on the threaded projections of two screws (9).
Tighten nuts (7) to a torque of 5 Nm ± 10% holding screws (9).
Position the regulator (1) on the inner side of the frame engaging the pin (12) into the vibration damper.
Fit the screws (3) with relevant washer and tighten them to a torque of 6 Nm ± 10%.
Connect the connectors (2).
Refit the ECU (Refitting the ECU).

Electric starting system
The electric starting system consists of a solenoid starter (1) and a starter motor (2).
For removal of the solenoid (1) refer to chapter “Solenoid starter”, for removal of the starter motor refer to chapter
“Starter motor".
Starter motor
Electric features:
12 V / 0.7 kW
The starter motor is highly compact and reliable, therefore rarely raises any operating issue.
In case of faults:
- ensure that the starter motor wiring terminal is properly tightened under the nut and shows no sign of oxidation;
- if the terminal is properly tightened and free from oxidation, remove the starter motor and test it under no-load
conditions (no load applied to the shaft).
Warning
Secure the starter motor to a test bench, making sure not to damage the casing.
Warning
Use a fully charged 12 V battery for the test.
- Use battery-motor connection cables which are no longer than 70 cm and with the same cross-section as the cable
on the vehicle itself;
- connect the negative terminal of the battery to an unpainted area of the starter motor casing and the positive
terminal to its electrical terminal;
- the shaft of the starter motor should rotate freely and at a high speed.
Warning
Take care not to short-circuit the two cables connected to the battery.

REMOVAL

Drain the coolant (Changing the coolant).
Remove the water hoses from the water pump cover (Removing cooling system hoses and unions).
Remove the generator cover (Removing the generator cover).
Remove the flywheel/generator assembly (Removing the flywheel/generator assembly).
Remove the starter motor idler gear (Removing the starter motor idler gear).
Working on the RH side of the motorcycle, remove cap (C), loosen nut (A), collecting washer (B) and slide out the
starter motor cable (1).
Loosen the rear screw (2) retaining the starter motor (4).
Working on the LH side of the motorcycle, loosen the retaining screws (3) and (6).
Remove starter motor (4).

REFITTING
Visually check the gasket (5) for wear and replace it if necessary.
Check that the pre-applied threadlocker is still present on the screws (3) and (6). Otherwise, use the indicated
product.
Fit the starter motor (4) on crankcase, as shown in the figure.
Start the fastening screws (3), and (6) on the starter motor (4).
Tighten the screws (3) and (6) to a torque of 13.5 Nm (Min. 12.5 Nm. - Max. 14.5 Nm).
Check that the pre-applied threadlocker is still present on the screw (2). A maximum of three removal/refitting
Start the rear screw (2) retaining the starter motor (4).
Apply the specified product to nut (A).

Position starter motor cable (1) on starter motor and start nut (A) placing washer (B) in-between.
Tighten nut (A) to a torque of 5 Nm ± 10%, and refit cap (C).
Important
Fill the protection cap with protective grease before fitting it on the starter motor.
Refit the starter motor idler gear (Refitting the starter motor idler gear).
Refit the flywheel/generator assembly (Refitting the flywheel/generator assembly).
Refit the generator cover (Refitting the generator cover).
Refit the water hoses on the water pump cover (Refitting cooling system hoses and unions).
Fill the cooling system (Changing the coolant).
Fill the lubrication system (Changing the engine oil and filter cartridge).
Solenoid starter
Note
The solenoid starter (1) is located inside the electrical components compartment, beneath the passenger seat.

REMOVAL
Remove passenger seat (Removing the seat).
Remove the cap (A).

Disconnect the regulator connector (B) and remove the protection cap (2).
Loosen the screws (3) and collect the elastic washers (4).
Remove the starter motor-solenoid starter cable (5) and the battery positive terminal-solenoid starter cable (6).
Remove the solenoid starter (1) from the electrical components compartment by sliding it from the brackets (B).

REFITTING
Introduce the solenoid starter (1) on the brackets (B) of the electrical components compartment fully home.
Insert elastic washers (4) on the thread of screws (3).
Position the starter motor-solenoid starter cable (5) and the battery positive terminal-solenoid starter cable (6) on
solenoid starter (1) and start the screws (3).
Reconnect the regulator connector (B) and refit the protection cap (2) and cap (A).
Refit the passenger seat (Refitting the seat).
Headlight

REMOVAL
The following components must be removed before removing the headlight.
• Headlight fairing (Removing the headlight fairing);

• Front half fairing (Removing the front half fairing).
Disconnect the headlight connector (Branch 2).
Loosen the two screws (1) securing headlight lower cover (2) to the headlight (3).
Release the two pegs (4) fixing headlight lower cover (2) to RAD-DUCT (5) from both sides of the motorcycle.
Remove the headlight lower cover (2) by releasing the tabs (A) from the rubber blocks (B).
From both sides of the motorcycle, loosen the two screws (5) fixing the headlight (3) to the front subframe (6).
Remove the headlight (3).

FITTING
Fit the two special rubber blocks (7) into the relevant holes in the headlight (3), orientating them as shown in the
figure.
Fit the two clips (8) on the headlight (3), aiming them as shown in the figure.
Fit the two vibration dampers (9) in the relevant holes of the headlight (3).
Position the headlight (3) on front subframe (6) and start screws (5).
Position the headlight lower cover (2).
Fit the headlight lower cover (2) on the headlight, inserting the tabs (A) on the rubber blocks (B).
Fix the rear part of the cover (2) by inserting the rubber blocks (C) on the pins (4) of the RAD-DUCT (5).
Start the screws (1) securing headlight lower cover (2) to the headlight (3).
Connect the headlight connector (Branch 2).
Refit the following components.
• Front half fairing (Refitting the front half fairing).

• Headlight fairing (Refitting the headlight fairing).
Replacing the light bulbs — Headlight
This model features a FULL-LED headlight so, in case of failure, the whole headlight will have to be replaced (Headlight).
Aligning the headlight
Position the vehicle with tyres inflated at the indicated pressure and a person seating on the seat, perfectly
perpendicular to his/her longitudinal axis.
Position the vehicle 10 metres (32.81 ft) from a wall or a screen.
On the wall or surface, draw a horizontal line at the same height from the ground as the centre of the headlight and a
vertical line aligned with the longitudinal axis of the motorcycle.
Note
If possible, perform this check in dim light.
Switch on the low beam. The height of the upper limit between the dark area and the lit area must not be more than
9/10 of the height from the ground of the headlight centre.
Note
The procedure described here is in compliance with the Italian Standard establishing the maximum height of the light
beam. Owners in other countries will adapt said procedure to the provisions in force in their countries.
For China standard only

By turning the left screw (1), the vertical alignment of the left low beam and high beam is adjusted. By turning the
right screw (2), the vertical alignment of the right low beam and high beam is adjusted.
Switch the low beam on and cover the RH low beam. Adjust the uncovered (LH) low beam vertically using the
adjustment screw (1). Turn the steering wheel all the way to the right and use the spanner supplied to turn screw (1)
more easily.
Switch on and check the left high beam as well, acting on the same screw (1) if necessary. By turning the screw (1) on
the headlight clockwise, the beam moves up (UP), vice versa, it moves down (DOWN).
Having adjusted the left low beam and high beam, cover the left side of the headlight assembly and carry out the
same procedure, using screw (2), to adjust the right low beam and high beam.
By turning the screw (1) on the headlight clockwise, the beam moves up (UP), vice versa, it moves down (DOWN).
Note
The procedure described here is in compliance with the Italian Standard establishing the maximum height of the light
beam. Owners in other countries will adapt said procedure to the provisions in force in their countries.
Tail light

REMOVAL
Before removing the tail light, it is necessary to:
• Remove the seat (Removing the seat);

• Disconnect the tail light (Branch 11).
Loosen screws (1) and (2) fixing the rear mudguard (3) to the rear subframe (4) only if the tail light is to be removed
together with the rear mudguard.
Loosen the rear screw (5) that retains the rear mudguard (3) to the rear subframe (4).
If it is not necessary to remove the rear mudguard but only the tail light, follow the instructions below.
Undo the screws (6) and the screw (7) fixing the lower rear mudguard (8).
Remove the lower rear mudguard (8).
Loosen the two screws (9) with their washers and remove the tail light (10) from the rear of the vehicle.

REFITTING
Position the tail light (10).

Start the two screws (9) with relevant washer and tighten them to a torque of 5 Nm ± 10%.
Position the rear mudguard
Start the screws (6) and the screw (7) fixing the lower rear mudguard (8).
Replacing the light bulbs — Tail light
The tail light on this motorcycle is a LED light.

In case of malfunctions or breakage, it will be necessary to replace the entire tail light (Tail light).
Gear/neutral sensor

REMOVAL
Disconnect the gear/neutral sensor (Branch 9).
Loosen screws (1) and remove the sprocket cover (2).
Loosen the two screws (3) and remove sensor (4).

REFITTING
Apply the specified product to the thread of screws (3)
Position the gear/neutral sensor (4), aiming it as shown in the figure and start the screws (3).
Tighten the screws (3) to a torque of 2.5 Nm (Min. 2 Nm. - Max. 3 Nm).
Check that the pre-applied threadlocker is still present on the screws (1). A maximum of three removal / refitting
Position sprocket cover (2) and start screws (1).
Connect the gear/neutral sensor (Branch 9).

Oil pressure sensor
The oil pressure sensor (pressure switch) (1) is located on the front lower area.

REMOVAL
Remove the sump guard (Removing the sump guard).

Remove the horizontal exhaust manifold (Removing the exhaust system).
Disconnect the oil pressure sensor connector (A).
Loosen the screw (2) securing the pressure switch support (3) to the engine.
Loosen the pressure switch oil pipe (4) from the engine, collecting the aluminium gasket (5).
Remove the oil pressure sensor (1) from the support (3) by releasing the rubber block (B) from the rib (C).

REFITTING
Introduce the oil pressure sensor (1) in the support (3) by fitting the rubber block (B) in the rib (C).
Fit the aluminium gasket (5) on the pressure switch oil pipe union (4).
Start and tighten the pressure switch oil pipe (4) to a torque of 32 Nm ± 10%.
Refit the pressure switch support (3) on the engine and start the screw (2).
Reconnect the oil pressure sensor connector (A) (Branch 7).

Refit the horizontal exhaust manifold (Refitting the exhaust system).
Refit the belly pan (Refitting the belly pan).
Engine temperature sensor
The engine temperature sensor (1) is located on the vehicle LH side, on the water union of horizontal head.

REMOVAL
Disconnect the connector (A) from engine temperature sensor (1).

Loosen and remove engine temperature sensor (1), collecting seal (2).

REFITTING
Fit the seal (2) on the engine temperature sensor thread (1).
Apply the specified product to the thread of engine temperature sensor (1).
Start the engine temperature sensor (1) on the water union.
Tighten engine temperature sensor (1) to a torque of 23 Nm (Min. 20 – Max. 26).
Reconnect the connector (A) to the engine temperature sensor (1).
There are two air temperature sensors in the vehicle:
Ambient air temperature sensor (1).

For removal and refitting, please refer to chapter “Removing the structural components and frame" and “Refitting the structural
components and frame".
Intake air temperature sensor (2).

For removal and refitting, refer to chapters "Removing the airbox and throttle body" and "Refitting the airbox and throttle body".
Side stand switch

REMOVAL
Disconnect the side stand (Branch 6).
Loosen the screw (1) and remove the side stand switch (2).

REFITTING
Refit the side stand switch (2) and start the screw (1).
Connect the side stand (Branch 6).
Checking the fuses
The fuse boxes are located under the rider seat and are laid out as follows:
• Fuse box (A) and (B) in front of the battery.

• Main fuse (C) on the RH side.
• Fuses (D) on the solenoid starter on the RH side.
As far as boxes (A) and (B) are concerned, to expose the fuses, lift the box protective covers. Mounting position and
ampere capacity are marked on box cover, as shown in the following tables.

Fuse box (A) key

Fuse box (A) key

1 – –

2 – –


4 Diagnostics 7.5 A




8 Spare 10 A

9 Spare 20A

10 Spare 15A

Fuse box (B) key


1 ABS 10 A

2 ABS 25 A

3 BBS 15 A

4 Dashboard 20 A

Fuse box (B) key


6 Load relay 25 A

7 – –

8 Spare 10 A

9 Spare 20 A

10 Spare 15 A
Horn

REMOVAL
Disconnect the horn (Branch 5).
Loosen screw (1) while holding nut (2) on the opposite side.
Remove the horn (3).

REFITTING
Position the bracket on the horn (3) and start the screw (1).
Start the screw (1) in the nut (2).
Tighten screw (1) to a torque of 8 Nm ± 10% by holding nut (2) on the opposite side.
Connect the horn (Branch 5).

Coils

REMOVING THE VERTICAL HEAD COIL

Remove the spark plug from vertical head using tool part no. 88713.2877.

REMOVING THE HORIZONTAL HEAD COIL
Working on either sides of the motorcycle, loosen screws (3) and release the RAD-DUCT pins (A) from the rubber
blocks (B) of the headlight lower cover.
Lift the water radiator assembly (2) to access the coil.

REFITTING THE VERTICAL HEAD COIL
Insert coil (5).
Tighten screw (3) with washer (4) to a torque of 10 Nm (Min. 9 Nm. - Max. 11 Nm).

REFITTING THE HORIZONTAL HEAD COIL
Insert coil (6).
Tighten screw (4) with washer (5) to a torque of 10 Nm (Min. 9 Nm. - Max. 11 Nm).
Position water radiator assembly (2).

Fit the pins (A) of RAD-DUCT into rubber blocks (B) of the lower headlight cover and start screws (3).
Electric fans

REMOVING THE ELECTRIC FANS
Loosen the screws (1), nut (2) and remove the RH electric fan (3) from the RH bracket (4).
Repeat the operation to remove the LH electric fan.
Loosen the screws (5) with elastic washers (6) and washers (7) and remove the RH bracket (4) from the water radiator
(8).
Proceed in the same way to remove the left-hand bracket.

REFITTING THE ELECTRIC FANS
Insert elastic washers (6) and washers (7) on the screws (5).
Fit the RH bracket (4) on the water radiator (8) and start screws (5).
Proceed in the same way to refit the left-hand bracket.
Fit the RH electric fan (3) on RH bracket (4) and start screws (1) and nut (2).
Tighten screws (1) and nut (2) to a torque of 5 Nm ± 10%.
Repeat the operation to refit the LH electric fan.
Electronic control unit

REMOVAL
Disconnect the two connectors (1) of ECU (2).
Undo and remove the two screws (3) with the relevant washer (4).
Remove the control unit (2).

REFITTING
Insert ECU (A) inside rubber support (B) by fitting pins of control unit into the rear holes and front slots of the support.
Note
At the end of the installation, the cap head (B) and the cap (C) must be at the relevant holes on the support (B), as
shown in the figure.
Position control unit (2).
Start and tighten screws (3) with washers (4).

Connect the two connectors (1).

Map sensor

REMOVAL

Disconnect the map sensors (Branch 4).
Remove the two map sensors (1) and (2) by pulling them off the tabs on the frame.
• (1) vertical head Map sensor;

• (2) horizontal head Map sensor.
Disconnect the two pipes by loosening the clamps (3).

REFITTING
• (4) horizontal head map sensor pipe L = 215 mm (8.46 in);

• (5) vertical head Map sensor pipe.
Insert the four spring clamps (3) into the pipes (3) and (4).
Lubricate the two map sensor O-rings with engine oil.

Fit the two MAP sensors (6) in the two supports (7) by introducing the pins with O-rings in the support recesses and,
at the same time, pins in the MAP sensor holes as shown in the figure.
Fit the vertical head / map sensor preformed pipe (5) on the MAP sensor support fitting (7) by orienting it so that the
reference (B) is aligned with the centre (A) of the MAP support.
Fit the Map sensor / horizontal head pipe (4) on the fitting of the other MAP sensor support (7).
Secure pipes (4) and (5) on the relevant supports (7) by means of spring clamps (3), positioning them as shown in the
images.
Warning
When installing the hoses on the supports make sure that the Map sensor ducts are not obstructed.
Reconnect the two pipes to the respective fittings, securing them with clamps (3).
Secure the two map sensors (1) and (2) in the tabs on the frame.
Connect the map sensors (Branch 4).

Black Box System (BBS)

REMOVAL
Undo the four screws (1) and remove the seat support plate (2).
Undo the two fixing screws (3) and remove the 12 Volt socket support (4).
Disconnect BBS connector (5).

Undo the two screws (6) and remove the BBS (8), recovering the two washers (7).

REFITTING
Install BBS control unit (A) on rubber support (B), as shown in the figure.
Fit the BBS control unit (8), orienting it as shown in the figure, by fitting its rubber support on the electrical component
support.
Fit the two washers (7) onto two screws (6).
Start the screws (6) with washers on the electrical component support.
Tighten the two screws (6) to a torque of 3 Nm ± 10%.
Connect connector (5) of the BBS.

Connect the 12V socket.
Insert the 12V socket support (4) under the guides (9), bringing it into position on the electrical component support,
and start the two screws (3).
Tighten the two screws (3) to a torque of 0.85 Nm ± 10%.
Position the seat support plate (2).
Start the four screws (1) and tighten them to a torque of 10 Nm± 10%.

Electronic Throttle Valve (ETV)
ETV (1) is positioned on the throttle body.

In case of failure it is not possible to replace only the ETV, but it is necessary to replace the complete throttle body.

REMOVAL
Undo the screws (17) and remove the upper cover of the airbox (16).
Disconnect the horizontal and vertical injector connectors (A).

Remove the fuel pipe set (B) by loosening the relevant screws (C).
Disconnect the potentiometer connector (D).
Working on the lower side of the airbox (16) loosen the eight screws (18) and remove the throttle body.

REFITTING
Fit the two O-rings (25), inserting them perfectly into their relevant seats on the lower airbox cover (16).
Position the throttle body (26) inside the lower airbox cover, orienting it as shown in the figure.
Fit the two O-rings (27) on the two intake funnels (28), fitting them perfectly into their respective seats.
Position the two intake funnels (28) on the throttle body and secure them by tightening the four screws (29).
Tighten the screws (29) to a torque of 5 Nm ± 10%, in a cross pattern.
Start screws (18) and tighten them to a torque of 8 Nm ± 10%, in a cross pattern.
Reconnect the horizontal injector wiring branch connector and vertical injector wiring branch connector (A) to the
corresponding injectors.
Note
It is possible to distinguish between the injector wiring branches by observing the letters “V” and “O” on the labels
attached to the cables.
Apply the indicated product (diluted at 50% with water) to the hose grommets (30).
Insert the hose grommets (30) perfectly into their respective seats on the lower airbox cover, as shown in the figure.
Using three self-locking ties (green in the figure), tie the throttle body fuel pipe set and wiring together in the indicated
positions, as shown in the figure.
Reconnect the potentiometer connector (D) and secure the fuel pipe set (B) by tightening the screws (C) to a torque of
5 Nm ± 10%.
Couple the upper airbox cover (16) to the lower one and secure the parts by tightening the screws (17) in the
positions shown in the figure.
Tighten the screws (17) to a torque of 2.25 Nm ± 10%, following the sequence shown in the figure.

Rpm sensor (pick-up)

REMOVAL
Remove the ABS control unit support bracket (Removing the ABS control unit).
Disconnect the engine rpm sensor (Branch 7).
Loosen the screw (1) with the relevant washer (2) and remove the rpm sensor (3).

REFITTING
Make sure that the O-rings (4) are present inside rpm sensor housing.
Position rpm sensor (3), fit the washer (2) and start the screw (1).
Tighten the screw (1) to a torque of 10 Nm (min. 9 – max. 11).
Connect the rpm sensor (Branch 7).

Refit the ABS support bracket (Refitting the ABS control unit).
Oxygen sensors
Disconnect the horizontal oxygen probe (1) and vertical oxygen probe (2) as shown in chapter "Branch 7".
Loosen and remove horizontal oxygen sensor (1).
Loosen and remove vertical oxygen sensor (2).
During refitting operation, tighten the oxygen sensors (1) and (2) to a torque of 24.5 Nm ± 10%.
Reconnect the two oxygen sensors (Branch 7).
Inertial Measurement Unit (IMU)

REMOVAL
Loosen the two screws (1) securing the IMU (2) by counter-holding the nuts (3).
Remove the nuts (3) with their washers (4) and the two screws (1).
Disconnect the connector (5) and remove the IMU (2).

REFITTING
Position a self-locking tie (7) as shown in the figure, so that the IMU is centred over the two holes.
Insert the left screw (1) as shown in the figure.

Apply bubble wrap or similar to the key and insert the nut (3) as shown in the figure.
Apply grease to the nut (3) and position the washer (4).
In this way the nut (3) and washer (4) will form one piece.
Start nut (3) with washer (4) from inside the vehicle, between frame and airbox as shown in the figure.
Remove clamp (7).
Insert the right screw (1) and from the side shown in the figure, start the nut (3) with its washer (4).
Hold nut (3) from the opposite side and tighten screws (1) to a torque of 6 Nm ± 10%.
Instrument panel
The motorcycle is equipped with an instrument panel featuring a TFT colour display.
The instrument panel provides all the information necessary for safe riding and allows customising vehicle track
alignments and parameters.

The figure shows the warning lights in “Full” (left) and “Rally” (right) display modes.
The following table lists the warning lights:

no. Description Colour

1 Left turn indicator Green

2 ABS system malfunction Amber yellow
• flashing: ABS in self-diagnosis mode and/or functioning with degraded performance;

• on: ABS disabled and/or not functioning due to a fault in the ABS control unit.

3 Low engine oil pressure Red
Important
If the ENGINE OIL light stays ON, stop the engine or it may suffer severe damage.

4 RH turn indicator Green

5 DTC intervention

no. Description Colour
Amber yellow
(display)

6 Immobilizer Red

7 Heated handgrips enabled (if present) (display)

8 Service coupon Amber yellow
(display)

9 Warning lights and secondary tank (if present) warning lights Amber / red
(display)

10 DAVC Diagnosis Amber yellow
(display)
• flashing: DTC/DWC enabled, but with degraded performance;
• on: DTC disabled and/or not functioning due to a fault in the control unit.

11 Fog lights on, if present Amber yellow
(display)

12 MIL Amber yellow
(display)
• The warning light is steady on when an engine management error occurs. Proceed slowly,
avoid heavy acceleration and overtaking manoeuvres.
• The flashing warning light is activated to signal a critical emission error and may cause
damage to the catalytic converter.

13 Generic error Amber yellow
(display)

14 Side stand down Red (display)
Note
When the side stand is extended, the fuel indicator will not update.
When the side stand is in the rest (horizontal) position, the first update of the fuel indicator will
occur only after a few seconds.

15 High beam on Blue (display)

16 DRL – Daytime running light set in 'Auto' mode Green (display)
(not present on versions for China and Canada)

17 DRL – Daytime running light set in 'Manual' mode Green (display)
(not present on versions for China and Canada)
The arrangement of the warning lights in the “Rally” display mode is also the same for the Turn by turn display if
present.
Upon key-on, the instrument panel displays the Ducati Logo and carries out a check routine of the LED warning lights
in sequence.
After this routine, the instrument panel displays the main screen in use before last key-off.
During this first check stage, if the motorcycle speed exceeds 5 km/h (3 mph), the instrument panel will stop:
• the display check routine and display the standard screen containing updated information;
• the warning light check routine and leave ON only the warning lights that are actually active at the moment.

The previous figure shows the warning lights in “Full” and “Rally” display modes.
The following table lists the warning lights:
Function buttons

(1) Up control button

(2) Down control button

(3) Riding mode change and ENTER function button

(4) Cruise control RES/+

(5) Cruise control SET/-

(6) Cruise control ON/OFF

(7) ABS deactivation

(8) Three-position turn indicators:
• position (8a), left turn indicator

• central position, OFF
• position (8b), right turn indicator.

(9) Warning horn

(10) Light selector switch:
• high beam, pushed up

• low beam, in the middle
• high-beam flasher and “Start/Stop Lap” function, pushed down

(11) Hazard lights (red)

(12) Handgrip heating (if any)

(13) DRL light (if fitted) / fog lights

(14) Engine start

(15) Engine start enabling, pushed up (red)

(15) Engine stop, pushed down (red)
Error warnings
The instrument panel manages error warnings in order to allow the rider to identify any abnormal motorcycle
behaviour in real time. If there is an error, the instrument panel displays it in the red large format (A) for the first 10
seconds and then in the small format (B). The indication then remains active until the error is reset. If there are
several errors, they are displayed one after the other every 5 seconds. The figure shows the error “Traction control”.
Immobilizer system
To increase protection against theft, motorcycle features an electronic engine locking system (IMMOBILIZER) which is
automatically enabled upon every Key-Off. Inside of each key handgrip there is an electronic device that modulates the
signal sent by a special antenna integrated in the ignition switch upon starting. Such modulated signal represents the
"password", that changes upon every starting, that allows the control unit to acknowledge the key and thus starting
the engine.
System Operation
Key electronic codes are stored inside instrument panel control unit, which serves as Immobilizer.
The transponder contained inside each key (A) is powered by the antenna inside the key switch (B). Instrument panel
control unit (C) reads the electronic code stored inside the key and compares it to the codes enabled for engine start,
then it communicates to engine control unit - through the CAN line - whether engine starting can be enabled.
Note
Activations through diagnosis instrument

The DUCATI diagnosis instrument (DDS 3) allows performing a series of activations to check some instrument panel
functions and resetting parameters or warning lights.
After each activation, the instrument panel will restore its standard functions.
Note
The activations must be performed only with key turned to ON, engine off and battery voltage ≥ 11.0 V.
Keys
The Owner receives a set of two keys. They contain the "Immobilizer system code". Keys (B) are those for the
standard use, i.e. to:
• start the engine;

• open the fuel tank plug;
• open the seat lock.
Warning
Separate the keys and use only one of the two black keys to ride the bike.
1. Release keys from tie (1) in order to prevent any interference during the acquisition of the transponder code present
inside the keys.
Note
Make sure that keys are at least 50 cm far from one another.
2. Make the Key-ON with the first key.

3. Make the Key-OFF before the countdown of 30 tenths of a second indicated on the instrument panel elapses
(approx. 3 sec.) and remove the key.
4. Make the Key-ON with the second key.

5. Make the Key-OFF before the countdown of 30 tenths of a second indicated on the instrument panel elapses
(approx. 3 sec.) and remove the key.
Make a new Key-ON with the first key.

If the procedure has been successfully completed, the instrument panel will show “PROGRAMMING OK”.
Key duplication

Loss or damage of one of the keys
In case one of the two keys is lost or damaged, carry out the following procedure:
1) Order a new spare key;
2) Make a mechanical copy of the key using the black key as a reference;
3) Using the DDS 2.0 diagnosis instrument, reset the keys, following the “Key reset procedure” shown below.
4) Carry out the “New system key programming procedure” shown in chapter “Keys”.

Key reset procedure
To reset the key programmed in the instrument panel control unit through the DDS 2.0 diagnosis instrument, carry out
the following procedure:
1) Turn the Key-ON with the old key;
2) Access the "Self-diagnosis" section of instrument panel control unit;
3) Select "Settings";
4) Select "Key Reset".
Note
Once key reset procedure is completed, no key will be programmed in the instrument panel control unit: the
programming procedure of the 2 keys explained at the beginning of the chapter will have thus to be carried out.

Loss or damage of both keys
In case both keys are lost or damaged, the following spare parts must be ordered:
1) complete switch kit consisting of:
— Keys
— Lock unit
2) Instrument panel:
install the kit and then carry out the key programming procedure for the new system explained in chapter "Keys".
Warning
If instrument panel control unit is replaced, the Pin Code must be set again otherwise the recovery procedure cannot
be carried out.

Instrument panel damage and replacement
In case of instrument panel failure, it can be replaced by ordering a new spare instrument panel; then the key
programming procedure for the new system explained in chapter "Keys" has to be carried out.
Warning
If instrument panel control unit is replaced, the Pin Code must be set again otherwise the recovery procedure cannot
be carried out.

Key switch mechanical damage
In case of key switch mechanical damage, the Key-ON cannot be carried out and, based on the system, proceed as
follows (in this vehicle, for the I2K-2 system with con REMOVABLE transponder):
— order a new spare key switch with locks;
— remove the transponders from both original keys and insert them inside the new ones (to replace the transponder,
follow the procedure below).
Restoring motorcycle operation via the PIN CODE
If the PIN code has been activated through the "PIN Code" function of the "Settings” menu, the instrument panel
displays the message “PIN Code” with the space to enter the four digits of the PIN.
Entering the code:
• The numbers displayed above the digit indicate that the number can be changed from 0 to 9 using buttons (1) and
(2).
• Press ENTER (3) to confirm and move on to the next digit.
• Repeat the procedure until all 4 digits have been set.
Once the fourth and last digit has been set, press ENTER (3) and the instrument panel will behave as follows:
• If there is a problem during the PIN check, the instrument panel displays the indication “Time’s up” for 2 seconds
and then goes back to the main screen.
• if the PIN code is not correct, the instrument panel displays "Wrong" for 2 seconds and then goes back to the
previous screen to allow you to try again.
• if the PIN is correct, the instrument panel shows "Correct" for 2 seconds, and then displays the main screen.
Removing the front wheel
Support the bike so that the wheel to be removed is raised from the ground.
Working on either sides of the motorcycle, loosen screws (1) and remove front brake callipers (2) without
disconnecting them from the hoses.
Warning
Do not operate the brake lever when the callipers are removed. This can cause the brake pad pistons to come out.
Loosen and remove nut (3) on wheel shaft left side.

Collect washer (4).
Working on either sides of the motorcycle, loosen screws (5) securing pin on fork axle lugs.
Slide out wheel shaft (6) completely and remove the front wheel (7).
Collect spacers (8) and (9).
Working on either sides of the front wheel, remove the sealing rings (10).
Overhauling the front wheel

WHEEL HUB BEARINGS
Before checking the dimensions, check for wear on wheel hub bearings. Check for wear by hand after cleaning and
degreasing the bearings in their seats.
Turn the internal ring and check that the internal balls move freely: any irregularity indicates deformations like those
indicated in values "A" and "B".
An excessive wear can cause vibrations and instability of the vehicle and therefore it is necessary to replace them.
To remove the bearings and the sealing rings from the wheel hub follow the instructions below.
Position a drift (C) against the inner ring of the bearing (10).
Tap with a hammer until removing the bearing (10).
Apply the drift at different points to facilitate the removal.
Important
Once removed, the used bearings and sealing rings must not be refitted.
Before fitting new bearings, check that the seat is clean and free from scoring and damage.
Apply the indicated product inside wheel rim seat before refitting bearing (10).
Refit bearing (10) on wheel rim seat, using a tubular drift (D) that only bears on the outer ring of the bearing (10) to
drive the latter fully home.
Use the same method to install the sealing rings (9).
Ensure that spacer (8) is fitted between the two wheel hub bearings.
Note
Wheels must be rebalanced after repair, maintenance and overhaul operations.

INSPECTING THE WHEEL SHAFT
For the check values refer to paragraph (Front Wheel).

Check the wheel shaft (7) for straightness. Turn the shaft on a reference surface and measure maximum distortion
using a feeler gauge.

CHECKING SPOKED WHEEL RIM AXIAL AND RADIAL CLEARANCE
After you have checked the bearings, check the rim as follows.
Visually inspect the rim for cracks, scoring and deformation: change the rim if damaged.
Check axial and radial clearance of spoked wheel rims as follows.
Set spoked wheel rim on the centring tool.
Set dial gauge at a right angle to the surface to be measured:
Reset dial gauge stylus and spin the wheel to read axial and radial clearance.
Warning
Standard axial and radial clearance should be <= 0.8 mm.
If the values measured are not within the tolerance limits, replace the wheel.

CHECKING SPOKE TENSION
To check spoke tension, follow the procedure below:
Set the motorcycle on the front service stand so as to take the wheel off the ground and let it spin freely.
Briefly hit each spoke with a screwdriver and listen to the sound it makes.
Note
Sound frequency depends on spoke length and diameter.
If sound is even and clear, spoke tension is correct.

In case of a hollow sound, spoke tension is not correct and it is necessary to restore proper tensioning.
Use the torque wrench (A) part no. 88713.2777 with two inserts (B) and (C).
Tighten the nut corresponding to slack spoke to 4 Nm, using a 4 mm wrench to hold.
Warning
If there are three or more slack spokes, first tension them and then check wheel rim axial and radial clearance because
it might have deformed.
Refitting the front wheel
When all the necessary inspections have been completed, refit the wheel as follows.
Check that the central spacer is present on the wheel rim by following the reference procedure (Overhauling the front
wheel).
Working on the RH side of the front wheel, refit the sealing ring (10).
Apply the indicated product to the sealing ring (10).
Fit spacer (9) in the front wheel.
Working on the LH side of the front wheel, refit the sealing ring (10).
Apply the indicated product to spacer (8).
Fit spacer (8) in the front wheel.
Apply the specified product on the shank and thread of the wheel shaft (6).
Refit the front wheel (7) between the fork axle lugs.
Working on the RH side of the motorcycle, insert wheel shaft (6), driving it fully home on wheel hub.
The marks on the wheel shaft (6) (Red shaft) must be parallel to the fork leg inclination (Green shaft).
Working on the LH side of the motorcycle, insert washer (4) on wheel shaft end.
Apply the indicated product to thread and underhead of the retaining nut (3).
Screw nut (3) without tightening it.
Working on either sides of the motorcycle, position brake callipers (2) on fork axle lugs and start screws (1).
Pull the brake lever many times.
Tighten nut (3) to a torque of 63 Nm ± 5% by holding wheel shaft (6) in position.
Check that the marks on the wheel shaft (6) (Red shaft) are still parallel to the fork leg inclination (Green shaft).
Position the motorcycle front wheel on the ground and push up and down the handlebars to load the suspension; in
this way the fork bottom ends will be properly seated onto the wheel shaft.
If previously removed, apply specified product to the screw threads (5).
Start screws (5) on fork axle lugs.
Tighten the screws (5) to a torque of 19 Nm ± 5%, following a 1-2-1 sequence.
Removing the rear wheel
Set the motorcycle on the rear service stand.

Slacken and remove the chain from the rear sprocket (Adjusting the chain tension).
Working on the RH side of the motorcycle, loosen nut (1), collecting washer (2) and remove the chain tensioner slider
(5).
Working on the LH side of the motorcycle, slide out the wheel shaft assembly (3) and remove the rear wheel.
Collect spacers (6) and (7).

Overhauling the rear wheel

WHEEL HUB BEARINGS
Before checking the dimensions, check for wear on wheel hub bearings. Check for wear by hand after cleaning and
degreasing the bearings in their seats.
Turn the internal ring and check that the internal balls move freely: any irregularity indicates deformations like those
indicated in values "A" and "B".
An excessive wear can cause vibrations and instability of the vehicle and therefore it is necessary to replace them.
To remove the bearings and the sealing rings from the wheel hub follow the instructions below.
Position a drift (C) against the inner ring of the bearing (10).
Tap with a hammer until removing the bearing (10).
Apply the drift at different points to facilitate the removal.
Important
Once removed, the used bearings and sealing rings must not be refitted.
Before fitting new bearings, check that the seat is clean and free from scoring and damage.
Apply the indicated product inside wheel rim seat before refitting bearing (10).
Refit bearing (10) on wheel rim seat, using a tubular drift (D) that only bears on the outer ring of the bearing (10) to
drive the latter fully home.
Use the same method to install the sealing rings (9).
Ensure that spacer (8) is fitted between the two wheel hub bearings.
Note
Wheels must be rebalanced after repair, maintenance and overhaul operations.

CHECKING SPOKE TENSION
To check spoke tension, follow the procedure below:

Set the motorcycle on the rear service stand so as to take the wheel off the ground and let it spin freely.
Briefly hit each spoke with a screwdriver and listen to the sound it makes.
Note
Sound frequency depends on spoke length and diameter.
If sound is even and clear, spoke tension is correct.

In case of a hollow sound, spoke tension is not correct and it is necessary to restore proper tensioning.
Use the torque wrench (A) part no. 88713.2777 with two inserts (B) and (C).
Tighten the nut corresponding to slack spoke to 4 Nm, using a 4 mm wrench to hold.
Warning
If there are three or more slack spokes, first tension them and then check wheel rim axial and radial clearance because
it might have deformed.

CHECKING SPOKED WHEEL RIM AXIAL AND RADIAL CLEARANCE
Check axial and radial clearance of spoked wheel rims as follows.

Set spoked wheel rim on the centring tool.
Set dial gauge at a right angle to the surface to be measured:
Reset dial gauge stylus and spin the wheel to read axial and radial clearance.
Warning
Standard axial and radial clearance should be <= 0.8 mm.
If the values measured are not within the tolerance limits, replace the wheel.
Refitting the rear wheel
If previously removed, proceed as follows to refit chain tensioner slider (4).

Apply the indicated product to the shaft thread (3).
Refit chain tensioner slider (4) on shaft (3).
Tighten chain tensioner slider (4) to a torque of 20 Nm ± 10%.
In case of tyre replacement, fit the balancing weights, respecting the values indicated in the figure.
Check the central spacer is present on the wheel rim by following the reference procedure (Overhauling the rear wheel).
Refit spacers (6) and (7) on rear wheel, aiming them as shown in the figure.
Apply the specified product to the shank and thread of the wheel shaft assembly (3).
Working on the LH side of the motorcycle, install chain on rear sprocket and refit rear wheel inside swinging arm,
making sure that spacers are correctly fitted.
Insert the wheel shaft assembly (3) on the swinging arm, aiming the chain tensioner slider as shown in the figure.
Working on the RH side of the motorcycle, refit the chain tensioner slider (5) on the wheel shaft assembly, aiming it as
Apply the specified product to nut (1).
Fit washer (2) and screw nut (1).
Check the correct chain tensioning (Adjusting the chain tension).
Removing the front brake master cylinder
Warning
The brake master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical
nature of this component. Incorrect overhaul can endanger rider and passenger safety. Maintenance operations on
these units are limited to replacement of the following parts: control lever, fluid reservoir assembly and relative
fasteners and master cylinder fasteners.
Warning
Drain the braking system fluid (Changing the front brake system fluid).
Remove the RH rear-view mirror (Removing the rear-view mirrors).
Remove the right hand guard (Removing the hand guards).
Working on motorcycle RH side, release the front brake switch wiring from fastening ties (Branch 1) and disconnect
connector (A).
Undo the special screw (1), collecting the sealing washers (2) and remove the front brake master cylinder / ABS
control unit hose (3) from the front brake master cylinder assembly (4).
Undo the screws (5) securing the U-bolt (6), and then remove the front brake master cylinder assembly (4) from the
handlebar.
Collect spacer (7).
Refitting the front brake master cylinder
Warning
Warning
Match front brake master cylinder assembly (4) and U-bolt (6) on the RH side of handlebar, by positioning them so
that the upper junction surfaces are aligned with printing (B) on the handlebar.
Secure front brake master cylinder assembly (4) and the U-bolt (6) by starting screws (5).
Tighten screws (5) to a torque of 10 Nm ± 10% following the sequence 1-2-1 starting from the upper screw.
Fit spacer (7) in the front brake master cylinder (4).
Position the front brake master cylinder / ABS control unit hose fitting (3) on the front brake master cylinder assembly
(4), interposing the NEW gaskets (2) and start the special screw (1) without tightening it.
Warning
Whenever removed, seals must be replaced by new ones on refitting.
Warning
An incorrectly positioned hose can cause system faults and interfere with moving parts.
Aim the front brake master cylinder / ABS control unit hose (3) as shown in the figure by respecting values X=36.5° ±
2° and then tighten the special screw (1) to a torque of 27 Nm (Min. 25.5 Nm - Max. 28.5 Nm).
Connect front brake switch connector (A) to the front brake switch wiring branch and refit all retaining ties (Branch 1).
Refit the right hand guard (Refitting the hand guards).

Refit the RH rear-view mirror (Refitting the rear-view mirrors).
Restore the braking system fluid (Changing the front brake system fluid).
Maintenance operations
Warning
For all maintenance operations (wear check and replacement of brake pads and brake fluids, etc.) see section
(Maintenance operations).
Removing the front brake system
Drain the front brake system fluid (Changing the front brake system fluid).
Remove the front brake master cylinder (Removing the hydraulic front brake master cylinder).
Loosen screw (1) so as to release calliper / calliper hose (2) from hose grommet (3).
Undo the special screw (4) that retains the calliper / calliper hose (2) and the hose between the front brake calliper /
ABS control unit (5) to the left front brake calliper and collect the seals (6).
Undo the special screw (7) that retains the hose between the calliper / calliper (2) to the right front brake calliper and
collect the seals (6).
Loosen the retaining screws (8) and remove the left front brake calliper (9) from the fork leg.
Loosen screws (8) and remove the right front brake calliper (10) from fork leg.
Remove the hoses between front brake calliper and ABS control unit (Routing wiring harnesses / hoses).
Smontaggio dischi freno
I dischi anteriori sono composti da una parte solidale al cerchio ruota e da una fascia frenante.
Dovendo sostituire il disco è necessario sostituire entrambi i componenti.
Rimuovere la ruota anteriore (Smontaggio ruota anteriore).

LATO SINISTRO
Svitare le viti (1), rimuovere la ruota fonica (3) e il disco freno (2) dal cerchio ruota anteriore.

LATO DESTRO
Svitare le viti (1) e rimuovere il disco freno (2) dal cerchio ruota anteriore.
Overhauling the front brake components
Important
The brake callipers manufacturer advises against servicing the brake callipers due to the safety critical nature of this
component. Incorrect overhaul of this component could endanger rider safety.
Operations should be limited to replacement of the pads, fasteners and the bleed valve assembly.
The brake disc must be clean, without any signs of rust, oil, grease or dirt and no deep scoring.
To check the wear of the brake discs, follow the data detailed in Section "Hydraulic brakes".
Refitting the brake discs
When refitting the disc on the front wheel rim, perfectly clean the bearing surfaces.

RIGHT SIDE
Check that the pre-applied threadlocker is still present on screw threads (1). Otherwise, use the indicated product.
Fit brake disc (2) on front wheel rim, and start screws (1).

LEFT SIDE
Fit brake disc (2) and phonic wheel (3) on front wheel rim, and start screws (1).
Refit the front wheel (Refitting the front wheel).
Check the AIR-GAP between speed sensor and phonic wheel (Adjusting the AIR-GAP between phonic wheel and sensor).
Refitting the front brake system
Refit the front brake master cylinder (Refitting the front brake master cylinder).
Refit the hose between front brake master cylinder and ABS control unit (Routing wiring harnesses / hoses).
Refit the front brake calliper/ABS control unit hose (Routing wiring harnesses / hoses).

Working on either sides of the motorcycle, position the left front brake calliper (9) and the right front brake callipers
(10) on fork axle lugs and start screws (8).
Upon system refitting, pay attention to the orientation of the fittings of calliper/calliper hose (2) and front brake
callipers/ABS control unit hose (5).
Position the fitting of the calliper / calliper hose (2) on the right front brake calliper, orientating it as shown in the
figure, interposing the NEW seals (6) and tighten the special screw (7).
Aim the hose between calliper/calliper (2) with respect to the front brake calliper as shown in the figure by respecting
value X = 46.6° ± 4° and then tighten the special screw (7) to a torque of 27 Nm (Min. 25.5 Nm - Max. 28.5 Nm).
Warning
If incorrectly positioned, hoses can affect brake operation and foul moving parts. Position the component as shown in
the figure.
Warning
Position the fittings of the front brake calliper/ABS control unit hose (5) and calliper/calliper hose (2) on the left front
brake calliper, orientating them as shown in the figure, interposing the NEW seals (6) and tighten the special screw
(4).
Orient the calliper/calliper hose (2) and the front brake calliper/ABS control unit hose (5) with respect to the left front
brake calliper, as shown in the figure, observing the values Y = 46.6° ± 4° and Z = 57.8° ± 4°, then tighten the
special screw (4) to a torque of 27 Nm (Min. 25.5 Nm - Max. 28.5 Nm).
Warning
If incorrectly positioned, hoses can affect brake operation and foul moving parts. Position the component as shown in
the figure.
Warning
Position the rubber block of calliper / calliper hose (2) in the appropriate seat of the hose grommet (3) on the rear side
of the front mudguard.
Close the upper flap of the hose grommet (3) and fasten it by starting the screw (1).
Fill the front braking system (Changing the front brake system fluid).
Operate the front brake lever two or three times to pressurise the circuit so that the brake pads are brought into
contact with the brake disc.
Hold the front brake lever pulled towards the handgrip and simultaneously tighten the screws (8) to a torque of 45 Nm
± 5%.
Removing the rear brake control
Warning
Drain the rear braking system fluid (Changing the rear brake system fluid).
Undo the special screw (1), remove the rear brake master cylinder/ABS control unit hose (2) from the rear brake
master cylinder (3) and recover the seals (4).
Remove the hoses between rear brake master cylinder / ABS control unit (Routing wiring harnesses / hoses).
Undo the screws (5), keeping the nuts (6) on the opposite side, and remove the rear brake master cylinder (3) from
the rod (7).
Working on motorcycle RH side, release the rear brake switch wiring from fastening ties (Branch 9) and disconnect
connector (A).
Loosen pin (8) and remove the rear brake lever (9) collecting O-rings (10), washer (11), bushing (12) and spring (13).
Loosen screw (14), keeping the nut (15) on the opposite side, and remove the rod (7) and spacer (16) from the rear
brake lever (9).
Undo the screws (17) and remove the microswitch cover (18), recovering the spacers with collar (19).
Remove the microswitch (20) from the right front footpeg holder plate (21).
Disassembling the rear brake control
The brake master cylinder is supplied only as a complete unit; internal components cannot be replaced.
If the bush (2) inside the rear brake pedal (1) needs to be replaced, grease the external surface and fit the new bush
using a press to insert it. The bush must be placed at the indicated value.
After performing an operation on the rear brake control, check the brake pedal position following the instructions
detailed in Section "Adjusting the position of the gear pedal and rear brake pedal".
Refitting the rear brake control
Fit the microswitch (20) by inserting it fully home into the holes in the right front footpeg holder plate (21).
Fit the spacers with collar (19) on the microswitch cover (18), positioning them as shown in the figure.
Position the microswitch cover (18) fully home on microswitch pins and start screws (17).
Important
Check that the microswitch cable is positioned in the respective seat of the microswitch cover. During assembly, make
sure that the cable is NOT crushed under the cover.
Insert screw (14) on rear brake lever (9).
From the opposite side, insert the spacer (16), orienting it as shown in the figure, on the threaded projection of the
screw (14).
Fit the rod (7) on the spacer (16) and start the nut (15).
Tighten screw (14) to a torque of 7.5 Nm ± 10% by counter-holding nut (15).
Insert the pad (21) on the protrusion of the rear brake lever (9), with the largest hole (B) facing outwards, as shown in
the figure.
Screw adjuster dowel (22) onto the rear brake lever (9) projection.
Tighten adjuster (22) on the rear brake lever (9) projection, until obtaining the indicated value (X) = 7 mm (0.28 in).
Screw the nut (23) onto the adjusting dowel (22), tightening it to a torque of 5 Nm ± 10%.
Apply a bead (J) of tamper-proof paste, as shown in the figure.
Check that the pre-applied threadlocker is still present on the pin (8). A maximum of three removal/refitting operations
is recommended.
Fit the first O-ring (10) on pin (8).
Apply the indicated product on the pin (8), avoiding the thread.
Insert pin (8) on the rear brake lever (9) from the indicated side, until fully home.
Apply the product indicated in the O-Ring seat of the rear brake lever (9) and insert the second O-ring (10) on the pin
(8).
Position the bushing (12) and spring (13) by inserting the curved end (C) into the seat of the brake lever assembly (9),
checking the orientation as shown in the figure.
Fit the rear brake lever assembly on the RH front footpeg holder plate and start pin (8).
During the operation, take care to position the straight end (D) of the spring (13) in correspondence with the recess of
the footpeg holder plate, as shown in the figure.
Tighten pin (8) to a torque of 24 Nm ± 10%.
Connect rear brake switch connector (A) to the rear brake switch wiring branch and refit all retaining ties (Branch 9).
Apply the indicated product on the stem of rod (7).
Insert the rear brake master cylinder (3) onto the rod (7) and start the screws (5).
On the opposite side, screw nuts (6) on the threaded end of screws (5).
If previously removed, refit the hoses between rear brake master cylinder / ABS control unit (Routing wiring harnesses /
hoses).
Position the rear brake master cylinder / ABS control unit hose fitting (2), aiming it as shown in the figure, on the rear
brake master cylinder (3), interposing the NEW gaskets (4) and start the special screw (1) without tightening it.
Warning
Note
Pay particular attention to the hose routing and hose coupling on the rear brake master cylinder.
Aim the hose between rear brake master cylinder / ABS control unit (2) with respect to the rear brake master cylinder
(3) as shown in the figure by respecting value Y = 41.7° ± 4° and then tighten the special screw (1) to a torque of 27
Nm (Min. 25.5 Nm - Max. 28.5 Nm).
Fill the rear braking system (Changing the rear brake system fluid).
Check that rear brake pedal has a free play (X) = 2 ÷ 5 mm (0.08 ÷ 0.19 in) before the brake bites.
If not, modify the length of the cylinder push-rod in the following mode.
• Loosen the lock nut (E) on the master cylinder rod.

• Tighten the lock nut (E) to a torque of 7.5 Nm ±10%, and check play again.
Removing the rear brake calliper
Important
The brake calliper manufacturer advises against servicing the brake calliper or master cylinder due to the safety critical
nature of this component. Incorrect overhaul can endanger rider and passenger safety.
Remove the rear wheel (Removing the rear wheel).

Drain the rear braking system fluid (Changing the rear brake system fluid).
Undo special screw (1), remove rear brake calliper / ABS control unit hose (2) and collect seals (3).
Slide out the rear brake calliper (4) from relevant calliper holder plate (5).
Remove the hoses between rear brake calliper / ABS control unit (Routing wiring harnesses / hoses).
To replace the brake pads follow instructions in "Checking brake pad wear and replacing rear brake pads".
Only the following parts should be replaced:
• Calliper: pads, fasteners and bleed valve assembly.

• Master cylinder: control pedal, bleed valve assembly, reservoir and relevant components.
Removing the rear disc.
Loosen the screws (1), and remove the phonic wheel (2) and brake disc (3).
Refitting the front brake disc
When refitting the brake disc on the rim, perfectly clean the bearing surfaces.
Fit brake disc (3) and phonic wheel (2) on rear wheel rim, and start screws (1).
Refit the rear wheel (Refitting the rear wheel).

Refitting the rear brake calliper
Important
The brake calliper manufacturer advises against servicing the brake calliper or master cylinder due to the safety critical
nature of this component. Incorrect overhaul can endanger rider and passenger safety.
If removed, insert pin (7) in the calliper holder plate (5) after having lubricated it with the indicated product.
Check for the presence of spring (6) and dust seal (8).
Position the calliper holder plate (5) on the swinging arm and start screw (9).
Ensure that the calliper holder is engaged on the relevant guide on swinging arm.
Apply the indicated product to rear calliper pin (10) and insert it inside calliper holder plate (5).
If previously removed, refit the hoses between rear brake calliper / ABS control unit (Routing wiring harnesses / hoses).
Position the rear brake calliper/ABS control unit hose union (2) on the rear brake calliper, by placing the NEW seals (3)
in-between and start the special screw (1), without tightening.
Warning
Warning
Aim the hose between rear brake calliper / ABS control unit (2) with respect to the rear brake calliper (4) as shown in
the figure by respecting value X = 3.4° ± 4° and then tighten the special screw (1) to a torque of 27 Nm (Min. 25.5
Nm - Max. 28.5 Nm).

Fill the rear braking circuit (Changing the rear brake system fluid).
Operating principle
The Ducati ABS brake system manages the front and rear brake systems separately. The operating mechanism
consists of a pulse generator (phonic wheel), with a ring of slots, fitted onto each wheel. There are sensors on LH fork
leg bottom end and on rear brake calliper holder plate. With vehicle running, they read the slots on the phonic wheel
thereby detecting instant wheel speed. These sensors output data to ABS control unit, which contains software with a
special control algorithm developed by Ducati. The software compares the vehicle average speed with the instant
wheel speed reading and assesses any slipping condition. If control values are exceeded when the rider commands a
certain pressure on brake calliper, the control unit shall hydraulically control the braking system, which is nearly locked
up. The system can modulate pressure at the calliper through a set of solenoid valves which first prevent any further
increase of hydraulic pressure (1 valve closing), and then make the pressure decrease (2 valve opening). The 2 valve
is opened in a series of pulses (with less than 10 milliseconds between successive pulses), to reduce pressure in steps.
When the wheel begins to turn again in response to the diminished braking force applied and its rotation speed
reaches the reference value, the exhaust valve 2 will be closed. Simultaneously, the inlet valve 1 is reopened,
restoring normal operation of the brake system. The ABS control unit can monitor and modulate brake force in the
three following different conditions: dry road surface (high grip), wet or slippery road surface (poor grip) and uneven
road surface. The ABS is activated when the vehicle exceeds 5 km/h for the first time since key-on.
The hydraulic component of the ABS system consists of a primary circuit (from the cylinder to the control unit and
from the control unit to the calliper) and a secondary circuit (completely within the control unit).
Please find below a chart explaining ABS hydraulic operation.
Key to ABS hydraulic system colours:

Green: oil delivery
Light blue: oil return
Key to ABS hydraulic system

A Rear brake master cylinder

B Front brake master cylinder

1A Rear brake calliper inlet valve

1B Front brake calliper inlet valve

2A Rear brake calliper exhaust valve

2B Front brake calliper exhaust valve

3 Brake master cylinder

4 Little tanks

5A Rear calliper

5B Left front calliper

6B Right front calliper

7 Pressure transducer
Brake system diagram.

Braking without ABS.
ABS 1 modulation: braking.

ABS 2 modulation: pressure partial reduction on callipers.
ABS 3 modulation: pressure total reduction on callipers.

ABS system operation information
The operation of the system is based on the analysis of the speed signals for front and rear wheels; the system is
automatically deactivated if either of these signals is missing.
Note
In the event of the ABS control unit detecting a fault in the ABS electronic management system, it activates the
specific fault warning indicator on the instrument panel and restores conventional braking functionality without ABS.
Hydraulic faults in the brake system and faults not directly related to the ABS system (e.g.: worn brake pads) cannot
be detected by the ABS control unit.
Important
The operation of the system is based on the values read for the front and rear wheel speeds; take great care not to
damage the phonic wheels and relative speed sensors when removing the wheels or when working close to these
components; the phonic wheels damage may compromise the operation of the system and cause dangerous
malfunctions.
ABS diagnosis
The diagnostic function of the ABS ascertains the functionality of the main system components via hardware/software
tests, but cannot modify the operating parameters of the ABS strategy.
From the model menus of the DDS 3.0 diagnosis software, select Desert X family, then model Desert X, and then
select bike model year and press Global Scan button.
Now connect tester to bike CAN diagnostic socket, to locate connector refer to the video displayed in screen showing
the diagnostic connector position on bike.
Wait for the correct configuration to be loaded and, when requested, switch the vehicle to key-on state.
Tester communicates to the different control units present on bike, ABS control unit included; wait for the scan to be
completed.
Among the displayed information a "dot" icon is shown: based on its colour, it refers to validated errors inside the
different control units.
In particular, if errors are stored, icon will be yellow or if errors are currently present, icon will be red, while if no errors
are present, icon will be green.
To make a deeper analysis of the ABS control unit, select ABS control unit and SELF-DIAGNOSIS or, as an alternative,
make a double selection on the same item with your mouse.
Once in this configuration, a number of parameters and states of the ABS control unit and information concerning the
control unit itself may be selected and displayed.
The INFO menu allows reading the software version loaded on the control unit as well as other information.
Select the function "View parameters and states"
This function allows the tester to display the following ABS system parameters and states:
Viewable parameters
Viewable states
Select the function "View errors"
This tester function provides the user with information concerning the error list in the ABS control unit memory,
indicating if errors are stored or current. The following codes are given after a short description of the diagnosis type:
MEM, indicating that the error has been stored previously by the ABS control unit but has not been detected in the
current test session. ATT, indicating that the error is current and has been detected during the current test session.
Note
While ATT indicates that the error has been found during the current test session, it does not necessarily indicate that
the error is actually active at the time of indication. For example: disconnecting the front wheel speed sensor causes
the code ATT to be displayed after the error description, but the code continues to be displayed even once the cause of
its activation has been eliminated by reconnecting the sensor, as the ABS will only check sensor operation again after
the next key-off/key-on cycle. As a result, always perform a key-on/key-off cycle after any work on the ABS system,
interrupting and re-establishing communication between the diagnostic instrument and the ABS control unit before
checking the updated ABS error list again.
The abbreviations for all the errors displayed are given as follows:

Description PCODE

Front wheel speed sensor [Open circuit and short-circuit to ground or positive] C1033

Front wheel speed sensor [Mismatching signal] C1034

Rear wheel speed sensor [Open circuit and short-circuit to ground or positive] C1031

Rear wheel speed sensor [Mismatching signal] C1032

Front brake calliper pressure sensor inside ABS control unit [Hardware error] C1331

Front brake calliper pressure sensor inside ABS control unit [Offset error] C1332

Pressure sensor power supply error inside the ABS control unit C1333

Speed sensor [Front and rear wheel speed comparison error] C1024

ABS front inlet valve fault C1054

ABS front outlet valve fault C1049

ABS rear inlet valve fault C1052

ABS rear outlet valve fault C1048

ABS pump motor fault C1015

ABS solenoid valve relay malfunction C1014

ABS control unit fault C1021

ABS control unit [Long undervoltage] C1058

ABS control unit [Long overvoltage] C1059

CAN controller hardware malfunction U2925

CAN line error (BUS-OFF) U2922

CAN communication error with instrument panel control unit U2923

Error from engine control unit U2929

CAN communication error with BBS control unit U2926

Wrong IMU control unit assembly C1092

IMU signal plausibility error C1094

Signal not valid from IMU control unit U2927

CAN communication error with IMU control unit U2928

Description PCODE

ABS control unit [Undervoltage] U2930

ABS control unit [Overvoltage] U2931

Wrong vehicle variant C1335

Error from BBS control unit [frame BBS_Data_03] U2924

Vehicle variant not configured in EEPROM C1334

Wrong IMU control unit U2332

IMU MEMS internal error C051C

IMU internal memory error C051D

IMU microcontroller internal supervisor error C051E

IMU microcontroller SW compliance error C0520

CAN line error (BUS-OFF) U0001

Odometer information missing error U0100

IMU microcontroller internal error upon initialisation U3012
ABS system deactivation
ABS (Antilock Braking System) intervention can be customised and possibly disabled.
ABS can only be deactivated if the riding mode is set to "ENDURO" or "RALLY".
The ABS can only be deactivated with the motorcycle at a standstill.
The ABS will be automatically reactivated when the instrument panel is switched on, even if it had been disabled
during previous use.
To temporarily disable the ABS, press and hold button (A).

The warning "Hold to disable ABS" (B) will be displayed followed by "Release to disable ABS".
• If the “ABS” button is released too soon, the message “ABS still active” (C) will be displayed for a few seconds.
• If the disable procedure has been carried out correctly, the "ABS Off" warning (D) is displayed.
Warning
The “ABS Off” warning will remain active as long as the ABS system is disabled. Press the “ABS OFF” button to re-
enable the ABS system - once re-enabled the “ABS Off” warning will disappear.
If you are attempting to disable the ABS while in a riding mode other than Rally or Enduro, "Not allowed in current
riding mode" will be displayed for a few seconds.
Changing the front phonic wheel sensor

REMOVAL

Remove the front mudguard (Soft link to serviceCode:DSX.05.040.001 not exists).
Disconnect front speed sensor connector (A) from the main wiring.
Remove all ties and fasteners from the front speed sensor wiring (Branch 6).
Loosen the fixing screw (1) and remove the front speed sensor (2) with its calibrated shims (3).

REFITTING
Before refitting, make sure that contact parts between front speed sensor (2) and its seat are free of damage and
perfectly clean.
Fit the front speed sensor (2) with its calibrated shims (3) in its seat and start the screw (1).
Check air-gap between front speed sensor (2) and front phonic wheel as explained under "Adjusting the AIR-GAP of phonic
wheel sensor".
Tighten screw (1) to a torque of 8 Nm ± 10%.
Reposition the front speed sensor wiring by restoring all fasteners (Branch 6).
Connect front speed sensor connector (A) to the front speed sensor wiring branch.
Refit the front mudguard (Refitting the front mudguard).

Changing the rear phonic wheel sensor

REMOVAL
Remove the RH underseat cover (Removing the side body panels and the tail guard).
Working on motorcycle RH side, release the rear speed sensor wiring from fastening ties (Branch 9) and disconnect
connector (A).
Loosen the fixing screw (1) and remove the rear speed sensor (2) with its calibrated shims (3).

REFITTING
Before refitting, make sure that contact parts between rear speed sensor (2) and its seat are free of damage and
perfectly clean.
Fit the rear speed sensor (2) with its calibrated shims (3) in its seat and start the screw (1).
Check air-gap between rear speed sensor (2) and rear phonic wheel as explained in chapter "Adjusting the AIR-GAP of
phonic wheel sensor".
Reposition the rear speed sensor wiring by restoring all fasteners (Branch 9).
Connect rear speed sensor connector (A) to the rear speed sensor wiring branch.
Refit the RH underseat cover (Refitting the side body panels and the tail guard).
Removing the ABS control unit
Drain the front braking system (Changing the front brake system fluid).
Drain the rear braking system (Changing the rear brake system fluid).
Disconnect connector (1) from the ABS control unit (2).
Remove the Purge valve (3) sliding it out of ABS support bracket.
Remove the canister assembly (4) sliding it out of ABS support brackets (A).
Loosen the special screws (5) that retain hoses (6), (7), (8) and (9), removing the relevant seals (10).
Warning
Working on either sides of the motorcycle, loosen screws (11) and remove ABS support assembly (12) from the frame.
Loosen screws (13) and remove the ABS control unit (2) from ABS control unit support (12).
Important
Do not open the ABS control unit: if faulty, replace it.
Should it be necessary to replace one or several hoses, refer to "Routing wiring harnesses/hoses".
Refitting the ABS control unit

PRE-FITTING THE ABS CONTROL UNIT SUPPORT
Fit clips (13) in the indicated areas of ABS control unit support (12), aiming them as shown in the figure.
Fit vibration dampers (14) on ABS control unit support (12).
Insert the spacers with collar (15) in the vibration dampers (14), orienting them as shown in the figure.
Fit rubber pads (16) on ABS control unit support (12), letting poppets (B) completely come out on the opposite side.
Remove the protective film (C) on the rear side of the neoprene pad (17).
Apply the pad (17) on the ABS control unit support (12) as shown in the figure, by evenly pressing on the whole pad
surface to make it perfectly adhere.
Apply a drop of the indicated product in the centre of the groove of the rubber sheath (18), smearing the product on
the whole inner surface.
Fit the sheath (18) on the relevant profile of ABS control unit support (12), as shown in the figure.
Evenly press on the whole outer surface of the sheath (18), making it adhere perfectly.
Immediately remove any product excess coming out of the sheath (18).

Position the ABS control unit (2) on the ABS control unit support (12), aiming it as shown in the figure and start the
screws (13).
Tighten the screws (13) to a torque of 6.8 Nm ± 10%.
Important
Do not open the ABS control unit: if faulty, replace it.
Place the ABS support (12) inside the frame, as shown in the figure.
Working on either sides of the motorcycle, start screws (11) that fix the ABS support (12) to the frame.
Hoses (6), (7), (8) and (9) must be secured in place using NEW seals (10) on unions and starting special screws (5).
Warning
Tighten special screws (5) to a torque of 27 Nm (min. 25.5 - max. 28.5), aiming the hoses with respect to the ABS
control unit (2) as indicated by the values:
• X = 43.9° ± 4° ABS control unit / front brake calliper hose (6).

• Y = 43.5° ± 4° ABS control unit / front brake master cylinder hose (7).
• J = 33.2° ± 4° ABS control unit / rear brake master cylinder hose (8).
• Z = 33° ± 4° ABS control unit / rear brake calliper hose (9).
Refit the canister assembly (4) fitting it on ABS support brackets (A).
Fit the Purge valve (3) in the ABS support bracket.

Connect connector (1) to the ABS control unit (2).
Important
If the ABS hydraulic control unit has been replaced, it will be supplied with the secondary circuit already filled with
fluid. Control unit must thus be assembled and the system filled and drained as a traditional system.
Fill the front braking system (Changing the front brake system fluid).
Fill the rear braking circuit (Changing the rear brake system fluid).

Routing wiring harnesses/hoses
The routing of the ABS system wiring has been optimised to ensure the minimum obstruction.
Each section is designed to prevent interference with parts that might damage wires or cause operating failures when
riding.
• ABS control unit / front brake calliper hose (1).

• ABS control unit / front brake master cylinder hose (2).
• ABS control unit / rear brake calliper hose (3).
• ABS control unit / rear brake master cylinder hose (4).
• Calliper / calliper hose (5).

CENTRAL AREA HOSES

POSITION TYPE INVOLVED PARTS NOTES

(A) Big self-locking ABS control unit / front brake master cylinder hose (at the rubber Tie to ABS hose
tie block) bracket

ABS control unit / front brake calliper hose (at the rubber block)

(B) Insert the front brake calliper / ABS control unit hose inside hose
grommet fixed to the frame.

FRONT AREA HOSES


(A) Big self-locking ABS control unit / front brake master cylinder hose (at the rubber Tie to ABS hose
tie block) bracket



(C) Fast Point ABS control unit / front brake calliper hose


(D) Hose clamp ABS control unit / front brake calliper hose (at the rubber block) Fix to bottom yoke


(A) Big self-locking tie ABS control unit / front brake master cylinder hose (at the rubber Tie to ABS hose
block) bracket



(E) Special rubber tie ABS control unit / front brake master cylinder hose

Throttle cable and connectors



(F) L. 39 mm (1.53 in) ABS control unit / front brake master cylinder hose
button tie
Throttle cable



(G) Hose clamp ABS control unit / front brake master cylinder hose Tie to the steering
head


Throttle cable

REAR AREA HOSES


(H) Small self-locking tie ABS control unit / rear brake master cylinder hose



(L) Small self-locking tie ABS control unit / rear brake master cylinder hose


(M) L. 62 mm (1.53 in) button tie ABS control unit / rear brake hoses

Rear stop sensor connector, cable and wiring branch



(L) Small self-locking tie ABS control unit / rear brake master cylinder hose


(N) Big self-locking tie ABS control unit / rear brake master cylinder hose (at the Tie to ABS hose
rubber block) bracket

ABS control unit / rear brake calliper hose (at the rubber
block)

(P) Small self-locking tie ABS control unit / rear brake master cylinder hose


(Q) Hose clamp ABS control unit / rear brake calliper hose Fix to the rear swinging
arm

(R) L. 39 mm (1.53 in) ABS control unit / rear brake master cylinder hose
button tie
Rear fluid reservoir hose


(P) Small self-locking tie ABS control unit / rear brake master cylinder hose


(Q) Hose clamp ABS control unit / rear brake calliper hose Fix to the rear swinging arm
Adjusting the AIR-GAP of phonic wheel sensor
Important
The following procedure applies both to the front and the rear adjustment.
The adjustment must be performed in any case of maintenance that requires the following components to be removed
and refit:
• Replacing or refitting the wheel.

• Replacing or refitting the front speed sensor (1).
• Replacing or refitting the front phonic wheel (2).
• Replacing or refitting the brake discs.
• Replacing or refitting the rear phonic wheel (3).
• Replacing or refitting the rear speed sensor (4).
• (Front) replacing or refitting the forks.
• (Rear) replacing or refitting the calliper holder plate.
Refit the front (1) and rear (4) speed sensors by placing the calibrated shims (A) in-between and start screws (5).
The AIR-GAP between ABS sensor and phonic wheel must be within 1.3 mm ÷ 1.9 mm.
For this purpose, use a feeler gauge to check the air-gap; then, carry out three measures of the air-gap, one every
120° of wheel turn.
If the difference between the minimum and maximum values measured is higher than 0.40 mm, replace the phonic
wheel.
Once checked that the difference is lower than or equal to 0.40 mm (0.016 in), carry out the shimming of the front (1)
or rear (4) speed sensor by means of the suitable calibrated shims (A).
The shims used measure 0.2 mm (0.008 in) or 0.5 mm (0.02 in).
Use them as required to reach the correct shimming.
Warning
Shim pack shall never exceed 3 mm.
Phonic wheels cleaning

It is important to check that both phonic wheels (2) and (3) are always clean.
Avoid using solvents, abrasives and aiming air or water jets directly on the phonic wheel (2) or (3).
Bleeding of the ABS hydraulic system
If brake controls feel "spongy" due to the presence of air bubbles in the system, bleed as usual, as described in
chapter "Changing the front brake system fluid" and "Changing the rear brake system fluid".
Before bleeding a brake master cylinder, move back the calliper pistons to let any air build-up in the ABS control unit
flow into the master cylinder.
Purge must be carried out by means of the corresponding unions (A) placed on the callipers and the brake master
cylinders.
Important
Do not undo the special screws securing the pipe unions on the ABS hydraulic control unit, unless control unit
replacement is necessary.
Important
If the ABS hydraulic control unit has been replaced, it will be supplied with the secondary circuit already filled with
fluid. Control unit must thus be assembled and the system filled and drained as a traditional system.
Removing the rear-view mirrors
Loosen lock nuts (3).

Loosen the LH rear-view mirror (1) clockwise and the RH rear-view mirror (2) counter clockwise, respectively.
Refitting the rear-view mirrors
Screw the left rear-view mirror (1) clockwise and the right rear-view mirror (2) counter clockwise, respectively.
Tighten the lock nuts (3) to a torque of 40 Nm ± 10%.
Note
It is possible to manually adjust the left (1) and right (2) rear-view mirrors in the possible directions indicated by the
arrows; this type of adjustment must be carried out with care to avoid forcing the position of the rear-view mirror, thus
damaging it.
Removing the hand guards
The following procedure applies to both hand guards hence, the procedure to be adopted on the RH hand guard
assembly is used as an example.
Loosen the screw (1) with the washer (2) that retain the RH hand guard assembly (3) to the front brake master
cylinder, keeping the nut (4) with the other washer (2) on the opposite side.
Loosen screw (5) without completely unscrewing it and remove RH hand guard assembly (3).
If necessary, remove spacer (6) from the front brake master cylinder assembly.

REMOVING THE RH HAND GUARD ASSEMBLY
Loosen screws (7) and remove arm (8) from hand guard (9).
Reassembling the hand guards
The following procedure applies to both hand guards hence, the procedure to be adopted on the RH hand guard
assembly is used as an example.

PRE-FITTING THE RH HAND GUARD ASSEMBLY
If previously removed, refit counterweight (10) on hand guard (9).

Insert screw (5) inside hand guard hole (9), placing spacer with collar (11) in-between, and aiming it as shown in the
figure.
Insert on screw thread (5): counterweight (10), spacer (12), bushing (13) and counter bushing (14), aiming
components as shown in the figure.
Loosen screw (5) on counter bushing (14) without tightening it.
Position the arm (8) on the hand guard (9), aiming it as shown in the figure and start the screws (7).
Fit spacer (6) in the front brake master cylinder assembly.
Refit the RH hand guard assembly (3) by inserting counterweight fully home on handlebar, positioning it as shown in
the figure.
Insert washer (2) on the thread of screw (1).

Start screw (1) retaining RH hand guard assembly (3) to front brake master cylinder.
From the opposite side, insert the other washer (2) on the threaded end of screw (1) and screw nut (4).
Tighten screw (1) to a torque of 10 Nm ± 10% by holding nut (4) on the opposite side.
Removing the handlebar
Remove the rear-view mirrors (Removing the rear-view mirrors).

Remove the hand guards (Removing the hand guards).
Remove the throttle control (Removing the throttle control).
Remove the front brake master cylinder (Removing the hydraulic front brake master cylinder).
Remove the clutch master cylinder (Removing the clutch master cylinder assembly).

REMOVING THE LEFT HANDGRIP
Slide the LH handgrip (1) out of the handlebar using a pressure air gun.

REMOVING THE HEATED HANDGRIPS
To remove the handlebar, we recommend not to disconnect the heated handgrips but to slide them out.
If it is necessary to remove them for replacement reasons, proceed as follows.
Left handgrip
Disconnect the LH heated handgrip connector (A) and all its fixing points (Branch 3).
Remove the two protection plugs (3) and loosen the two retaining screws (4).
Slide the heated handgrip (5).
Right handgrip
The "heating" system is integrated in the throttle control.
Remove the throttle control (Removing the throttle control).
Disconnect the LH heated handgrip connector (B) and all its fixing points (Branch 1).

REMOVING THE SWITCHES
The following procedure applies to both switches hence, the procedure to be adopted on the left-hand switch is used as
an example.
Disconnect connector (C) from left-hand switch.
Insert tool (D) part no. 88713.4967 inside seat (E) of left-hand switch (6).
Push tool (D) until releasing left-hand switch (6).
Slide LH switch (6) out of the handlebar and collect the support (7).

REMOVING THE HANDLEBAR
Loosen the four screws (8) and remove the two upper U-bolts (9).
Remove handlebar (10) from its seat of the lower U-bolt (11).
Refitting the handlebar
The handlebar features an adjustment that allows the rider’s posture to be customised based on the riding conditions.
The dual adjustment can be either “ROAD” or “OFF” (Off Road).
Note
In the following picture, with alignment to the lower reference mark, the handlebar is installed in “OFF” mode.
Centre the handlebar (10) on the bottom U-bolt (11) so that the silk-screen prints (F), depending on the customer’s
request, coincide with the side edges of the bottom U-bolt (11).

Refit the two upper U-bolts (9) on handlebar (10), as shown in the figure and start the screws (8) without tightening.
Check that the handlebar (10) has remained correctly in place, centred on the bottom U-bolt.
Tighten screws (8) to a torque of 25 Nm ± 5%, in the sequence 1-2-3-4-1-2, as shown in the figure.

REFITTING THE SWITCHES
The following procedure applies to both switches hence, the procedure to be adopted on the left-hand switch is used as
an example.
Position support (7) by inserting pin inside handlebar hole (10), and aiming tooth (E) towards handlebar inner side, as
Fit left-hand switch (6) on handlebar (10), driving it fully home on support (7).
Check that the switch is correctly blocked.
Connect connector (C) to left-hand switch.

HEATED HANDGRIPS
Left handgrip
Fit heated handgrip (5) inside handlebar.

Disconnect the LH heated handgrip connector (A) and all its fixing points (Branch 3).
Position the heated handgrip wiring and restore its fixing points (Branch 3).
Connect the LH heated handgrip connector (A) to the main wiring.
Right handgrip
The "heating" system is integrated in the throttle control.

Refit the throttle control (Refitting the throttle control).
Position the heated handgrip wiring and restore its fixing points (Branch 1).
Connect the RH heated handgrip connector (B) to the main wiring.

REFITTING THE LEFT-HAND HANDGRIP
Fit the LH handgrip (1) in the handlebar using a pressure air gun.
Refit the clutch master cylinder (Refitting the clutch master cylinder assembly).
Refit the front brake master cylinder (Refitting the front hydraulic brake master cylinder).
Refit the throttle control (Refitting the throttle control).
Refit the hand guards (Refitting the hand guards).
Refit the rear-view mirrors (Refitting the rear-view mirrors).
Removing the throttle control

Remove the right hand guard (Removing the hand guards).
Disconnect the throttle control connector (1) from the throttle wiring branch.
Remove all the ties preventing wiring removal (Branch 1).
Loosen screws (2) partially and slide throttle control (3) out of handlebar.
Important
Pay special attention NOT to completely loosen screws, to avoid compromising the correct operation of throttle control.
Refitting the throttle control
Fit throttle control (3) by inserting the pin (A) in the hole (B) on handlebar (4).
Assemble the two parts of the throttle control.

Tighten the screws (2) to 3.5 Nm ± 10%, following a 1-2-1 sequence.
Position throttle control wiring by restoring all the fastening ties (Branch 1).
Connect the throttle control connector (1) to the throttle wiring branch.
Refit the right hand guard (Refitting the hand guards).
Removing the clutch master cylinder assembly
Warning
The clutch master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical
nature of this component. Incorrect overhaul of this component could endanger rider safety.
Warning
Drain the clutch system (Changing the clutch system fluid).

Remove the LH rear-view mirror (Removing the rear-view mirrors).
Remove the LH hand guard (Removing the hand guards).
Working on the LH side of the motorcycle, release the clutch switch wiring from fastening ties (Branch 3) and
disconnect connector (A).
Loosen the special screw (1), collecting the seals (2) and remove clutch hose (3) from the clutch master cylinder
assembly (4).
Undo the screws (5) securing the U-bolt (6), and then remove the clutch brake master cylinder assembly (4) from the
handlebar.
Collect spacer (7).
Refitting the front brake master cylinder
Warning
The clutch master cylinder manufacturer advises against servicing the brake master cylinder due to the safety critical
nature of this component. Incorrect overhaul of this component could endanger rider safety.
Warning
Match clutch master cylinder assembly (4) and U-bolt (6) on the LH side of the handlebar, positioning them so that the
upper junction surfaces are aligned with printing (B) on the handlebar.
Secure clutch master cylinder assembly (4) and U-bolt (6) by starting screws (5).
Tighten screws (5) to a torque of 10 Nm ± 10% following the sequence 1-2-1 starting from the upper screw.
Fit spacer (7) in clutch master cylinder assembly (4).
Position the clutch hose union (3) on the clutch master cylinder assembly (4) by placing NEW seals (2) in-between and
start special screw (1), without tightening.
Warning
Warning
Aim clutch hose union (3) as shown in the figure, by respecting value X = 36.5° ± 2°, then tighten special screw (1) to
a torque of 27 Nm (Min. 25.5 Nm - Max. 28.5 Nm).
Connect clutch switch connector (A) to the clutch switch wiring branch and refit all retaining ties (Branch 3).
Refit the left hand guard (Refitting the hand guards).

Refit the LH rear-view mirror (Refitting the rear-view mirrors).
Restore the clutch system fluid (Changing the clutch system fluid).
Removing the clutch assembly
Warning
Drain the clutch system (Changing the clutch system fluid).
Loosen the retaining screws (1) of the clutch slave cylinder unit (2).
Slide out the clutch slave cylinder (2).
Loosen special screw (3) with the relevant washers (4) and remove the clutch hose (5).
Refitting the clutch assembly
Warning
Apply the specified product to seal (6).

Fit seal (6) onto the clutch slave cylinder unit (2).
Lay clutch slave cylinder unit (2) on the engine and aim it as shown in the figure, inserting it on clutch pin (A), then
start screws (1).
Tighten screws (1) to a torque of 10 Nm ± 10%, following a 1-2-3-1 sequence.
Note
To bring the clutch slave cylinder internal surface near the casing cover as evenly as possible, screw and tighten the
retaining screws alternatively in steps.
Position the clutch hose (5) on the clutch slave cylinder unit by placing NEW seals (4) in-between and start the special
screw (3), without tightening.
Warning
Warning
Aim clutch hose union (5) as shown in the figure with respect to clutch slave cylinder unit (2), by respecting value X =
95° ± 4°, then tighten special screw (3) to a torque of 27 Nm (Min. 25.5 Nm - Max. 28.5 Nm).
Restore the clutch system fluid (Changing the clutch system fluid).

CLUTCH SYSTEM HOSE POSITIONING


(A) L. 39 mm (1.53 in) button tie Clutch hose


Clutch switch cable

LH heated handgrip cable (optional)

(B) L. 39 mm (1.53 in) button tie Clutch hose


Clutch switch cable



LH heated handgrip cable (optional)

(C) Hose clamp Clutch hose Hose grommet welded to frame

(D) L. 82 mm (3.23 in) button tie Clutch hose Tie to the frame
Removing the steering damper

REMOVING THE STEERING DAMPER WITH SUPPORTS
Loosen the screws (1) that retain the steering damper support (2) to the steering head.
Unscrew the screws (3) and remove the steering damper assembly (4).

REMOVING THE STEERING DAMPER WITHOUT SUPPORTS
Loosen the screw (5) with spacer (6) that retain the steering damper (4) to the steering damper support.
Loosen screw (7) and slide steering damper (4) out of the relevant damper clamp (8).
Loosen screw (9) and remove damper clamp (8) from lower steering damper support (12), collecting O-ring (10) and
spacer (11).
Refitting the steering damper

REFITTING THE STEERING DAMPER WITH SUPPORTS
Position the steering damper (4) on its support and start the screws (3).
Start the screws (1) that retain the steering damper support (2) to the steering head.

REFITTING THE STEERING DAMPER WITHOUT SUPPORTS
If previously removed, fit the ball joint (13) fully home in its seat on the damper clamp (8).
Lock the ball joint (13) by making no. 3 chamfers at 120° in points (A) on the damper clamp (8), as shown in the
figure.
Start screw (9) in the damper clamp.

Insert the spacer (11) with O-ring (10) on screw threaded end (9), aiming it as shown in the figure
Position the damper clamp (8) on the lower steering damper support (12) and start screw (9).
Fit the steering damper (4) centring it on the larger diameter section (B) (highlighted in red) into its damper clamp (8)
and start screw (7).
Start the screw (5) with spacer (6) that retain the steering damper (4) to the steering damper support.
Removing the ignition switch
Disconnect key switch (A) and immobilizer antenna (B) connectors and remove all ties preventing wiring removal
(Branch 3).
Loosen screws (1) and remove key switch assembly (2) from the steering head.
Refitting the ignition switch

Position key switch (2) on the steering head and start screws (1).
Connect key switch (A) and immobilizer antenna (B) connectors and refit all wiring ties (Branch 3).
Removing the gear change control
Engage the first gear.

Loosen screw (1) by holding nut (2) on the opposite side.
Loosen screw (10), holding nut (11) on the opposite side, remove Quick-shift control (12) and collect spacer (13).
Loosen screws (3) and remove sump guard bracket (4).
Remove the special ties (5), releasing the Quick-Shift control cable from the sump guard bracket (4).
Remove the self-locking tie (6), releasing the Quick-Shift control cable from the side stand sensor cable.
Disconnect the Quick-Shift control connector (7).
Mark the position of the gearbox con-rod (8) on the gear selector shaft, close to the opening (A), as shown in the
figure.
Loosen the screw (9) and remove the gearbox con-rod (8).
Loosen pin (14) and remove the gearchange lever (15) collecting O-rings (16) and washer (17).
Disassembling the gear change control
If the bushing (A) inside gearbox pedal (1) needs to be replaced, apply the indicated product to the outer surface of
bushing (A) and fit it on the gearbox pedal (1) using a press. The bushing must be centred in its seat, between the two
outer surfaces.
Warning
After working on the gear change control, check the position of the gear pedal.
Refitting the gear shift

PRE-ASSEMBLING THE QUICK-SHIFT CONTROL
Fully screw, without tightening, the nut (17) on the uniball threaded pin (18).
Apply the indicated product to the uniball (18) thread (D).
Screw the uniball (18) on the Quick-Shift control (12), until the distance between centres (X) is 98 ± 0.5 mm (3.86 ±
0.02 in).
Screw the nut (17) fully home on the Quick-shift control (12) and tighten it to a torque of 5 Nm ± 10%.
Once adjustment is completed, the uniball (18) and the Quick-Shift control (12) seats must be aligned on the same
surface.

REFITTING THE GEAR SHIFT
Fit the first O-ring (16) on pin (14).

Grease pin (14) stem with the indicated product, avoiding the thread.
Insert pin (14) on gearchange lever (15) from the indicated side, until fully home.
Apply product to grease O-ring seat onto gearchange lever (15), and insert the second O-ring (16) on pin (14).
Fit the washer (17) on pin (14).
Check that the pre-applied threadlocker is still present on the pin (14). Otherwise, use the indicated product.
Refit gearchange lever assembly on LH front footpeg holder plate and start pin (14).
Tighten pin (14) to a torque of 23 Nm ± 10%.
Position the gearbox con-rod (8) on the gear selector shaft, by timing the opening (A) with the previously-made
marking, as shown in the figure.
Start screw (9) of the gearbox con-rod (8).
Connect the Quick-Shift control connector (7).
Fasten the side stand cable to the Quick-Shift control connector, using self-locking tie (6).
Refit the special ties (5), securing the Quick-Shift control cable to the sump guard bracket (4).
Position sump guard bracket (4) and start screws (3).

Start screw (10) on the gearchange lever, insert spacer (13) and Quick-Shift control (12) on the thread of screw (10),
and screw nut (11).
Tighten screw (10) to a torque of 10 Nm ± 10% by counter-holding nut (11).
Position the Quick-Shift control close to the gearbox con-rod and start screw (1).
On the opposite side, start nut (2) on the thread of screw (1).
Removing the front fork
Before removing this part, it is first necessary to remove the following parts:
Remove the front brake callipers (Removing the front brake system).
Remove the front mudguard (Soft link to serviceCode:DSX.05.040.001 not exists).
Remove the front wheel (Removing the front wheel).
Remove the phonic wheel sensor (Replacing the front phonic wheel sensor).
Loosen screws (1) and remove LH mudguard support bracket (2).
Loosen screws (1) and remove RH mudguard support bracket (3).
Loosen the screws (4) securing the fork legs to the steering head (5).
Loosen the screws (6) securing the fork legs to the bottom yoke (7).
Pull out the LH fork leg (8) and RH fork leg (9) downwards in order to carry out all the necessary overhaul operations.
Overhauling the front fork

GENERAL SAFETY RULES
Carefully read the procedures below before working on the fork for any reason whatsoever.
Please remember that suspension installation, maintenance and repair require specific knowledge, equipment and
know-how.
After complete disassembly, always renew seals upon reassembly.
When tightening nuts or bolts close to one another, always follow a 1-2-1 sequence; comply with the specified
tightening torques. Never use flammable or corrosive solvents to clean parts, since they could damage the seals.
If necessary, use specific detergents, in preference biodegradable, non corrosive, non flammable ones or having a high
flash point, compatible with the seal materials.
Before reassembling, always lubricate the fork mating parts.
Always smear seal lips with some grease before reassembly.
When using a screwdriver to install or remove snap rings, O-rings, guide bushes or sealing rings, make sure not to
scratch or damage the parts.
Note
It is recommended to overhaul one fork leg at a time.
Do not modify the fork components.

SAFETY AND ENVIRONMENT PROTECTION RULES
Disposal
Note

USING THE VICE
Some service procedures might require the use of the vice to hold some fork components.
Warning
Incorrect use of the vice could damage the fork, even though damage might not be immediately visible, and jeopardise
its safety features.
Carefully comply with the following instructions:

Only use the vice when it is absolutely necessary.
Always use a vice with jaws made from soft material.
Do not tighten vice too much.
Do not vice fork at positions where the least deformation might damage the part and cause suspension malfunction.
The figure shows areas (A) and (B) recommended to fasten the fork to the vice.

EQUIPMENT

PART NO. IMAGE

88713.4302

88713.0957

88713.0958

88713.0025

PART NO. IMAGE

88713.0030

REMOVAL
Note

Remove the forks (Removing the front fork).
Lock the fork (1) with a vice using tool (C) part no. 88713.4302 taking care not to damage the sleeve.
Discharge the spring and note down the preload value.
Loosen the top plug (2) using tool (D) part no. 88713.0025.
Remove fork (1) from the vice and drain all oil in a suitable container.
To help draining, move damper rod a few times, then leave sleeve upside-down until fluid has completely drained.
Position the fork in the vice as shown in the figure.
Use tool (A) part no. 88713.0957 to lower preload tube (5) and remove top plug (2) by loosening nut (15) with a 14
mm wrench.
Remove the preload tube (5).
Remove spring (6).
Remove spring (14) from dust seal (7).

Remove dust seal (7) from outer sleeve (1).
Use suitable tools to remove snap ring (8) from the sleeve.
Slide out outer sleeve (1) from fork leg (9) by hitting several times to counter-hold the sliding bushing resistance.
Use suitable tools to remove sliding bushing (13) from the leg.
Remove bushing (12), shim (11) and oil seal (10).

REFITTING
Note
Protect the sliding bushing seat with some adhesive tape.
Lubricate fork leg with fork oil and install, in this sequence:
• Spring (14).
• Dust seal (7).
• Snap ring (8).
• Oil seal (10).
• Shim (11).
• Bushing (12).
Note
Pay attention to the direction of installation of oil seal, spring must face outward.
Remove the adhesive tape previously applied.
Fit leg (9) into the outer sleeve (1).

Install bushing (12) in its housing.
Fit shim (11) on bushing.
Use tool (D) part no. 88713.0030 to push bushing/shim assembly fully home on the sleeve.
Then, using the same tool, install oil seal (10).
Fit snap ring (8) and dust seal (7).

Refit spring (14) on dust seal (7).
Insert the sliding bushing (13) in its seat.
Screw tool (B) part no. 88713.0958 on the damper rod leg.
Fill in 681 cm3 (41.55 in3) of specific oil in both legs.

Insert spring (6) inside the sleeve, paying attention to aim it with the narrowest end facing up and into contact with
preload tube (5).
Insert preload tube (5).
Use tool (A) part no. 88713.0957 to lower the preload tube and spring.
Remove tool (B) part no. 88713.0958 and screw top plug (2) fully on the damper rod leg.
Screw in the plug fully home and tighten lock nut (15) to a torque of 15 Nm ± 1.5 Nm using a 14 mm wrench, holding
the top plug (2) during the operation.
Remove tool (A) part no.88713.0957 starting from the plate shown in the figure.
Use tool (D) part no. 88713.0025 to tighten nut (2) to a torque of 22.5 Nm ± 7.5 Nm.
Restore the preload value, previously noted.
Refit the forks (Refitting the front fork).

Refitting the front fork
Refit the legs setting them at the height (X) = 11.4 ± 0.5 mm (0.45 ± 0.02 in) with respect to the steering head.
Warning
The difference in height between the two fork legs must be no greater than 0.1 mm (0.004 in).
If the screws were removed upon disassembly, smear the threads of screws (4) and (6) with the specified product.
Working on one fork leg at a time, tighten screws (4) retaining the forks to steering head (5), to a torque of 10 Nm ±
5%, following a 1-2-1 sequence and starting with the top screw.
Tighten screws (6) retaining the forks to bottom yoke (7) to a torque of 16 Nm ± 5%, following a 1-2-1 sequence, and
starting from the top screw.
Position the LH mudguard support bracket (2) on the LH fork end and start screws (1).

Position the RH mudguard support bracket (3) on the RH fork end and start screws (1).
Refit the phonic wheel sensor (Replacing the front phonic wheel sensor).
Refit the front mudguard (Refitting the front mudguard).
Refit the front brake callipers (Refitting the front brake system).
Warning
Do not use the motorcycle when front mudguard is not in place since this part supports the brake lines and avoids that
they interfere with the wheel under braking.
Adjusting the steering head bearing clearance
Adjust steering bearing clearance as explained under Section "Adjusting the steering head bearing clearance".
If the problems found are not solved, check the wear of steering bearings (1) and replace them, if necessary, as
described in paragraph "Removing the steering tube components".
Steering angle adjustment
The following procedure applies to both adjuster dowels, hence the procedure to be adopted on the LH adjuster dowel
is used as an example.
Steering adjuster dowels (1) are located on the bottom yoke.

Loosen nut (2) and adjust dowel (1) making sure that, during steering, there is no interference with the handlebar (3)
and all the parts fitted on it.
Once steering has been adjusted, apply the indicated product to the part of thread of adjuster dowel (1), where nut (2)
will be positioned once tightened.
While holding adjuster dowel (1) screw nut (2) by driving it fully home.
Removing the steering tube components
Remove the handlebar (Removing the handlebar).

Remove the steering damper (Removing the steering damper).
Remove fork legs (Removing the front fork).
Warning
All parts fitted to the steering head and bottom yoke, including wiring and hoses, can remain on the motorcycle
provided they do not hinder the following operations.
Loosen screws (13), holding nuts (14) on the opposite side, collect washers (15), washers (16), and remove lower U-
bolt (17).
Undo screw (1) and pull the steering head (2) upwards.
If necessary, remove silent-blocks (18) from steering head (2).
Loosen screw (19) that retains hose grommet (20) to bottom yoke (4).
Adequately support bottom yoke (4) then loosen ring nut (3) using tool part no. 88713.1058.
Remove sealing ring (5), internal ring (6) and ball bearing (7) from bottom yoke shaft (4).
Important
Check the integrity of the removed components and if deteriorated or damaged replace them with components of the
same type.
Remove the bottom yoke (4) from the steering tube, pulling it downwards.
Remove ball bearing (7), internal ring (6), sealing ring (5) and washer (9).
Important
same type.
Using a suitable punch, remove the outer bearing races (8) from the steering tube. Proceed with extreme care to avoid
damaging the seats.
Important
same type.
Loosen screws (21) and remove splash guard (22) from bottom yoke (4).
Refitting the steering tube components
Important
same type.
Thoroughly clean contact surfaces.

If previously removed, refit the external rings (8) inside the seats of the steering tube using tool part no. 88713.1062
and proceed as follows:
• Heat the steering tube to 150 °C.

• Place outer rings (8) correctly in their seats on the steering tube.
• Insert fixed bush (9), with the threaded hole, into the lower ring of the tool.
• Insert the other movable bush (10) into the upper end of the tool rod and drive it fully home against the upper
bearing ring.
• Tighten nut (11), and use a wrench to seat outer rings (8) fully in the steering tube.
• Leave the tool fitted until the steering tube has cooled down to ensure that bearings are properly seated.
Apply specified product to the outer rings (8).

Position splash guard (22) on the bottom yoke (4) and start screws (21).
Insert washer (9), sealing ring (5) (with the rim facing upwards) and inner ring (6) of the lower bearing onto the
bottom yoke shaft (4) after heating it for about 10 minutes to 120 °C.
Insert in the bottom yoke shaft (4) the drift (E) part no. 88713.1072 and push the inner ring (6) on sealing ring (5),
manually pushing for at least 10-15 seconds.
Apply the indicated product on the inner ring (6).
Fit the ball bearing (7) in the bottom yoke shaft (4) with the smallest diameter of the cage facing upwards.
Apply the indicated product to the ball bearing (7).
Insert the bottom yoke shaft (4) into the steering tube, and push it in until it is axially seated.
Apply the indicated product to the ball bearing (7).
Fit the ball bearing (7) in the bottom yoke shaft (4) with the smallest diameter of the cage facing downwards.
Apply the indicated product on the inner ring (6).
Insert inner ring (6) on bottom yoke shaft (4), aiming it as shown in the figure.
Insert the sealing ring (5) on the bottom yoke shaft (4) with the flat side facing upwards.
Apply the indicated product on the ring nut (3) thread.
Tighten the ring nut (3) by hand on the bottom yoke shaft (4) until it seats against the sealing ring.
Tighten the ring nut (3) to the torque of 35 Nm ± 5%, using the tool part no. 88713.1058 where the torque wrench
will be applied.
Place the rubber block of the front brake callipers / ABS control unit hose in the relevant seat of hose grommet (20).
Fasten hose grommet (20) on bottom yoke (4) by starting screw (19).
If previously removed, apply the indicated product to end (A) of silent-blocks (18).
Fit silent-blocks (18) fully home on steering head (2).
Apply the specified product to screw (1) thread and underhead.

Refit the steering head (2) on the ring nut and start the screw (1) without tightening.
Refit fork legs (Refitting the front fork).
Apply the indicated grease to the underhead of screws (13).
Apply indicated threadlocker on the screw thread (13).
Position lower U-bolt (17) on the steering head, placing washers (15) in-between, and start screws (13).
On the opposite side, insert washers (16) and screw nuts (14) on the threaded end of screws (13).
Refit the steering damper (Refitting the steering damper).
Refit the handlebar (Refitting the handlebar).
Assembling the front fork lowered springs set

Carefully read the procedures below before working on the fork for any reason whatsoever.
know-how.
After complete disassembly, always renew seals upon reassembly.
When tightening nuts or bolts close to one another, always follow a 1-2-1 sequence; comply with the specified
tightening torques. Never use flammable or corrosive solvents to clean parts, since they could damage the seals.
If necessary, use specific detergents, in preference biodegradable, non corrosive, non flammable ones or having a high
flash point, compatible with the seal materials.
Before reassembling, always lubricate the fork mating parts.
Always smear seal lips with some grease before reassembly.
When using a screwdriver to install or remove snap rings, O-rings, guide bushes or sealing rings, make sure not to
scratch or damage the parts.
Note
It is recommended to overhaul one fork leg at a time.
Do not modify the fork components.

SAFETY AND ENVIRONMENT PROTECTION RULES
Disposal
Note

USING THE VICE
Some service procedures might require the use of the vice to hold some fork components.
Warning
Incorrect use of the vice could damage the fork, even though damage might not be immediately visible, and jeopardise
its safety features.
Carefully comply with the following instructions:

Only use the vice when it is absolutely necessary.
Always use a vice with jaws made from soft material.
Do not tighten vice too much.
Do not vice fork at positions where the least deformation might damage the part and cause suspension malfunction.
The figure shows areas (A) and (B) recommended to fasten the fork to the vice.

LOWERED SPRING SET
Important
Before assembly, make sure that all parts are clean and in perfect conditions. Take all the necessary measures to avoid
damaging any part you are working on.

Position Name

(1) Fork lowered springs

(2) Rear shock absorber lowered spring

(3) Lowered side stand

(4) Shim

EQUIPMENT

PART NO. IMAGE

88713.4302

88713.0957

88713.0958

PART NO. IMAGE

88713.0025

REMOVING THE SPRING

Remove the forks (Removing the front fork).
Lock the fork (1) with a vice using tool (C) part no. 88713.4302 taking care not to damage the sleeve.
Discharge the spring and note down the preload value.
Loosen the top plug (2) using tool (D) part no. 88713.0025.
Remove the fork from the vice and reposition it as shown in the figure.
Take the outer sleeve (1) down.
Warning
Pay attention not to let oil flow out of the fork leg.
Use tool (A) part no. 88713.0957 to lower preload tube (5) and remove top plug (2) by loosening nut (15) with a 14
mm wrench.
Remove the preload tube (5).
Remove the original spring (6), ensuring that oil remains in the fork sleeve.

FITTING THE LOWERED SPRING
The figure shows the differences between the original components present inside fork and the components of the
"Lowered spring kit".
The lowered spring (16) and the original spring (6) are of the same length, but are different in shape, because lowered
spring (16) has different turns since it has a double K.
Screw tool (B) part no. 88713.0958 on the damper rod leg.
In both legs, check the specific oil quantity, the dimension must be 105 mm (4.13 in).
Move the damper rod downwards, to the limit stop; in both legs, check that the level of oil contained in the fork with
respect to the edge of sleeve (1) is (X)= 105 mm (4.13 in).
Insert lowered spring (16) inside the sleeve, paying attention to aim it with the narrowest end, having a diameter of
23.5 mm (0.92 in), facing up and in contact with preload tube (5).
Fit the preload tube (5) in the spring.
Warning
The spring must be positioned as indicated.
Use tool (A) part no. 88713.0957 to lower the preload tube and spring.
Remove tool (B) part no. 88713.0958 and screw top plug (2) fully on the damper rod leg.
Screw in the plug fully home and tighten lock nut (15) to a torque of 15 Nm ± 1.5 Nm using a 14 mm wrench, holding
the top plug (2) during the operation.
Remove tool (A) part no.88713.0957 starting from the plate shown in the figure.
Use tool (D) part no. 88713.0025 to tighten nut (2) to a torque of 22.5 Nm ± 7.5 Nm.
Restore the preload value, previously noted.
To remove the original side stand and install the lowered stand, refer to the procedures "Removing the side stand” and
“Refitting the side stand”.
Refit the forks (Refitting the front fork).

Assembling the rear shock absorber lowered spring set

Carefully read the procedures below before working on the shock absorber for any reason whatsoever.
know-how.

LOWERED SPRING SET
Important

Position Name

(1) Fork lowered springs

(2) Rear shock absorber lowered spring

(3) Lowered side stand

(4) Shim

REMOVING THE REAR SHOCK ABSORBER SPRING
Remove the rear shock absorber (Removing the rear shock absorber).
Remove O-rings (B) and bushings (C) from both sides of the rear shock absorber.
As an alternative, two Velcro straps can be used to lock them in place as shown in the figure.
To remove the original spring (5), fit rear shock absorber (6) on a spring puller (A) available on the market.
When positioning the tool (A), check that retainer (A1) is correctly positioned.
Compress the spring (5) just as much as needed to remove the plate (7) from the rear shock absorber (6).
Remove the plate (7) from the rear shock absorber (6).
If plate (7) removal proves to be difficult, it is recommended to lower drift (8).
Decompress spring (5) and remove rear shock absorber (6) from spring puller (A).
Remove spring (5) from rear shock absorber (6).

FITTING THE REAR SHOCK ABSORBER LOWERED SPRING
Fit the shim (4), positioning it on buffer (8), as shown in the figure.
The lowered spring (2) can be identified since it measures 204.5 mm (8.05 in).
Fit the lowered spring (2) in the rear shock absorber (6), aiming it so that, when the assembly is complete, the
narrowest coils are on the “swinging arm side”.
Fit rear shock absorber (6) on a spring puller (A) available on the market.
When positioning the tool (A), check that retainer (A1) is correctly positioned.
Compress the lowered spring (2) just as much as needed to refit the plate (7).
Fit the plate (7) into the rear shock absorber (6).
Decompress lowered spring (2) and remove rear shock absorber (6) from spring puller (A).
Make sure that the two fixing holes are aligned as shown in the figure.
If previously removed, fit O-rings (B) and bushings (C) from both sides of the shock absorber.
Refit the rear shock absorber (Refitting the rear shock absorber).
To remove the original side stand and install the lowered stand, refer to the procedures "Removing the side stand” and
“Refitting the side stand”.
Removing the rear shock absorber
Remove the side body panels (Removing the side body panels and the tail guard).
Remove the shock absorber protection (1) by loosening the two screws (2).
Support the rear side of the vehicle using suitable equipment.
From the LH side of the vehicle, loosen the screw (3) that retains shock absorber (5) at the top, while holding nut (4)
on the opposite side.
Loosen the lower screw (6) retaining the rear shock absorber.
Remove rear shock absorber by sliding it out of the rear frame.
Overhauling the rear shock absorber
Important
For any problem concerning the shock absorber operation, contact a KAYABA authorised service centre.
Refitting the rear shock absorber
Apply to the screw (6):
• The indicated threadlocker on the thread;

• The indicated grease on the cylinder head.
Position the rear shock absorber (5) and start screw (6).
Apply the indicated product to screw (3) threading.

Start screw (3) retaining shock absorber (5) at the top while inserting nut (4) on the opposite side.
Tighten screw (3) to a torque of 70 Nm ± 5% while holding nut (4) on the opposite side.
Remove the equipment previously used to lift the vehicle.
Position the shock absorber protection (1) and start screws (2).
Refit the side body panels (Refitting the side body panels and the tail guard).
Removing the rear swinging arm
Remove LH and RH frame covers (Removing the side body panels and the tail guard).
Loosen the two screws (1) and remove the two relevant hose guides.
Release rear calliper hose (2) and rear speed sensor cable (3) from swinging arm.
Support the rear part of the vehicle with suitable equipment.

Loosen the screw (4) retaining the rear shock absorber (5) to the swinging arm.

Loosen the swingarm shaft (7) retaining nut (6).
From the vehicle opposite side, remove the swingarm shaft.
During this operation pay attention not to damage the swinging arm.
Remove spacers (A), (B) and (C).
Inspecting the swinging arm shaft
Before refitting the swinging arm shaft (3), check it carefully for distortion.
Turn the shaft on a reference surface and measure distortion using a feeler gauge (Rear wheel).
Overhauling the rear swinging arm
Remove the swinging arm (Removing the rear swinging arm).
Inside the swinging arm, at the pivot point on the frame there are the following components:
Right side (starting from the outer side):
• external bearing (1);

• internal spacer (2);
• internal bearing (3);
internal side spacer (4).
left side (starting from the inner side):
• internal seal (4);

• roller bearing (5);
• roller bearing (6);
• external seal (7).
Warning
The removed bearings and seal rings must not be reused: replace them with components of the same type.
Left side
After applying the indicated product on the seat (B) of swinging arm, fit the two roller bearings (5) and (6) and the
relevant external sealing ring (7) and internal sealing ring (4).
Warning
Respect the bearing and seal ring assembly direction.
The bearings must be fitted with the writings facing outwards.

The sealing rings must be fitted with the "flat" side facing outwards.
Upon reassembly, respect the indicated values.
X = 0.70 mm (0.03 in);
Y = 4.75 mm (0.19 in).
Right side
After applying the indicated product on seat (A) of the swinging arm, insert the internal spacer (2) and the two
bearings (1) and (3). Comply with the indicated installation and inspection sequence:
- fit the internal bearing (3), taking it fully home on the relevant shoulder of swinging arm;
- fit the spacer (2) from the external side, taking it fully home on bearing inner ring (3);
- fit the external bearing (1), taking it fully home on spacer (2).
Warning
Respect the bearings correct position.
Note
The two bearings must be installed by applying pressure on the outer ring (yellow one in the figure) rather than on the
inner ring (blue one in the figure).
Refitting the rear swinging arm

PRE-FITTING
Apply the indicated product on the two seats (A) and (B) of the swinging arm.
Fit the two bearings (1) and (3) and the inner spacer (2) in the seat (A) of the swinging arm.
Note
The two bearings must be positioned so that the side with “markings” is facing outwards.
Fit roller bearing cages (5) and (6) and the two seals (4) and (7) in the seat (B) of swinging arm.
Note
The two sealing rings must be set so that the "flat" side is facing outwards.
Note
The two roller bearing cages must be positioned so that the side with “markings” is facing outwards.
Drive bearing (3) fully home on swinging arm.

Fit the spacer (2), taking it fully home on bearing inner ring (3).
Fit bearing (1), driving it fully home on spacer (2).
Note
The two bearings must be installed by applying pressure on the outer ring (yellow one in the figure) rather than on the
inner ring (blue one in the figure).
Important
After assembly, make sure that spacer has no end float.
Drive roller bearing cages (5) and (6) on the swinging arm, and fit seals (4) and (7) respecting the values X = 0.70
mm (0.03 in) and Y = 4.75 mm (0.19 in).
Use the indicated product to lubricate the internal surface of the two roller bearing cages (5) and (6).
Make sure that the lower surface of lower chain sliding shoe (8) is clean.
Apply the neoprene pad (9) as shown in the figure.
Position the chain sliding shoe (8) on the swinging arm by starting the two screws (10).
Make sure that the lower surface of upper chain sliding shoe (11) is clean.
Apply the neoprene pad (A) as shown in the figure.
Position the upper chain sliding shoe (11) on the swinging arm and fix it by starting the screw (12) and the screw (13).
Tighten screw (12) to a torque of 5 Nm ±10% and screw (13) to a torque of 2 Nm ± 10%.
Working on both sides, tighten nuts (12) on screws (13).
Apply the indicated product on the threaded projection of the two screws (13).
Start the two screws (13) inside the holes of swinging arm and tighten them until reaching value (X) = 28 mm (1.10
in).
While holding the two screws (13), screw the two nuts (12), until driving them fully home on swinging arm.
Tighten nuts (12) to a torque of 2 Nm ± 10%, while holding the two screws (13).
Position the chain guard (14) on the swinging arm and fix it with the screws (15).
Fit the two protection caps (16) on the swinging arm, in the positions shown in the figure.
Apply the indicated product along the whole perimeter of the cap (17).
Fit rubber cap (17) onto swinging arm, positioned with arrow (18) pointing up, as shown in the figure.

FITTING
Apply the specified product to the threads of the two adjusters (19) and ring nuts (20), and check that no grease
reaches the adjuster surface (21).
Screw the adjusters on the ring nut side opposite to the one with the flats until bringing the surfaces flush with each
other, as shown in the figure.
Start (on the frame external side) the two adjusters (19) in the relevant threads on the frame.
Tighten the two adjusters (19) to a torque of 5 Nm ± 10%, until they come out (on the opposite side) by at least 2
mm (0.079 in), as shown in the figure (2).
Loosen the two adjusters (19) until their surfaces are flush with the internal profiles of the frame, as shown in the
figure (1).
Position the swinging arm in the frame by placing the spacers (A), (B) and (C) in-between.
Apply the indicated product to pin (7).
Insert the swingarm shaft (7) trying to centre it on the frame.
Starting from the RH side adjuster (20) of the vehicle, tighten them to a torque of 60 Nm ± 5%.
Apply the indicated product to the two threadings of the swingarm shaft.
Starting from the LH side of the vehicle, insert nut (6), tightening it by hand and leaving a couple of threadings
between the pin and the nut, as shown in the figure.
Start nut (6) on vehicle RH side.

Tighten nut (6) to a torque of 70 Nm ± 5% while holding the other nut (6) on the opposite side.
Apply to the screw (4):
• The indicated threadlocker on the thread;

• The indicated grease on the cylinder head.
Position the rear shock absorber (5) and start screw (4).
Reposition wiring (3) and rear brake calliper hose (2).

Tighten the two hose guides (1) to a torque of 7 Nm ± 10%.
Refit LH and RH frame covers (Refitting the side body panels).
Inspection of the final drive
To ensure best performance and a long life of chain, the wear status of front and rear sprocket teeth must be
frequently checked, both as for profile and thickness and, if need be, replace them.
To check the final drive wear, visually check the front sprocket (1) and the rear sprocket (2).
The possible wear of front or rear sprocket tooth shows through the characteristic "hook" shape. If the teeth are worn
as shown in the figure (dotted line), the final drive must be replaced.
Warning
Make sure that the rear sprocket, front sprocket and chain are all replaced together as a set.
In case a new rear sprocket and a new front sprocket are installed, turn rear wheel and make sure that there are no
side movements or out-of-rounds during rotation. A wrong alignment could originate axial thrusts on chain inner link
that can be detected through a side wear of front and rear sprocket teeth.
Removing the front sprocket
Undo the screws (2), and remove the sprocket cover (1).
Slacken the chain (Adjusting the chain tension).
Lift the safety tab (4) at both “Closing” points.
Engage the first gear and loosen nut (3).

Remove nut (3) and lock washer (4) on sprocket.
Loosen the screws (G) and remove the lower chain sliding shoe (H).
Remove the front sprocket (5) from the gearbox secondary shaft.

REMOVING THE CHAIN
Remove the chain using tool (X) part no. 88713.1344.

The tool consists of a holder (A), a punch (B), a body (C) and two wrenches (D) and (E).
Fit the link to be opened into the holder (A).
Fit the punch (B) into the body (C) and manually undo the screw until the punch no longer protrudes.
Fit the holder (A) and the link into the body (C).
Manually turn the bolt (F) on body (C) so that the punch (B) gets against the pin, taking care that they are aligned.
Fit the hexagon wrench (D) into the hexagonal part of the body (C) and the wrench (E) onto the bolt.
Turn clockwise the bolt (F) until the pin comes out.
The link from the spare parts comes in a bag with the O-rings. During assembly, and to the extent available, add the
grease contained in the bag.
Warning
Do not clean elements from their grease: upon assembly, take the link from the plate and not from the pins (see figure
below).
Refitting the front sprocket

REFITTING THE CHAIN
The link from the spare parts comes in a bag with the O-rings. During assembly, and to the extent available, add the
grease contained in the bag.
Warning
Do not clean elements from their grease: upon assembly, take the link from the plate and not from the pins (see figure
below).
Close the chain again using the tool (X) part no. 88713.1344 used to open the chain.
The tool consists of a holder (A), a punch (B), a body (C), two wrenches (D) and (E) and a plate holder (F).
Connect the two ends of the chain with the external link, and manually fit the plate onto the pins.
Warning
Lubricate the pins abundantly; try to avoid touching them with your hands.
Fit the holder (A) onto the external link.

Fit the punch (B) into the body (C) and the plate holder (F).
Fit the body (C) onto the holder (A) which holds the chain in position.
Manually turn the bolt (G) until the plate holder (F) is seated against the plate itself.
Use wrenches (D) and (E) to turn the bolt (G) clockwise until the chain pin is in contact with the holder (F).
Remove the holder (A) from the tool.
Manually turn the bolt (G) until the punch (B) is brought into contact with the pin to be riveted, taking care that they
are aligned.
Use wrenches (D) and (E) to turn the bolt clockwise until the punch (B) is seated against the chain plate.
To complete riveting, repeat the entire procedure with the second pin.
Warning
Carefully check the two pins: the figure shows the correct result of the procedure.

REFITTING THE FRONT SPROCKET
If previously removed, refit the front sprocket spacer (9) as follows:

Apply the specified product to O-ring (10).
Fit the O-ring seal (10) on the front sprocket spacer (9), as shown in the figure.
Important
The O-ring must be renewed upon removal.
Apply the indicated product on the inside of the sealing ring (A).
Insert the front sprocket spacer (9) with O-ring (10) on the gearbox secondary shaft, aiming it as shown in the figure
and driving it fully home.
Check that the splines of the gearbox secondary shaft and the sprocket are in perfect condition.
Fit the front sprocket (5) on the gearbox secondary shaft, orienting it as shown and pushing it over the groove.
Fit the chain on the front sprocket (5).
Fit lock washer (4).
Check that the pre-applied threadlocker is still present on screw threads (G). A maximum of three removal/refitting
Install lower chain sliding shoe (H) fixing it by starting screws (G).
Tighten screws (G) to a torque of 5 Nm ± 10%.
Apply the indicated product and start retaining nut (3).
Bend washer (4) as shown in the figure.
Tension the chain (Adjustment of chain tension).
Fit the sprocket cover (1) and tighten the screws (2) to a torque of 6 Nm ± 10 %.
Replacing the rear sprocket
Loosen the six rear sprocket (2) retaining nuts (1).
Remove the rear sprocket (2) from the rear sprocket flange.
Refitting the rear sprocket
Apply the specified product to the thread in point (A) of the six cush drive damper pins (3).
Fit the six cush drive damper pins (3) in the relevant holes of the flange (4).
Tighten pins (3) to a torque of 44 Nm ± 5%, in the sequence shown in the figure.
Apply the indicated product to threaded pins (3).
Fit the rear sprocket (2) centring it on the threaded pins (3).
Fit the spacer (5), orienting it as shown in the figure until it is fully home against the rear sprocket flange (4).
Start the nuts (1).
Tighten nuts (1) to a torque of 55 Nm ± 5%, in a cross pattern.
Washing the chain
The chain cleaning is extremely important for its duration. In fact, it is necessary to remove any mud, soil, sand or dirt
from the chain using a jet of water and then dry it immediately using compressed air at a distance of at least 30 cm
(11.81 in). In particular, in case of Off-Road use of the bike, it is possible that excessive wear of the links occurs due to
the contact with the chain sliding shoe; friction could in fact cause the chain to overheat, altering the heat treatment of
the links and making them particularly fragile; in extreme cases, link breakage direction is vertical and transversal
cracks start from the base of the link until reaching the pin seat.
Note
Avoid the use of steam, fuel, solvents, hard brushes or other methods that could damage the O-rings; also avoid direct
contact with the battery acid as it could cause mini cracks in the links.
Once chain washing and cleaning operations are over, it can be lubricated.
Lubricating the chain
The pin-bush area is the critical point subjected to the heaviest stress due to the high operating loads, and where the
high temperatures reducing the anti-wear effectiveness of the lubricant layer present on all chain parts are reached.
(A) = Pin
(B) = Bush
(C) = Lubricant
We remind you that the O-rings fitted on all Ducati model chains have the double function to retain the incorporated
lubricant and avoid infiltrations of foreign bodies in the pin-bush area.
In case of poor lubrication, the following symptoms could appear:

- appearance of reddish areas (symptom of oxidation);
- squeaking and noisiness;
- stretching;
- stiff joints.
This is the reason why lubrication is an essential operation since it:
- reduces friction and heat build-up;
- keeps the O-rings soft, avoiding cracking and consequent possible breakage;
- protects metal components against oxidation;
- increases drive efficiency;
- lengthens the service life of the whole drive system.
Chain can be lubricated in two ways:
1) Brush lubrication:
when using a brush, it is enough to lay a thin layer of oil along the whole chain; then eliminate the excess lubricant
with a clean cloth.
Warning
Use SAE 80W-90 mineral oil or specific chain lubricants, making sure they do not contain additives that could damage
the O-rings.
2) Spray lubrication:
- put the motorcycle on the rear paddock stand.
- make the rear wheel turn fast in the direction opposite to the direction of travel;
- apply the lubricant jet inside the chain between the inner and outer links, in the point immediately before the
engagement point on the sprocket. Due to the centrifugal force, the lubricant, made fluid by the solvents contained in
the spray, will expand in the working area between the pin and the bush, ensuring perfect lubrication.
- repeat the operation by aiming the lubricant jet to the central part of the chain so as to lubricate the rollers, and to
the outer plates as shown in the figure.
- after lubrication, wait 10-15 minutes to allow the lubricant to act on the internal and external surfaces of the chain
and then remove the excess lubricant with a clean cloth.
Note
Lubricate the chain at least every 400 km (248 mi) or more frequently when using the bike with high outside
temperatures (40°C) (104 °F) or after long travels on the highway at high speed.
Lubricate the chain without waiting for it to cool down after use, so that the new lubricant can penetrate better
between the inner and outer links and be more effective in its protective action.
Do not use the motorcycle immediately after lubricating the chain as the lubricant, still fluid, would be centrifuged
outwards causing possible soiling of the rear tyre or the rider's footpeg.
Removing the footpegs

FRONT FOOTPEGS
The procedure shows only one footpeg but it applies to both footpegs.
Remove split pin (1), washer (16), pin (2), spring (3) and footpeg (4).
Remove rubber insert (5) by pulling it from footpeg (4).

REAR FOOTPEGS
The procedure shows only one footpeg but it applies to both footpegs.
To remove the rear footpeg (12) remove, in the following order:
• split pin (6);

• pin (8);
• washers (7);
• footpeg retainer (9);
• ball (10);
• spring (11);
• footpeg (12).
Remove rubber insert (13) by pulling it from footpeg (13).

REMOVING THE RH FRONT FOOTPEG HOLDER PLATE ASSEMBLY
Loosen screw (1) securing bracket (2).

Slide out the rear brake master cylinder unit (3) from the rod (4).
Remove the self-locking tie (A).
Remove the rubber tie (B) and disconnect the rear brake switch connector (5).
Loosen screws (6), screws (8) and remove RH front footpeg holder plate assembly (7) collecting bushings (9).

REMOVING THE LH FRONT FOOTPEG HOLDER PLATE ASSEMBLY

figure.
Loosen screws (10), screws (11) and remove LH front footpeg holder plate assembly (12).
Remove the rubber tie (13) and disconnect the side stand connector (14).
Remove the self-locking tie (15), releasing the Quick-Shift control wiring branch from the side stand sensor wiring.

REMOVING THE REAR FOOTPEG HOLDERS
Loosen the screws (1) and remove the two rear footpeg holders (2).
Refitting the footpegs

REFITTING THE LH FRONT FOOTPEG HOLDER PLATE ASSEMBLY
Connect side stand connector (14).

Fasten side stand connector (14) to the starter motor cable, using button tie (13).
Fasten the side stand cable (14) to the Quick-Shift control connector, using self-locking tie (15).
Apply the specified product to the thread of screws (10) and screws (11).
Position the LH front footpeg holder plate assembly (12) and start screws (10) and screws (11).
Tighten screws (10) and screws (11) to a torque of 42 Nm ± 5%.

Refit the special ties (5), securing the Quick-Shift control cable to the sump guard bracket (4).

REFITTING THE RH FRONT FOOTPEG HOLDER PLATE ASSEMBLY
Start screws (8) of the RH front footpeg holder plate assembly (7).
On the opposite side, insert bushings (9) on the threaded end of screws (8).
Position the RH front footpeg holder plate assembly (7) and start screws (8) and screws (6).
Connect rear brake switch connector (5) and secure it to the rear speed sensor connector, refitting rubber tie (B), as
Using self-locking tie (A), fasten the rear stop sensor cable to the rear brake master cylinder / ABS control unit pipe.
Insert the rear brake master cylinder unit (3) on the rod (4).
Position bracket (2) and start screws (1).


REFITTING THE REAR FOOTPEG HOLDERS
Apply the indicated product to the four screws (1).

Position the two footpeg holder supports (2) and start screws (1).
Position the heel guard (4) on rear footpeg holder support (2) and fix it by starting the two screws (3).
Repeat the procedure with the other heel guard.

REFITTING THE REAR FOOTPEGS
Insert footpeg retainer (9) into the hole of the rear footpeg holder support, aiming it as shown in the figure.
Insert the spring (11) into the special hole of footpeg assembly (12).
Apply the indicated product on spring (11) top.
Fit the ball (10) on the spring (11).
Insert washer (7) on pin (8) and apply the indicated product on pin (8).
Fit footpeg assembly (12) on the rear footpeg holder support, aiming it as shown in the images and lock it in place by
inserting pin (8) from the indicated side, with washer (7) in-between.
On the opposite side, insert washer (7) on pin (8) projection.
Insert split pin (6) inside the relevant hole of pin (8), and bend its ends.
Check the correct operation of the footpeg assembly (12).
Apply the indicated product on the rubber insert (13) buffer.

Fit rubber insert (13) on footpeg (12), by inserting buffers into their seats and exerting a pressure until they click in
place.
Note
The insert (13) and the footpeg (12) can be identified by the words “DX” (RH) and “SX” (LH) stamped on them in area
(A).

REFITTING THE FRONT FOOTPEGS
Position spring (3) on footpeg (4), so that end (C) rests on the footpeg.
Position footpeg (4) inserting the end (A) of spring (3) in the hole (B) of the front footpeg holder plate.
Apply the indicated product to shaft (2).
Insert pin (2) inside the indicated hole of plate, from the side shown in the figure.
On the opposite side, insert washer (16) on pin (2) projection.
Insert split pin (1) inside the relevant hole of pin (2), and bend its ends.
Fit rubber insert (5) on footpeg (4), fully home in the relevant seat and exerting a pressure until it clicks in place.
Note
The insert (5) is correctly fitted to the footpeg if the edge (A) is fully visible at the bottom and along the external
perimeter, as shown in the figure.
Removing the side stand

REMOVING THE STAND GUARD
If stand guard (2) has to be removed, proceed as indicated below:

Working on motorcycle LH side, loosen the screws (1), remove the stand guard (2) from the sump guard (5) and

REMOVING THE SIDE STAND
Disconnect the side stand (Branch 6).
Removing the side stand without side plate
Loosen screw (1) and remove side stand sensor (2).

Disconnect springs (3) and (4).
Loosen nut (6).
Loosen pin (5).
Remove the side stand (7).
Removing the side stand with side plate
Loosen screw (8) that retains pre-silencer (9) to the side stand plate.
Remove the footpeg holder plate (Removing the footpegs).
Loosen screw (10) and remove sensor (11).
Disconnect springs (12) and (13).
Loosen nut (15).

Loosen pin (14).
Remove the side stand.
Refitting the side stand

REFITTING THE SIDE STAND
Fitting the side stand without side plate
Apply the indicated product to the surfaces (A) involved in the assembly operations between side stand plate (16) and
side stand (7).
Apply the indicated grease to the underhead and cylindrical section (B) of screw (5).
Fit the side stand aiming it as shown in the figure.
Start pin (5) and tighten it to a torque of 35 Nm ± 5%.
Apply the indicated product to nut (6).
Start nut (6) and tighten it to a torque of 35 Nm ± 5%.
Insert inner spring (3) inside outer spring (4), aiming it as shown in the figure.
Secure springs (3) and (4) to pin (D) of the side stand plate and to hook (E) of the side stand.
Position sensor (2) on the side stand by inserting sensor tooth (F) into stand hole (G) and aligning the sensor groove
with stand pin (H).
Fasten sensor (2) by starting screw (1).
Fitting the side stand with side plate
Apply the indicated product to the surfaces (A) involved in the assembly operations between side stand plate (16) and
side stand (7).
Apply the indicated grease to the underhead and cylindrical section (B) of screw (14).
Fit the side stand aiming it as shown in the figure.
Start pin (14) and tighten it to a torque of 35 Nm ± 5%.
Apply the indicated product to nut (15).
Start nut (15) and tighten it to a torque of 35 Nm ± 5%.
Insert inner spring (12) inside outer spring (13), aiming it as shown in the figure.
Secure springs (3) and (4) to pin (D) of the side stand plate and to hook (E) of the side stand.
Position sensor (11) on the side stand by inserting sensor tooth (F) into stand hole (G) and aligning the sensor groove
with stand pin (H).
Fasten sensor (2) by starting screw (1).
Refit the footpeg holder plate (Refitting the footpegs).
Start and tighten screw (8) that retains pre-silencer (9) to the plate to a torque of 10 Nm ± 10%.
Connect the side stand (Branch 6).

REFITTING THE STAND GUARD

STAND SENSOR TEST
When the assembly is complete, check the stand sensor.

Perform a key-on and position the motorcycle on the side stand, the relevant warning light should turn on on the
instrument panel.
Close the side stand and start the motorcycle.
Switch on the motorcycle, lower the side stand and engage the first gear. The motorcycle should switch off.
Removing structural components and frame
To carry out the necessary checks on the frame, remove all the fitted superstructures, referring to the removal
procedures outlined in the relevant sections of this manual:
• Remove the engine from the frame (Removing the engine);

• Remove the rear subframe (Removing the rear subframe);
• Remove the rear shock absorber (Removing the rear shock absorber);
• Remove the forks (Removing the front forks);
• Remove the steering assembly (Removing the steering tube);
• Remove the front braking system (Removing the front braking system).
• Remove the rear braking system (Removing the rear braking system);
• Remove the whole ABS system (Removing the ABS control unit).

REMOVING THE FRONT SUBFRAME
Loosen the screws (1) and remove them with relevant washer (2).
Separate the front subframe (3) from the frame (4).

REMOVING FRAME COMPONENTS
Loosen the screws (1) and remove tank pads (2).

Remove the ABS rubber blocks (3) and the tie clip (4).
Remove the front pads (5).
Remove the clamps (7) retaining the rubber pad (6).

Remove the rubber pads (6).
Remove the vertical head Map sensor (8) and the horizontal head Map Sensor (9) from the frame.
Loosen the two screws (10) and remove the voltage regulator (11).
Undo the screws (13) and remove the inertial platform (12) assembly.
Remove the vibration damper (14).

Removing the rear subframe
Remove the following components before removing the rear subframe:
• Fuel tank (Removing the fuel tank);
• Rider and passenger seat (Removing the seat);

• Number plate holder (Removing the number plate holder);
• Disconnect the whole wiring harness so that the subframe can be removed (Routing of wiring on motorcycle).
Loosen the screw (1) retaining the exhaust silencer (2) to the rear subframe (3) and counter-hold the relevant nut at
the opposite side.
Loosen the screws (4) from both sides of the vehicle.

Separate the rear subframe (3) from the frame (5).
Remove the electrical components compartment as shown in chapter (Removing the electrical components compartment).
Refitting the structural parts and frame

FITTING THE FRONT SUBFRAME
On the inner side of the headlight support (3), insert USB socket device connector (5) fully home in the relevant
opening, aiming it as shown in the figure.
On the outer side of the headlight support, fit the USB socket (6) plug collar on the connector (5) and fasten them by
fitting the fork edge (7) in the connector groove (5) as shown in the figure.
Close the plug (6) by inserting it in the USB socket device connector.
Place USB socket device (9) in the relevant seat of headlight support housing, as shown in the figure and fix it by
starting screws (8).
Lay the cable (10) of the USB socket device inside the headlight support, as shown in the figure.
Fit rubber support (11) on the headlight support, positioning it as shown in the figure.
Fit the air temperature sensor (12) inside the rubber support, aiming it as shown in the figure.
Fit the four vibration dampers (13) in the relevant holes of headlight support.
Insert the four spacers (14) in vibration damper pads (13), on the indicated side.
Fit the two clips (15) onto RH Plexiglas (16), aiming them as shown in the figure.
Fit the two clips (15) onto LH Plexiglas (17), aiming them as shown in the figure.
Position the RH Plexiglas support (16) and the LH Plexiglas support (17) on headlight support, aiming them as shown
in the figure and start the screws (18).
Start the four silent blocks (19) on instrument panel (21), and screw them applying enough force to obtain a slight
pre-tensioning.
Fit the four toothed washers (20) on the four silent block (19) threaded pins.
Place the instrument panel (21) on the headlight support by inserting the silent block (19) threaded pins in the
relevant holes of the support.
Important
The instrument panel is correctly placed if the main wiring harness connection can be seen through the opening (22) of
the headlight support.
Start the four nuts (23) on the four silent block (19) threaded pins.
Tighten the four nuts (23) to a torque of 3 Nm ± 10%.
Fit the headlight (Headlight).

Start screws (1) with the washer (2).

ASSEMBLING THE FRAME COMPONENTS
Fit vibration damper (14) on frame, as shown in the figure.
Position inertial platform assembly (12) on the inner side of the frame, aiming it as shown in the figure.
Start the three screws (13) to secure the inertial platform assembly (12) to the frame.
Position the voltage regulator assembly (11) in the inner side of the frame, engaging the pin (D) into the vibration
damper (C).
Start the two screws (10) to secure the voltage regulator assembly (11) to the frame.
Fit the vertical head (8) MAP sensor assembly support fully home on the frame tabs.
Fit the horizontal head (9) MAP sensor assembly support fully home on the frame tabs.
Fit the two rubber pads (6) fully home on the frame, by inserting pin (A) in the hole (B) as shown in the figure.
Secure the pads (6) to the frame by tightening the two big self-locking ties (7) as shown in the figure.
Fit the two front pads (5) fully home on the frame in the positions shown in the figure.
Apply the indicated product on the pin (E) and on the rear surface of the two ABS (3) pipe guide rubber blocks as
Fit the three rubber blocks (3) in the indicated areas of the frame, and aim them as shown in the figure.
Fit the tie clip (4) in the indicated area of the frame, and aim it as shown in the figure.
Place a tank pad (2) on the LH side of the frame and one on the RH side and start the screw (1).
Refit the following components on the frame:
• Refit the main wiring harness on the vehicle (Routing of wiring on the motorcycle);
• Refit the whole ABS system (Refitting the ABS control unit);
• Refit the rear braking system (Refitting the rear braking system);
• Refit the front braking system (Refitting the front braking system);
• Refit the steering assembly (Refitting the steering tube components);
• Refit the forks (Refitting the front forks);
• Refit the rear shock absorber (Refitting the rear shock absorber);
• Refit the rear subframe(Refitting the rear subframe);
• Refit the engine in the frame (Refitting the engine).
Refitting the rear subframe
Refit the electrical components compartment (Refitting the electrical components compartment).
Fit the protection caps (6) in the rear subframe threadings (3) as shown in the figure.
Apply the specified product to screws (4).

Bring the rear subframe (3) close to the frame (5) and start screws (4).
Place washer (A) between silencer and silencer support bracket and start screw (1).
On the opposite side, screw relevant nut on the threaded end of screw (1).
Tighten the screw (1) to a torque of 20 Nm ± 10% by counter-holding relevant nut.
Refit the following parts:
• Connect the whole wiring harness (Routing of wiring on motorcycle);

• Number plate holder (Refitting the number plate holder);
• Fuel tank (Refitting the fuel tank);
• Rider and passenger seat (Refitting the seat).
Removing the number plate holder
Loosen the three screws (1) retaining the rear wiring cover (A) to the lower rear mudguard (2).
Remove wiring cover (A).
Loosen screws (3) and (4) retaining the rear number plate holder assembly (5) to the frame.
Set aside number plate holder assembly (5) so as to reach the rear wiring.
Loosen the four screws (6) retaining lower rear mudguard (2).
Remove lower rear mudguard (2).
Following the instructions in chapter "Branch 11", disconnect:
• number plate light;

• tail light;
• rear turn indicators.
Loosen screw (7) and detach rear mudguard (8) from number plate holder (9).
Refitting the number plate holder

PRE-FITTING
Insert RH turn indicator cable and LH turn indicator cable inside spacers (13), aiming these latter as shown in the
figure.
Note
In order to differentiate the RH turn indicator (11) from the LH turn indicator (10), read the letters "P DX" (right) and
"P-SX" (left) on the relevant identification labels attached to the cables.
Couple the RH turn indicator (11) and the LH turn indicator (10) to spacers (13) and secure the parts in place by
starting screws (12).
Fit LH rear turn indicator assembly (11) and RH rear turn indicator assembly (10) in the corresponding housings on
lower rear mudguard (2), as shown in the figure.
Note
Clean the surface of tail light (14) where buffer (17) will be applied.
Remove protective film (B) from the rear side of buffer (17).
Apply buffer (17) on tail light (14) in the position shown in the figure.
Important
During this operation, take special care not to touch the adhesive surface of buffer (17) with your fingers. Exert
uniform pressure on buffer (17) so that it adheres perfectly to tail light (14).
Fit the two rubber blocks (15) on tail light (14) as shown in the figure.
Insert the two spacers (16) in rubber blocks (15) aiming them as shown in the figure.
Insert the four clips (18) inside the relevant brackets of the number plate holder frame, aiming them as shown in the
images.
Insert the two rubber blocks (19) inside the relevant brackets of the number plate holder, as shown in the images.
Fit tail light (14) on the number plate holder frame by inserting its pins in the previously fitted rubber blocks.
Start screws (22) with washers (23) on tail light (14), from the side shown in the figure.
Start the two screws (21) with the two washers (20) on tail light (14), from the side shown in the figure.
Tighten screws (22) to a torque of 0.85 Nm ± 10% and screws (21) to a torque of 5 Nm ± 10%.
Slide the sheath fully home on number plate light (24), so that it covers the cables (25).
Manually screw the two silent-blocks (26) fully home on number plate light (27) with enough force to obtain a slight
preload.
Position number plate light (27) on number plate holder plate (28) by sliding the number plate light wiring (C) inside
the opening on the holder plate, as shown in the figure.
Place the two toothed washers (31) between the two silent-blocks (26) and number plate holder plate (28).
Start the two screws (30) to fix number plate light (27).
Note
While tightening screws (30), make sure that the gap between number plate light (27) and number plate holder plate
(28) is the same on both sides, as shown in the figure.
Position number plate holder plate (33) on the number plate holder frame by inserting the number plate light wiring
(C) inside the opening on the number plate holder, as shown in the figure.
Start screws (32) and tighten them to a torque of 5 Nm ± 10%.
Secure the number plate light wiring (C) to the number plate holder frame placing a small self-locking tie (35) on cable
holder (34) as shown in the figure.
Insert cat’s eye pins (37) inside bracket (38).
Insert two washers (39) and tighten two nuts (40) to a torque of 0.7 Nm ± 10%.
Position the bracket with the cat’s eye on the number plate holder plate (38) and secure it with two screws (41) and
two nuts (42) after fitting the number plate.
For European version number plate holder plate, number plate holder brackets (43) must be installed as shown in the
figure.

FITTING
Following the instructions in chapter "Branch 11", connect:
• number plate light;

• tail light;
• rear turn indicators.
Position rear mudguard (2) and rear wiring cover (A) and start screws (1) and (6).
Following the indicated sequence, tighten:
• screws (4) to a torque of 10 Nm ± 10%;

• screws (3) to a torque of 24 Nm ± 10%;
• screw (7) to a torque of 5 Nm ± 10%.
Tighten screws (1) and (6) to a torque of 5 Nm ± 10%, following the indicated sequence.
Removing the electric components compartment
Remove the number plate holder (Removing the number plate holder).
Remove the rear subframe from the frame (Removing the rear subframe).
Remove the BBS (Black Box System).
Disconnect the main wiring harness (Routing of wiring on frame).
Disconnect cable (2) from bracket (3) and remove the pawl (1).
Loosen ring nut (4) and remove seat lock (5) from the electrical components compartment.
Remove protective cap (6).

Loosen screw (7) retaining the remote control switch – battery positive terminal cable, and screw (8) retaining the
remote control switch – starter motor cable.
Disconnect the remote control switch – battery positive terminal cable and the remote control switch – starter motor
cable.
Loosen the four retaining screws (9) and recover their spacers (10).
Detach electrical components compartment (11) from the rear frame and remove the main wiring harness.
Refitting the electric components compartment
Fit protective sheath (12) on the cables from remote control switch to starter motor (13) and battery negative terminal
(14).
Remove film (15) from protective sheath (12).
Wrap protective sheath (12) on itself so that it adheres perfectly to cables (13) and (14).
Secure protective sheath (12) by placing a small self-locking tie (16) on its centreline.
Insert the four spacers (10) and start screws (9).

Insert washers (A) on screw (7) retaining the remote control switch – battery positive terminal cable, and screw (8)
retaining the remote control switch – starter motor cable.
Position the two cables from remote control switch to starter motor and battery negative terminal.
Tighten screws (7) and (8) to a torque of 5 Nm ± 10%.
Position the remote control switch as shown in the figure and insert protective cap (6).
Insert seat lock (5) from electrical component support (D) outer side, aiming it as shown in the figure and inserting
teeth (B) and (C) inside the special recesses.
On support (D) inner side, insert bracket (3) on lock (5), aiming it as shown in the figure.
Secure lock (5) in place by starting and screwing ring nut (4).
Note
Aim ring nut (4) with the chamfered sides facing up.
Tighten ring nut (4) to a torque of 3 Nm ± 10%.
Fit seat lock latch cable (2) by inserting pawl (1) in its seat on the lock lever (3).
Fasten cable (2) by inserting it in the recess of bracket (3), where the relevant groove is (red in the figure).
Connect the main wiring harness (Routing of wiring on frame).
Refit the BBS (Black Box System).
Refit the rear subframe(Refitting the rear subframe).
Refit the number plate holder (Refitting the number plate holder).
Removing the fuel tank
Before removing the tank, the following parts must be removed:
• Rider seat (Removing the seat).

• Side fairings (Removing the side fairings).
• Steering damper (Removing the steering damper).
• Tank fairings (Removing the tank fairings).
Loosen the screws (1) retaining the fuel tank (2) on the front and back.
Working on either sides of the motorcycle, tighten taps (3).

Place a container at the cocks (3) under the motorbike.
Loosen clamps (4) and disconnect hose (5).
Disconnect the fuel pipe quick coupling (6) and the fuel pump connector (7) from the fuel pump.
Working on the LH side of the motorcycle, disconnect fuel level sensor connector (8).
Disconnect the tank ground connector (9).

Lift the front of the fuel tank (2) and disconnect the breather pipe (10) and the drain pipe (11).
ATTENTION: A spring (C) is inserted inside the breather pipe (10) to make the end of the pipe stronger. This is to
prevent any constriction of the breather pipe (10) that could create a vacuum in the fuel tank (2).
Remove fuel tank (2) from the motorcycle.
If necessary, remove the tank bracket (13), loosening screws (12).

Removing the tank filler plug
Insert key and open tank filler plug (1).
Loosen the four screws (2) and remove tank filler plug (1).
Refitting the tank filler plug
If removed, fit seal (3) at the bottom of tank filler plug (1), aiming it as shown in the figure.
Important
The seal must be fitted so that the written parts are visible.
Insert the fuel plug and start the four retaining screws (2).
Removing the fuel tank

REMOVING THE FUEL PUMP FLANGE
Loosen the six screws (1) and remove fuel pump flange (2), sliding it out as shown in the images.
During removal, pay attention not to damage the fuel pump (2).

REMOVING THE FUEL LEVEL SENSOR
Loosen the six screws (3) and remove fuel level sensor (4), sliding it out as shown in the images.
During removal, pay attention not to damage the fuel level sensor (4).
Refitting the fuel tank flange

REFITTING THE FUEL PUMP FLANGE
Insert fuel pump flange (2) inside the special seat of fuel tank, working and aiming it as shown in the image sequence.
Fasten fuel pump flange (2) by starting the six screws (1).
Tighten the six screws (1) to a torque of 5 Nm ± 10%, following the sequence shown in the image.

REFITTING THE FUEL LEVEL SENSOR
Insert fuel level sensor (4) inside the special seat of fuel tank, working and aiming it as shown in the image sequence.
Fasten fuel level sensor (4) by starting the six screws (3).
Tighten the four screws (3) to a torque of 4 Nm ± 10%.

Refitting the fuel tank

PRE-ASSEMBLING THE FUEL TANK
Insert the four clips (14) inside the relevant brackets of fuel tank (2), aiming them as shown in the images.
Insert the five special rubber blocks (15) inside the relevant brackets of fuel tank (2), aiming them as shown in the
images.
Insert the seven rubber blocks (16) inside the relevant brackets of fuel tank (2), aiming them as shown in the images.
Momentarily remove the two O-rings (17) from their seats on the two taps (18), see figure.
In order to keep the O-rings (17) in position during assembly, apply the indicated product (in two points at 180° to
each other) to the seats of the two O-rings (17), see figure.
Refit the two O-rings (17) in their seats on the taps (18).
Insert the two taps (18) into the corresponding holes in the fuel tank (2), aiming them with the fittings (A) facing as
shown in the pictures.
Keeping the two taps (18) pressed against the tank (2), secure them by finger tightening the screws (19) until they
are fully home.
Tighten the screws (19) to a torque of 5 Nm ± 10%, following a 1-2-1 sequence.
Fit the two rubber pads (20) on the fuel tank (2) by inserting them from the indicated side, letting poppets (B)
completely come out on the opposite side. If rubber pads prove difficult to fit, use the indicated product.
From the indicated side, insert the two spacers with collar (21) inside rubber pads (20) and drive them fully home.
Apply a drop of the indicated product in the centre of the groove of the rubber sheath (22), smearing the product on
the whole inner surface.
Fit the sheath (22) on the relevant profile of the fuel tank (2), as shown in the figure.
Evenly press on the whole outer surface of the sheath (22), making it adhere perfectly.
Immediately remove any product excess coming out of the sheath (22).

FITTING THE FUEL TANK
Refit fuel tank (2) on the motorcycle and connect the breather pipe (10) and the drain pipe (11).
Warning
To prevent detachment of the two pipes (10) and (11), when reassembling the tank, do NOT lubricate the two
couplings.
ATTENTION: A spring (C) is inserted inside the breather pipe (10) to make the end of the pipe stronger. This is to
prevent any constriction of the breather pipe (10) that could create a vacuum in the fuel tank (2).
Warning
(B).
Connect the tank ground connector (9).
Working on the LH side of the motorcycle, connect fuel level sensor connector (8).
Connect the fuel pipe quick coupling (6) and the fuel pump connector (7) to the fuel pump.
Connect hose (5) to taps (3) and secure it by tightening clamps (4) to a torque of 1 Nm ± 10%.
Open taps again (3).
Start the screws (1) retaining the fuel tank (2) on the front and back.

POSITIONING THE FUEL TANK PIPES
Fuel tank jointing pipe
Note
All clamps must be aimed as shown in the figures.
Insert fuel tank jointing pipe centreline inside hose grommet (A).
Fuel tank drain and breather pipes
• DRAIN pipe (1).

• Fuel tank BREATHER pipe to Y-shaped union (2).
• Canister filter BREATHER pipe (3).
• Pipe from canister filter to Y-shaped union (6).
• Pipe from Y-shaped union to presetting for rear tank (7).
Warning
Pipe (7) must always be plugged.
• DRAIN pipe (1).



button tie cable



branch

branch

Airbox drain pipe




Generator cable


connector


branch

branch

Airbox drain pipe




Generator cable

button tie cable

Side stand cable


branch

branch

Airbox drain pipe





(F) L = 82 mm (3.23 in) Airbox drain pipe Turn the oxygen sensor connection towards the
connector



Test to check correct positioning of fuel tank drain and breather pipes
During disassembly and reassembly of the fuel tank, the fuel tank breather and drain pipes may not be positioned
correctly, causing bottlenecks that could result in vacuum inside the tank.
After refitting the fuel tank, perform the following check for possible bottlenecks in the breather and drain pipes.
Note
The procedure to check the fuel breather pipe is described below; repeat the same procedure for the drain pipe.
Open the tank plug (D), ensuring that the fuel level is below the funnel of the tank plug.
Apply a workshop syringe (E) to the canister filter breather pipe (3) as shown in the figure.
Press the plunger of the syringe (E) and release it.
Test outcome:
• Positive: syringe plunger remains stationary after compression (pipe NOT obstructed).
• Negative: syringe plunger returns back due to back pressure (pipe obstructed).
In the event of a negative result, reposition the fuel tank breather pipe to clear any bottlenecks and repeat the test.
Once fuel tank (2) has been refitted, refit the following parts:
• Tank fairings (Refitting the tank fairings).

• Steering damper (Refitting the steering damper).
• Side fairings (Refitting the front half fairing).
• Rider seat (Refitting the seat).
Fitting the auxiliary fuel tank

REMOVING THE ORIGINAL COMPONENTS

Remove the side fairings (Removing the side fairings).
Remove the steering damper (Removing the steering damper).
Remove frame and underseat covers (Removing the side body panels and the tail guard)
Slacken and remove screw (36) while holding the nut (60).
Collect bushing (37) and silent-block (38).
Loosen screws (39) and remove silencer support bracket (40).
Collect the other silent-block (38) and washer (41).
Loosen the screws (42) and move the lower rear mudguard (43) so that the wiring inside it can be reached.
Remove connector plug (44) and loosen screws (45).
Note
For a better understanding of the procedure, the wirings shown in the figure are purely demonstrative and their length
does not correspond to the real one.

AUXILIARY FUEL TANK SET
Important
Please be reminded that the technical information contained in this document may undergo changes. We recommend
always checking such information against the data provided on the dedicated technical bulletins.
Important

Position Name

1 Quick coupling

2 Auxiliary wiring

3 Spacer with collar

4 Drift

5 Clamp

6 Clamp

7 Three-way union

Position Name
8 Union

9 TCEIF screw M5x9

10 Fuel pump cover

11 Spacer with collar

12 Drift

13 Auxiliary fuel tank

14 Silencer support bracket

15 Rubber tie

16 Auxiliary fuel tank delivery hose

17 Auxiliary fuel tank drain pipe

18 Rubber tie L = 39 mm (1.53 in)

19 Rubber tie L = 82 mm (3.23 in)

20 Clamp

21 Clamp

22 Union on tank

23 Rubber washer

24 TCEI screw M8x70

25 Cable retainer

26 Washer

27 M5 stud bolts

28 TBEI screw M5x8

29 Heat protection

30 TCEIF screw M5x14

31 Tank filler plug

32 TCEI M8x60 screw

33 Fuel tank bracket

34 Clamp

35 Auxiliary fuel tank breather pipe

PRE-FITTING THE WIRING AND FITTING THE LOWER REAR MUDGUARD
Connect the auxiliary wiring (2) to the presetting connector (46).

Route the auxiliary wiring (2) inside the seat (A).
Reposition the rear lower mudguard (43) by starting screws (42).
Note

PRE-ASSEMBLING THE TANK FILLER PLUG
Loosen and remove the screws (1) securing the tank filler plug (31).
Remove key nipple (2), remove the bracket (3) and collect the springs (4).
Remove spacer (5) from support (6).
Carrying out the procedure in reverse order, place the spacer (5) in the support (6) to insert the new key nipple (2).
Reposition bracket (3) and insert springs (4).
Insert the new key nipple (2).
Insert key (7) and turn it clockwise to lock nipple (2) in place.
Remove key (7) from key nipple (2).
During tank filler plug refitting, check the correct positioning of the two tabs (8) shown in the figure.
Start and tighten screws (1).

PRE-FITTING THE AUXILIARY FUEL TANK
If removed, fit seal (A) at the bottom of tank filler plug (31), aiming it as shown in the figure.
Important
The seal must be fitted so that the written parts are visible.
Fit tank filler plug (31) in fuel tank (13).
Start and tighten the four screws (30) to a torque of 5 Nm ± 10%.
Insert the two rubber washers (23) on the two unions (22).
Start the two unions (22) on the auxiliary fuel tank (13).
Tighten the two unions (22) to a torque of 2 Nm ± 10%.
Start the three stud bolts (27) on the auxiliary fuel tank (13).
Tighten the three stud bolts (27) to a torque of 5 Nm ± 10%.
Position heat guard (29) on the auxiliary fuel tank (13).
Start the three screws (28).
Tighten the three screws (28) to a torque of 5 Nm ± 10%.
Position the eight pads (12) on both sides of the auxiliary fuel tank (13).
Insert the four spacers with collar (11) inside the eight pads (12).
Position the four pads (4) on both sides of the auxiliary fuel tank (13).
Insert the two spacers with collar (3) inside the four pads (4).

FITTING THE AUXILIARY FUEL TANK AND SILENCER BRACKET
Note
Connect connector (2) to the auxiliary fuel tank (13).

Position the auxiliary fuel tank (13) in the frame.
Position tank bracket (33) on fuel tank (13).
Start the two screws (32).
Start but do not tighten the two screws (32).
Position the silencer support bracket (14) in the auxiliary fuel tank (13).
Start the four screws (24).
Tighten the four screws (24) and two screws (32) to a torque of 25 Nm ± 10%.
Position the “inner” silent-block (38) and washer (41) between silencer (47) and silencer bracket (14).
Position the “outer” silent-block (38) and bushing (37) in the silencer (47).
Start the screw (36) in the nut (60).
Tighten screw (36) to a torque of 20 Nm ± 10% while holding nut (60) on the opposite side.

AUXILIARY FUEL TANK CONNECTION HOSE LAYOUT
Take tank jointing hose (48).

Now cut the pipe (48) into two sections, thus obtaining pipe (49) and pipe (50).
Proceed as follows:
• Starting from the left end, cut the tank jointing hose (48) to dimension (X) = 75 mm (2.95 in), thus creating
hoses (49) and (50).
• From pipe (55) remove (Z) = 10 mm (0.39 in) as shown in the figure.
Connect the two hoses (49) and (50), created by cutting hose (48), to the three-way union (7), as shown in the figure.
Fasten hoses (49) and (50) on three-way union (7) using clamps (6).
Important
Check the diameter of the two ends of hose (49) before fitting. Connect the end with the larger diameter to the quick
coupling (7).
Insert the end of hose (16) in the quick coupling (1).
Secure the quick coupling (1) to the hose (16) with clamp (34).
Connect the quick coupling (1) to the fuel pump (61).
Insert the other end of the hose (16) inside the frame, as shown in the figure.
Keeping the hose (16) clamped between the frame and the electrical component support box, continue from the fuel
pump (61), as shown in the figure, towards the front of the motorbike.
Apply the two rubber ties (19) L= 82 mm (3.23 in) at the points (B) shown in the figure.
Insert the two cable retainers (25) into the holes on the inside of the frame.
Route the hose (16) under the canister support as shown in the figure.
Fix hose (16) to the two cable retainers (25).
Connect the tube (16) to the three-way union (7) from the end with the smaller internal hole.
Fasten hose (16) to the three-way union (7) using clamp (5).
Important
It is very important that the hose (16) is positioned in front of the other hoses, as shown in the figure.
Position the fuel pump cover (10).
Start the three screws (9) in the fixing holes.
Tighten the three screws (9) to a torque of 5 Nm ± 10%.
Connect the breather pipe (35) of the auxiliary fuel tank to the lower nipple (22) as shown in the figure.
Fasten pipe (35) to the lower nipple (22) with clamp (20).
Insert the other end between the frame and the electrical component support box.
Fasten the pipe (35) using two rubber ties (19) L= 82 mm (3.23 in) at the two points shown in the figure.
Continue by routing the pipe (35) between the brake fluid reservoir hose and the subframe following the rear brake
hose.
Apply the two rubber ties (18) L= 39 mm (1.53 in) at the two points shown in the figure, retaining the pipe (35) to the
rear brake hose.
Continue towards the inside of the motorbike. The breather pipe (35) is routed inside through the engine, in the
remaining space between the ABS control unit and the airbox bottom.
From the LH side of the vehicle, the pipe (35) has an excess length of 140 mm (5.51 in) which must be cut off before
the Tee union (7) is fitted to the main tank breather pipe.
After cutting, insert the Tee union (7) and position the pipe (35) as shown in the picture.
Disconnect the fuel tank breather pipe (53).
Now cut the pipe (53) into two sections, thus obtaining pipe (54) and pipe (55).
Proceed as follows:
• Pull the pipe (53) downwards so that it can be cut.

• Cut the pipe (53) at dimension (X) = 300 mm (11.8 in) starting from the upper end (tank side).
• After the cut, pipe (53) is split into two other pipes which will be numbered (54) and (55).
• From pipe (55) remove (Y) = 10 mm (0.39 in) as shown in the figure.
Fasten pipe (35) to the three-way union (7) using clamp (5).
Insert pipe (55) into the three-way union (7). Secure pipe (55) with clamp (6)
Insert pipe (54) into the three-way union (7).
Secure pipe (54) with clamp (6).
Note
Below is the final breather hose layout:
• Hose (54) from main fuel tank breather to coupling (7).

• Hose (55) from canister coupling to coupling (7).
• Hose (35) from auxiliary fuel tank breather to coupling (7).
Reposition the breather pipe (54) inside the frame as shown in the figure.
By working from the front of the vehicle, connect hose (50) and hose (49) to the left and right tank cocks,
respectively.
For hose positioning refer to chapter "Fitting the fuel tank".
Secure the hoses (49) and (50) to the two cocks with the clamps (56).
Tighten the two clamps to a torque of 1 Nm ± 10%.
Before using the vehicle, reopen the two cocks.
Connect the auxiliary fuel tank drain pipe (17) of the auxiliary fuel tank to the upper nipple (22) as shown in the
figure.
Fasten pipe (17) to the upper nipple (22) with clamp (21).
Position the auxiliary tank drain pipe (17) as shown in the figure.
Fix pipe by means of clamp (57).
Position cover (58) and start two screws (59).
Refit frame and underseat covers (Refitting the side body panels and the tail guard)
Refit the steering damper (Refitting the steering damper).
Refit the side fairings (Refitting the side fairings).

AUXILIARY FUEL TANK ACTIVATION WITH DDS 3.0
To activate the auxiliary fuel tank proceed as follows:
• Connect the DDS 3.0 to the diagnostic socket and perform the procedure on your PC;
• Select “Special functions” (1) and then “Bike configurator” (2).
• Select “Accessory activation without order check on DCS” (3).
• Press “Confirm” (4).
• Enter your credentials, USERNAME (5), PASSWORD (6) and then press the green confirmation tick (7).
• Select the accessory to be installed, i.e. the auxiliary fuel tank (8);
• Select the green confirmation tick (9).
• Continue the procedure by pressing “Confirm” (10).
• As required, perform a key-off;
• Wait for the power-latch (12).
• As requested, perform a key-on (13).
• The procedure is finished;
Removing the airbox and throttle body
To remove the airbox and throttle body, the following parts must be removed first:
• Rider seat (Removing the seat).

• Side fairings (Removing the side fairings).
• Secondary air system valve pipes (Removing the secondary air system).

REMOVING THE BLOW-BY PIPE
Working on the vehicle RH side, loosen the tie (1) and disconnect the blow-by pipe (2) from the airbox.
Loosen tie (3) and remove the blow-by pipe (2) from blow-by valve union.

REMOVING THE AIRBOX ASSEMBLY

Disconnect the injector connector (2) and the potentiometer connector (3).
Disconnect the vertical head Map Sensor connector (4).

Loosen screws (8) securing main wiring cover (9) to airbox assembly.
Disconnect air temperature sensor connector (13).
Move the main wiring (A) from the airbox assembly (14), as shown in the figure.
Disconnect connector of the secondary air valve (15).
From the indicated point, remove the self-locking ties (B), releasing the main wiring branch (C) from the clips (D) on
the airbox assembly (14).
Remove the button ties (E), (M), (N), (P), and release the airbox drain pipe (16).
Remove the airbox drain pipe (16), as shown in the figure.
Remove the self-locking ties (F), releasing the GAC hose (17) from the fuel pump wiring branch (G).
Working on both heads, loosen ties (18) securing airbox assembly to intake manifolds.
Remove the airbox assembly (14) from the motorcycle.

REMOVING THE THROTTLE BODY
Loosen the screws (1) that retain the airbox cover (2) and collect the two hose grommets (3).
Separate the upper airbox cover (4) from the lower airbox cover (5).
Working on lower airbox cover (5) side, remove the three self-locking ties (6).
Remove hose grommets (7) and (8) of fuel pipe (9) and wiring (10), respectively.
Disconnect the vertical injector (11) and the horizontal injector (12) wiring.
Disconnect the potentiometer (13).
Remove the wiring inside the airbox cover.
Loosen the eight screws (14) securing throttle body (15) to airbox cover.
Remove the throttle body.
Loosen the two screws (16) securing injectors (17) to throttle body (15).
Refitting the airbox and throttle body

REFITTING THE THROTTLE BODY
Apply the indicated product on the O-rings (A) of the two injectors (17), carefully avoiding to smear injector surfaces
and using the quantity of product strictly necessary to carry out the following assembly operations.
Fit the injectors (17) in the relevant seats on fuel pipe set (9), aiming them as shown in the figure.
Secure injectors (17) in place by inserting two retaining clips (18) inside grooves (B).
Warning
Clips must be aimed as shown in the figure and, after having driven them fully home, they must be perfectly seated
both on injectors and on fuel pipe set.
Apply the indicated product on the O-rings (C) of the two injectors (17), carefully avoiding to smear injector surfaces
and using the quantity of product strictly necessary to carry out the following assembly operations.
Position the fuel pipe set (9) by inserting injectors (17) into the relevant seats of throttle body (15), complying with
the layout and aiming shown in the figure.
Warning
In order to avoid damaging the O-rings (C), drive the injectors (17) fully home on the throttle body (15), keeping
them aligned with their seats.
Fasten injector couplings (17) by starting the two screws (16).
Fit the two rubber plugs (18) in the indicated areas of the lower airbox cover (5), inserting them from the external side
and making poppets (D) completely come out on the internal side.
If rubber parts prove difficult to fit, use the indicated product.
USA / CAL / CDN / MEX VERSIONS ONLY
Apply the indicated product on the two rubber plugs (18), as shown in the figure.
Fit the two O-rings (19), inserting them perfectly into their relevant seats on the lower airbox cover (5).
Position the throttle body (15) inside the lower airbox cover (5), aiming it as shown in the figure.
Tighten the two screws (16) to a torque of 5 Nm ± 10%, following a 1-2 sequence.
Fit the two O-rings (20) on the two intake funnels (21), fitting them perfectly into their respective seats.
Position the two intake funnels (21) on the throttle body (15) and secure them by starting screws (22) with pre-
applied threadlocker.
Tighten the four screws (22) to 5 Nm ± 10%, following a 1-2-3-4 sequence.
Partially secure throttle body (15) to airbox lower cover (5) by starting the four screws (14) marked with the sequence
number (1–2–5–6).
Continue securing throttle body (5) to airbox lower cover (7) by starting the other four screws (14).
Tighten the eight screws (14) to a torque of 8 Nm ± 10%, following a 1–2–3–4–5–6–7–8 sequence.
Lay down wiring in the lower airbox cover, sliding potentiometer wiring branch (13) over the throttle body fuel pipe set,
as shown in the figure.
Lay down wiring in the lower airbox cover (5), sliding potentiometer wiring branch (13) over the throttle body fuel pipe
set (9), as shown in the figure.
Note
Make sure that potentiometer wiring branch is NOT squeezed between fuel pipe set and the surface of the throttle
body.
Connect potentiometer wiring branch (13) male connector to the female connector on throttle body, aiming it as shown
in the figure.
Connect the horizontal injector wiring branch connector (12) and vertical injector wiring branch connector (11) to the
corresponding injectors.
Note
It is possible to distinguish between the injector wiring branches by observing the letters “V” and “O” on the labels
attached to the cables.
Apply the indicated product (diluted at 50% with water) to the hose grommets (7) and (8).
Insert the hose grommets (7) and (8) perfectly into their respective seats on the lower airbox cover, as shown in the
figure.
Using three small self-locking ties (6), fasten the throttle body fuel pipe set and wiring together in the indicated
positions, as shown in the figure.
Fit the vibration damper (23) in the indicated area of the upper airbox cover (4), aiming it as shown in the figure.
Couple the upper airbox cover (4) to the lower airbox cover (5) and secure the parts by starting screws (1) and two
hose grommets (3) in the positions shown in the figure.
Tighten the screws (1) to the specified torque, following the sequence shown in the figure.
Fit the air filter as shown in the chapter “Changing and cleaning the air filter”.
Fit seal (24) onto air temperature sensor (25), as shown in the figure.
Insert the air temperature sensor (25) in its seat on the airbox assembly and secure it by tightening the two screws
(26).
Fit the clamp (27) on the drain hose (28).
Fit the drain hose (28) by inserting it on the corresponding fitting of the airbox assembly.
Bring clamp (27) in place and tighten it as shown in the figure.
Position the two Hellermann cable rings (29) on the airbox assembly, centring them with respect to the notches (E),
and tighten the screws (30).
Tighten screws (30).

REFITTING THE AIRBOX ASSEMBLY
If previously removed, fit ties (18) in the seats of intake manifolds, aiming them as shown in the figure.
Apply the indicated product to the seats (L) of intake manifolds.
Refit the airbox assembly (14) on motorcycle, routing drain pipe (16) as shown in the figure.
During this procedure, make sure that the fuel pipe (H) is not squeezed between frame and airbox assembly.
Exert a pressure on the airbox assembly (14), making sure that the sleeves of the throttle body are correctly inserted
and fully home on horizontal and vertical head intake manifolds.
Working on both heads, tighten ties (18) to a torque of 2.5 Nm ± 10%.
Using self-locking ties (F), fasten the GAC hose (17) to the fuel pump wiring branch (G), as shown in the figure.
Reposition the airbox drain pipe (16), as shown in the figure.

Refit the button ties (E), (M), (N), (P), and secure the airbox drain pipe (16) as shown in the figure.


(E) L = 82 mm (3.23 in) Starter motor / solenoid starter
button tie cable



branch

branch

Airbox drain hose




Generator cable

(M) L = 82 mm (3.23 in) Starter motor / solenoid starter Turn the side stand connection towards the

connector


branch

branch

Airbox drain hose




Generator cable

(N) L = 82 mm (3.23 in) Starter motor / solenoid starter At sump guard bracket “purple” screw
button tie cable

Side stand cable


branch

branch

Airbox drain hose




(P) L = 82 mm (3.23 in) Airbox drain hose Turn the oxygen sensor connection towards the
connector



From the indicated point, refit the self-locking ties (B), fastening the main wiring branch (C) to the clips (D) on the
airbox assembly (14).
Connect connector of the secondary air valve (15).
Refit the main wiring harness (A) on the airbox assembly (14) and connect the air temperature sensor connector (13).
Position main wiring harness cover (9) on the airbox assembly and start the screws (8).

Connect the vertical head Map Sensor connector (4).
Connect the injector connector (2) and the potentiometer connector (3).
Warning
(B).

REFITTING THE BLOW-BY PIPE
Refit the blow-by pipe (2) on the motorcycle, aiming it as shown in the figure, inserting it in the blow-by valve union
and in the airbox.
Tighten clamp (3) to a torque of 1.5 Nm ± 10%, aiming it as shown in the figure.
Fasten the blow-by pipe (2) to the airbox using tie (1).
• Secondary air system pipes (Refitting the secondary air system).

• Fuel tank (Refitting the fuel tank).
• Side half fairings (Refitting the side half fairing).
• Rider seat (Refitting the seat).
Removing the air filters

Important
A clogged air filter will reduce air intake and engine power, increase fuel consumption and cause a build up of deposits
on the spark plugs. Do not use the motorcycle without a filter as impurities in the air could get into the engine and
cause damage.
Note
Do not dispose of replaced filters into the environment.
Disposal
If filtering element is replaced, do not dispose of waste into the environment. Collect and deliver waste to authorized
collecting centres. Dispose of waste in compliance with the prevailing local and national standards.
02 02* (Absorbents, filter materials (including oil filters not otherwise specified), wiping cloths, protective clothing
contaminated by dangerous substances).
Note
Important

Loosen the six screws (2) securing air filter cover (3) to the airbox upper shell (4).
Slide out the air filter (8).
Clean the air filter (8) with a jet of compressed air or replace it.

REMOVING THE HORIZONTAL HEAD BELT COVER AIR FILTER
Important
Working on the RH side of the motorcycle, loosen screws (14) and remove horizontal head belt cover (13).
Loosen screws (15) and remove the air filter (16) from the horizontal head belt timing cover (13).
Refitting the air filters
Fit the air sensor (8) on the airbox upper cover (4), aiming it as shown in the figure.
Position the air filter cover (3) on the airbox upper cover (4) and start the screws (2) in the positions shown in the
figure.
Tighten the six screws (2) to a torque of 2 Nm ± 10%, following the sequence shown in the figure.

REFITTING THE HORIZONTAL HEAD BELT COVER AIR FILTER
Refit filter (16) on the horizontal head belt cover (13) and start screws (15).
Tighten the screws (15) to a torque of 1.75 Nm (Min. 1.5 Nm. - Max. 2 Nm).
Working on the motorcycle RH side, position the horizontal head belt cover (13) and start the screws (14).
Removing the secondary air system
To gain access to secondary air system connector and pipes, the following parts must be removed:
• Rider seat (Removing the rider seat).

• Front fairing (Removing the front half fairing).
Disconnect connector (1) of the secondary air system valve (2).
Disconnect click clamp (3) and release vertical head secondary air system pipe (4).
Remove the two button ties (7) and (8) L= 39 mm (1.53 in).
Remove button tie (A) L= 62 mm (2.44 in).
Disconnect click clamp (5) and release horizontal head secondary air system pipe (6).
Remove the secondary air system actuator unit (2) by pulling it so as to release rubber blocks (12) from pins (11) and
actuator union (9) from rubber block (10).
During removal, pay attention not to damage the actuator.
Refitting the secondary air system
Fit the click clamp (14) on the horizontal head secondary air actuator hose (6) and a “click” clamp (14) on the vertical
head secondary air actuator hose (4).
Fit the hoses (6) and (4) on the appropriate fittings of the secondary-air actuator (2), orienting them so that the
references (A) and (B) on the hoses are parallel with the upper surface (C) of the actuator, see image.
Fit the two click clamps (14) in correspondence with the markings (D) and (E) on the hoses (4) and (6).
Fasten hoses (4) and (6) using click clamps (14), aiming them as shown in the figure.
Warning
Carefully check to have oriented the hoses as shown in the figure and that they are aligned with the actuator according
to the present markings.
Assemble the secondary air actuator unit (2), aiming it as shown in the figure, on the airbox assembly, inserting it in
the vibration damper (10) and on the pins (11) until fully home.
If the actuator union (9) proves difficult to fit inside rubber block (10) and rubber blocks (12) prove difficult to fit
inside pins (11), we recommend using the indicated product.
Position fuel pipe set (13) on the two hose grommets (14), as shown in the figure.
Make sure that fuel pipe set (13) is correctly positioned over vertical head secondary air system pipe (4).
Position pipe (6) as shown in the figure fastening it to secondary air system union with click clamp (5).
Position button tie (A) L= 62 mm (2.44 in) so as to fasten horizontal coil cable to horizontal head secondary air system
pipe.
Position pipe (4) as shown in the figure fastening it to secondary air system union with click clamp (3).
Position button tie (7) L= 39 mm (1.53 in) so as to fasten vertical coil cable to vertical head secondary air system pipe.
Position button tie (8) L= 39 mm (1.53 in) so as to fasten vertical head secondary air system pipe to airbox bracket.
Connect connector (1) of the secondary air valve (2).

• fuel tank (Refitting the fuel tank);

• front fairing (Refitting the front half fairing);
• rider seat (Refitting the rider seat).
Removing the silencer
Warning
Working on the RH side of the motorcycle, loosen screws (1) and remove heat guard (2) by releasing the rubber block
(A) from the pin (B) and collecting washers (15).
Undo screw (3) that retains the silencer to the silencer support bracket, while holding nut (4) from the opposite side
and collect washer (5).
Loosen clamp (6) and remove silencer (7).

REMOVING THE SILENCER BRACKET
Loosen the screws (8) and remove the silencer bracket (9) from the rear subframe.
Refitting the silencer

FITTING THE SILENCER BRACKET
Position the silencer bracket (9) on the rear subframe, aiming it as shown in the figure and start screws (8).

PRE-FITTING THE FULL HEAT GUARD
Insert the clip (10) in the rear silencer heat guard (11), aiming it as shown in the images.
Fit the drift (12) in the rear silencer heat guard (11), inserting it as shown in the figure and making sure that poppet
(B) comes out on the opposite side.
Position the front heat guard (13) on rear heat guard (11), inserting the attachment (C) in the cavity (D), and start the
screw (14).
Fit vibration damper (A) in the front heat guard (13), aiming it as shown in the figure.
Apply the indicated product to tie (6) thread.
Refit silencer (7) by driving it fully home against the pre-silencer and aiming clip (6) as shown in the figure.
Tighten clip (6) to a torque of 10.5 Nm ± 10%.
Place washer (6) between silencer and silencer support bracket and start screw (4).
On the opposite side, screw nut (5) on the threaded end of screw (4).
Position full heat guard (2) by inserting pin (B) in rubber block (A) and start screws (1), placing washers (15) between
the full heat guard (2) and the silencer, as shown in the figure.
Removing the exhaust system
Remove the exhaust silencer (Removing the exhaust silencer).

Remove frame and underseat covers (Removing the side body panels and the tail guard).
Remove the RH footpeg holder plate (Removing the footpegs).
Loosen the clamps (1) retaining the pre-silencer (2) to the vertical (3) and horizontal (4) exhaust manifolds.
Remove the button tie (A) and release the horizontal oxygen sensor connector (7).
Remove self-locking tie (6) and disconnect horizontal oxygen sensor connector (7).
Loosen two nuts (5) securing the horizontal exhaust manifold (4).
Loosen but do not remove nut (5) securing the horizontal exhaust manifold (4).
Loosen screw (8) that retains pre-silencer (2) to the con-rod of the side stand plate.
Remove pre-silencer (2).
Loosen nut (5), remove the horizontal exhaust manifold (4) and gaskets (9).
Loosen screw (10) and position rear brake master cylinder fluid reservoir (11) as shown in the figure.
Remove the clamps retaining the vertical exhaust oxygen sensor connector (13) (Branch 7).
Disconnect the vertical exhaust oxygen sensor connector (13).
Remove vertical exhaust oxygen sensor (14).
Working on either sides of the vehicle, loosen screws (15), collect washer (16) and remove the vertical heat protection
(17).
Loosen nuts (18), remove the vertical exhaust manifold (19) and gaskets (20).
Refitting the exhaust system

PRE-FITTING THE PRE-SILENCER
Fit the two vibration dampers (1) on con-rod (2).

Insert the two spacers with collar (3) in the lower damper of con-rod (2).
Insert the threaded bushing (4) in the upper damper of the con-rod (2), as shown in the figure.
Position con-rod (2), from the side of the just-assembled spacers, on pre-silencer (5).
Start the screw (6) to secure the con-rod (2) on pre-silencer (5).
Position exhaust support bracket (7), from the side of the just-assembled bushing, on con-rod (2).
Start screw (8) to secure bracket (7) on con-rod (2).
Position exhaust gasket (11) and flange (10) on pre-silencer (5) vertical inlet.
Fit exhaust clamp (9) on vertical inlet, gasket (11) and flange (10), aiming it as shown in the figure.
Aim exhaust clamp (9) as shown in the figure (B) and screw nut (9A) fully home without tightening.
Position exhaust gasket (11) and flange (10) on pre-silencer (5) horizontal inlet.
Fit exhaust clamp (9) on horizontal inlet, gasket (11) and flange (10), aiming it as shown in the figure.
Aim exhaust clamp (9) as shown in the figure (C) and screw nut (9A) fully home without tightening.

REFITTING THE EXHAUST SYSTEM
Fit the gaskets (20) on the stud bolts of the vertical head, orientating them as shown in the figure.
Fit the vertical exhaust manifold (19) on the vertical head stud bolts and fix it by starting nuts (18).
Tighten nuts (18) to a torque of 10 Nm ± 10%.
Position vertical heat guard (17) and start screw (15) with washer (16) on the RH side of the motorcycle.
Working on the LH side of the motorcycle, start screws (15) on vertical heat guard (17).
Start vertical exhaust oxygen sensor (14) on vertical exhaust manifold.
Tighten the vertical exhaust oxygen sensor (14) to a torque of 24.5 Nm ± 10%.
Connect vertical exhaust oxygen sensor connector (13) and secure it to the frame clip using relevant ties (Branch 7).
Position rear brake master cylinder fluid reservoir (11) and start screw (10).
Fit the gaskets (9) on the stud bolts of the horizontal head, orientating them as shown in the figure.
Position the horizontal exhaust manifold (4) inserting it on the horizontal head stud bolts and start nut (5).
Start vertical exhaust oxygen sensor on vertical exhaust manifold.

Tighten the vertical exhaust oxygen sensor to a torque of 24.5 Nm ± 10%.
Refit the pre-silencer (2) fully home on the vertical exhaust manifold and inserting it on the horizontal exhaust
manifold.
Start screw (8) that retains pre-silencer (2) to the con-rod of the side stand plate.
Start nuts (5) securing the horizontal exhaust manifold (4).
Connect the horizontal oxygen sensor connector (7).
Using the self-locking tie (6) fasten horizontal oxygen sensor cable to oil pressure switch support.
Using the button tie (A) fix the horizontal oxygen sensor cable (7) as shown in the figure (Branch 7).
Apply the specified product to ties (1).

Position ties (1) securing pre-silencer (2) on vertical (3) and horizontal (4) exhaust manifolds, aiming them as shown
in the figure, and tighten them to a torque of 5 Nm ± 10%.
Refit the RH footpeg holder plate (Refitting the footpegs).
Refit frame and underseat covers (Refitting the side body panels and the tail guard).
Refit the sump guard (Refitting the sump guard).
Refit the exhaust silencer (Refitting the exhaust silencer).
Canister filter system
The canister filter is a system that collects the fuel vapours released by the fuel tank. This filter is positioned along the
tank breather tube and must keep the fuel vapours when the vehicle is not moving.
To maintain the efficiency of the active carbons, the system is active while the engine is ON. The vacuum generated in
the intake manifolds makes fresh air flow through the canister filter and clean it.
The vapours generated while riding are conveyed to the intake system. To prevent the mixture from getting too rich,
the pipe has a purge valve that is opened and closed according to the riding conditions.
PARKED BIKE AND CLOSED PURGE VALVE
In this condition the vapours released by the tank by means of pipe (1) and ((1A) if present) reach the canister filter
(2).
The Purge valve (3) remains closed.
Filtered air flows out of pipe (4).
MOVING BIKE AND OPEN PURGE VALVE
In this condition air flows in pipe (1) ((1A) if present) to ventilate the tank.
The Purge valve (3) is open and so the fuel vapours coming from the canister (2) are sucked by vertical (5) and
horizontal (6) head intake manifolds.
Fresh air from outside enters from pipe (4).
MOVING BIKE AND CLOSED PURGE VALVE
In this condition air flows in pipe (1) ((1A) if present) to ventilate the tank.
The Purge valve (3) is closed and so there is no vapour passage through the vertical (5) and horizontal (6) head intake
manifolds.
Fresh air from outside enters from pipe (4).
Removing the canister filter
Remove the airbox (Removing the airbox).

REMOVING THE CANISTER AND MAP SENSOR PIPES
Working on the RH side of the motorcycle, disconnect the connector (A) from Purge valve (1).
Loosen clip (2) and remove canister pipe (3) from horizontal head intake manifold.
To make the following canister filter removal easier, loosen clip (2) and remove map sensor pipe (4) from horizontal
head intake manifold.
Loosen clip (2) and remove canister pipe (5) from vertical head intake manifold.

REMOVING THE CANISTER ASSEMBLY
Refitting the Canister filter

PRE-ASSEMBLING THE CANISTER PIPE SET
Time the rubber support (A), located on tank breather valve (1), aiming it so that timing tooth (B) is inserted inside
support recess shown in the figure.
Fit rubber support (2) on canister filter (3), positioning it as shown in the figure.
Pipe length:
• Pipe (5) length 70 mm (2.76 in).

If hoses prove difficult to assemble, use the indicated product.

Insert the end of preformed pipe (4) with the skirted section on tank breather valve union (1) with the rubber support
(2), as shown in the figure.
Insert pipe (5) end with the skirted section on tank breather valve union (1).
Fit the two (large GREEN) click clamps (6) on pipes (4) and (5), aiming them as shown in the figure.
Fit the three (small GREEN) click clamps (7) on pipes (5), (8) and (9).
Insert the T-shaped connector (10) on the free end of pipe (5), aiming it as shown in the figure.
Fit pipes (8) and (9) on union (10), from the side with clamps (7), complying with the arrangement shown in the
figure.
Move click clamps (6) and (7) to their positions and tighten them taking care to respect the arrangements shown in
the images.
Fit two spring clamps (11) on pipes (8) and (9), aiming them as shown in the figure.
Pipe length:
• Pipe (12) length 290 mm (11.42 in).

Fit the (small GREEN) click clamp (7) on pipe (4).
Connect the tank breather valve assembly by fitting pipe (4) on the indicated union of canister filter (3).
Fit the (large YELLOW) click clamp (13) on breather pipe (12).
Fit pipe (12) on the indicated union of canister filter (3), as shown in the figure.
Move click clamps (7) and (13) to their positions and tighten them taking care to respect the arrangements shown in
the images.
Fasten pipe (4) to rubber support (2) by tightening the large self-locking tie (14).
Pipe length:
• Pipe (15) length 110 mm (4.33 in).

• Pipe (16) length 230 mm (9.06 in).
• Pipe (17) length 470 mm (18.50 in).

Fit the three (large GREEN) click clamps (6) on pipes (15), (16) and (17), aiming them as shown in the figure.
Fit pipes (15), (16) and (17) on T-shaped union (10), from the side with clamps (6), complying with the arrangement
Fit the (large BLACK) click clamp (18) on pipe (15).
Fit plug (19) fully home on the free end of pipe (16).
Connect the 3-way breather assembly with plugged end by fitting pipe (15) on the indicated union of canister filter (3).

REFITTING THE CANISTER ASSEMBLY

REFITTING THE CANISTER AND MAP SENSOR PIPES
Insert canister pipe (5) onto the vertical head intake manifold union and fasten it using clamp (2).

Insert canister pipe (3) onto the horizontal head intake manifold union and fasten it using clamp (2).
Insert map sensor pipe (4) onto the horizontal head manifold union and fasten it using clamp (2).
Connect connector (A) to Purge valve (1).

POSITIONING THE PIPES
• Fuel tank breather pipe (1).

• Pipe from Y-shaped union to vertical head intake manifold (2).
• Pipe from canister to purge valve (3).
• Pipe from Y-shaped union to horizontal head intake manifold (4).
• Pipe from Y-shaped union to purge valve (5).
• Pipe from Y-shaped union to blanked presetting for rear tank (7).
• Canister breather pipe (8).


(A) Big self-locking tie Canister support

Pipe from canister to purge valve
Warning


(B) L = 82 mm (3.23 in) Starter motor / solenoid starter
button tie cable



branch

branch

Airbox drain hose




Generator cable

(C) L = 82 mm (3.23 in) Starter motor / solenoid starter Turn the side stand connection towards the

connector


branch

branch

Airbox drain hose




Generator cable

(D) L = 82 mm (3.23 in) Starter motor / solenoid starter At sump guard bracket “purple” screw
button tie cable

Side stand cable


branch

branch

Airbox drain hose




(E) L = 82 mm (3.23 in) Airbox drain hose Turn the oxygen sensor connection towards the
connector



Refit the airbox (Refitting the airbox).

Removing the engine
Support the motorcycle with suitable equipment.

REMOVING THE RIDER SEAT

REMOVING THE PASSENGER SEAT
Undo the screws (3), lift the front side of the passenger seat (4) and recover the spacers with collar (5).
Remove the passenger seat (4) by pulling it towards the front side of the motorcycle.

REMOVING THE WINDSCREEN
Working on either sides of the vehicle, loosen screws (1) and remove the Plexiglas windscreen (2).

REMOVING THE SIDE FAIRINGS
The procedure below describes how to remove one side fairing but it applies to both.
Extract the LH front turn indicator wiring placed behind the headlight, as shown in the figure, and remove the rubber
tie (A).
Disconnect LH front turn indicator connector (1).
Loosen the screw with short collar (2) and the nylon washer (3) retaining the LH side fairing (6) at the top.
Undo screw with short collar (2) retaining the LH side fairing (6) on the inside.
Loosen screw with long collar (4) fastening LH side fairing (6) at the bottom while holding threaded bushing (5) on the
opposite side.
Remove LH side fairing (6) from the motorbike by releasing pins (B) from rubber blocks (C), pin (D) from rubber block
(E) and special rubber block (7) from the slot (F).

REMOVING THE STEERING DAMPER
Loosen the screws (1) that retain the steering damper support (2) to the steering head.
Unscrew the screws (3) and remove the steering damper assembly (4).

REMOVING THE TANK CENTRAL COVER
Loosen the screws (1) and remove the central tank cover (2) by lifting it upwards, releasing the special rubber block
(A) from the cavity (B) and the pin (C) from the rubber block (D), as shown in the figure.

REMOVING THE SIDE CONVEYORS
Loosen screw (1) and remove LH conveyor (2).

Loosen screw (1) and remove RH conveyor (3).

REMOVING THE UNDERSEAT AND FRAME COVERS
Working on the motorcycle RH side, remove the tie (1), loosen screw (2) and remove the RH underseat cover (3).
Loosen screw (4) and remove the RH frame cover (5).
Working on the motorcycle LH side, remove tie (1), loosen screw (2) and remove the LH underseat cover (6).
Remove the LH frame cover (7).

REMOVING THE FUEL TANK
Loosen the screws (1) retaining the fuel tank (2) on the front and back.
Working on either sides of the motorcycle, tighten taps (3).
Place a container at the cocks (3) under the motorbike.
Loosen clamps (4) and disconnect hose (5).
Disconnect the fuel pipe quick coupling (6) and the fuel pump connector (7) from the fuel pump.
Working on the LH side of the motorcycle, disconnect fuel level sensor connector (8).
Disconnect the tank ground connector (9).
Lift the front of the fuel tank (2) and disconnect the breather pipe (10) and the drain pipe (11).
Remove fuel tank (2) from the motorcycle.

REMOVING THE SUMP GUARD
Working on motorcycle LH side, loosen the screws (1), remove the stand protection (2) from the sump guard (5) and
Working on either sides of the vehicle, loosen screws (3), lower screw (4) and remove the sump guard (5).

REMOVING THE WATER RADIATOR ASSEMBLY
Empty the cooling system (Changing the coolant).
Loosen tie (A) and disconnect the expansion reservoir (1) hose from the water radiator (2).
Loosen tie (3) and disconnect thermostatic valve/vertical head hose (4).
Loosen tie (3) and disconnect the water radiator/pump hose (5).
Remove the right (B) and left (C) electric fan connectors from the frame brackets.
Disconnect the right (B) and left (C) electric fan connectors.
Working on either sides of the motorcycle, loosen screws (7) and remove the water radiator assembly (2) from the
motorcycle by releasing the RAD-DUCT pins (D) from the rubber blocks (E) of the headlight lower cover.

REMOVING THE BLOW-BY PIPE
Working on the vehicle RH side, loosen the tie (1) and disconnect the blow-by pipe (2) from the airbox.
Loosen tie (3) and remove the blow-by pipe (2) from blow-by valve union.

REMOVING SECONDARY AIR SYSTEM VALVE PIPES AND COILS
Working on the vertical head, remove the self-locking ties (A), releasing the main wiring (D), starter motor cable (E)
and negative battery cable (F) from the wiring support bracket (7).
Disconnect the vertical coil connector (G).
Loosen clamp (1) fastening secondary air system pipe (2).

Slide the secondary air system pipe (2) out of the vertical head cover.
Move the main wiring from the vertical head, loosen screws (6) and remove wiring support bracket (7).
Remove hose grommet (8) from frame bracket, as shown in the figure.
Working on the horizontal head, remove button tie (B) and disconnect horizontal coil connector (C).
Loosen clamp (1) fastening secondary air system pipe (9).
Slide the secondary air system pipe (9) out of the horizontal head cover.
Loosen screw (11) and remove pipe support bracket (12).

REMOVING THE AIRBOX ASSEMBLY

Disconnect the injector connector (2) and the potentiometer connector (3).
Disconnect the vertical head Map Sensor connector (4).

Loosen screws (8) securing main wiring cover (9) to airbox assembly.
Disconnect air temperature sensor connector (13).
Move the main wiring (A) from the airbox assembly (14), as shown in the figure.
Disconnect connector of the secondary air valve (15).

From the indicated point, remove the self-locking ties (B), releasing the main wiring branch (C) from the clips (D) on
the airbox assembly (14).
Remove the button ties (E), (M), (N), (P), and release the airbox drain pipe (16).
Remove the airbox drain pipe (16), as shown in the figure.
Remove the self-locking ties (F), releasing the GAC hose (17) from the fuel pump wiring branch (G).
Working on both heads, loosen ties (18) securing airbox assembly to intake manifolds.
Remove the airbox assembly (14) from the motorcycle.

REMOVING THE SILENCER
Warning
Working on the RH side of the motorcycle, loosen screws (1) and remove heat guard (2) by releasing the rubber block
(A) from the pin (B) and collecting washers (15).
Undo screw (3) that retains the silencer to the silencer support bracket, while holding nut (4) from the opposite side
and collect washer (5).

REMOVING THE RH FRONT FOOTPEG HOLDER PLATE ASSEMBLY
Loosen screw (1) securing bracket (2).

Slide out the rear brake master cylinder unit (3) from the rod (4).
Remove the self-locking tie (A).
Remove the rubber tie (B) and disconnect the rear brake switch connector (5).

REMOVING THE LH FRONT FOOTPEG HOLDER PLATE ASSEMBLY

figure.
Loosen screws (10), screws (11) and remove LH front footpeg holder plate assembly (12).
Disconnect side stand connector (14).
Remove the self-locking tie (15), releasing the Quick-Shift control wiring branch from the side stand sensor wiring.

REMOVING THE EXHAUST SYSTEM
Loosen the clamps (1) retaining the pre-silencer (2) to the vertical (3) and horizontal (4) exhaust manifolds.
Loosen two nuts (5) securing the horizontal exhaust manifold (4).
Remove self-locking tie (6) and disconnect horizontal oxygen sensor connector (7).
Loosen but do not remove nut (5) securing the horizontal exhaust manifold (4).
Loosen screw (8) that retains pre-silencer (2) to the con-rod of the side stand plate.
Remove pre-silencer (2).
Loosen nut (5), remove the horizontal exhaust manifold (4) and gaskets (9).
Loosen screw (10) and position rear brake master cylinder fluid reservoir (11) as shown in the figure.
Remove the clamps retaining the vertical exhaust oxygen sensor connector (13) (Branch 7).
Disconnect the vertical exhaust oxygen sensor connector (13).
Remove vertical exhaust oxygen sensor (14).
Working on either sides of the vehicle, loosen screws (15), collect washer (16) and remove the vertical heat protection
(17).
Loosen nuts (18), remove the vertical exhaust manifold (19) and gaskets (20).

REMOVING THE STARTER MOTOR CABLE AND OIL PRESSURE SWITCH
Disconnect oil pressure switch connector (1).

Remove cap (2), loosen nut (3), collect washer (4) and slide out starter motor cable (5).

REMOVING THE CANISTER AND MAP SENSOR PIPES
Working on the RH side of the motorcycle, disconnect the connector (A) from Purge valve (1).
Loosen clip (2) and remove canister pipe (3) from horizontal head intake manifold.
Loosen clip (2) and remove map sensor pipe (4) from horizontal head intake manifold.
Loosen clip (2) and remove canister pipe (5) from vertical head intake manifold.
Loosen clip (2) and remove map sensor pipe (6) from vertical head intake manifold.

REMOVING THE CANISTER ASSEMBLY
Working on either sides of the motorcycle, loosen screws (2) that fix the ABS support to the frame.

REMOVING THE GROUND CABLE
Loosen screw (1) with washer (2) and remove ground cable (3) from crankcase.

REMOVING THE COOLING SYSTEM HOSES AND UNIONS
Loosen tie (1) and disconnect thermostatic valve/vertical head hose (2) from the vertical head union.
Loosen tie (1), tie (3) and disconnect the horizontal head / thermostatic valve hose (4) from the horizontal head union.
Disconnect water temperature sensor connector (7).

REMOVING THE CLUTCH SLAVE CYLINDER UNIT
Loosen screws (1) and remove the sprocket cover (2).

Loosen the retaining screws (3) of the clutch slave cylinder unit (4).
Slide out the clutch slave cylinder (4).

REMOVING THE GEAR SENSOR AND FRONT SPROCKET
Undo the screws (1) and remove the gear sensor (2), collecting the washers (3).
Loosen the screws (4) and remove the lower chain sliding shoe (5).
Slacken and remove the chain from the front sprocket (6) (Adjusting the chain tension).
Hammer down the edge of the lock washer (7), loosen nut (8) and remove sprocket (6).

REMOVING THE SWINGING ARM
Position tool (A) part no.88713.3220 below the engine as shown in the figure.
Working on the motorcycle RH side, loosen and remove the nut (1).
Working on the left side of the motorbike, slide out pin (2) and release the swinging arm assembly (3) from engine,
duly supporting it and taking special care not to damage wirings and pipes.
Loosen the adjusters (4).
During swinging arm assembly (3) removal, collect outer spacer (5), inner spacer (6) and spacer (7).

REMOVING THE ENGINE
Working on the RH side of the motorcycle, loosen the special screws (1) while holding nuts (2) from the opposite side.
Remove the engine from the frame.
Refitting the engine

REFITTING THE ENGINE
Apply the indicated product inside the needle roller bearings on the crankcase.
Position the engine inside the frame using tool part no. 88713.3220.
Apply the indicated product to the stem, underhead and thread of special screws (1).
Working on the RH side of the motorcycle, start the special screws (1) on frame, driving them fully home.
On the opposite side, screw without tightening nuts (2) on the thread of special screws (1).
Important
Tighten the nuts after fitting the swingarm shaft.

REFITTING THE SWINGING ARM
Apply the indicated product to the threads of adjusters (4), and check that no grease reaches surface (B).
Screw adjusters (4) on the ring nut (8) side opposite to the one with the flats until bringing the surfaces flush.
On frame (9) outer side, start adjusters (4) - if previously removed - and bring them flush with surfaces (C), as shown
in the figure.
Apply the indicated product in the seats of the bearings present in the swinging arm unit (3).
Insert the outer spacer (5), the inner spacer (6) and the spacer (7) in the swinging arm unit (3).
Apply the indicated product to pin (2).
Position the swinging arm unit (3), inserting it between frame (9) and engine (10), paying attention that the spacers
previously fitted remain in their seats, and insert the pin (2) from the LH side of the motorcycle.
Working on the RH side of the motorcycle, tighten adjuster (4) to a torque of 5 Nm ± 10%.
Working on the LH side of the motorcycle, tighten adjuster (4) to a torque of 5 Nm ± 10%.
Working on either sides of the motorcycle, tighten the ring nuts (8) to a torque of 60 Nm ± 5%.
Apply the indicated product to the threads of nuts (1).
Working on either sides of the motorcycle, screw nuts (1).
Now it is possible to tighten special screws (1) securing the engine to the frame to a torque of 60 Nm ± 5%, while
holding nuts (2).
Remove tool (A) part no. 88713.3220.

REFITTING FRONT SPROCKET AND GEAR SENSOR
If previously removed, refit the front sprocket spacer (9) as follows:

Apply the specified product to O-ring (10).
Fit the O-ring seal (10) on the front sprocket spacer (9), as shown in the figure.
Important
The O-ring must be renewed upon removal.
Apply the indicated product on the inside of the sealing ring (A).
Insert the front sprocket spacer (9) with O-ring (10) on the gearbox secondary shaft, aiming it as shown in the figure
and driving it fully home.
Check that the splines of the gearbox secondary shaft and the sprocket are in perfect condition.
Fit sprocket (6) on the secondary shaft, orienting it as shown in the figure.
Fit lock washer (7).
Drive nut (8) on the secondary shaft.
Bend washer (7), as shown in the figure.
Refit the chain to the front sprocket (6) (Adjusting the chain tension).
Position lower chain sliding shoe (5) and start screws (4).
Insert the screws (1) in the gear sensor (2).

On the opposite side, insert washers (3) on the threaded end of screws (1).
Position gear sensor (2) and start the screws (1).

REFITTING THE CLUTCH SLAVE CYLINDER UNIT
Apply the specified product to seal (5).

Fit seal (5) onto the clutch slave cylinder unit (4).
Refit the clutch slave cylinder unit (4) and start screws (3).
Tighten screws (3) to a torque of 10 Nm ± 10%, by in the 1 - 2 - 3 - 1 sequence.
Note
To bring the clutch slave cylinder internal surface near the casing cover as evenly as possible, screw and tighten the
retaining screws alternatively in steps.
Position sprocket cover (2) and start screws (1).

REFITTING THE COOLING SYSTEM HOSES AND UNIONS
Working on the horizontal head, insert thermostatic valve / horizontal head hose (4) in the horizontal head union and
tighten clamp (1) to a torque of 3 Nm ± 10%.
Insert the other hose end (4) inside horizontal head bleed union and tighten clamp (3) to a torque of 0.6 Nm ±10%.
Connect water temperature sensor connector (7).
Working on the vertical head, insert thermostatic valve / vertical head hose (2) in the vertical head union and tighten
clamp (1) to a torque of 3 Nm ± 10%.
Insert the radiator / water pump hose (6) in the water pump union and tighten clamp (5) to a torque of 3 Nm ± 10%.

REFITTING THE GROUND CABLE
Insert toothed washer (2) on the thread of screw (1).

Position ground cable (3) on the crankcase and start screw (1).

REFITTING THE CANISTER ASSEMBLY
Working on either sides of the motorcycle, start screws (2) that fix the ABS support to the frame.

REFITTING THE CANISTER AND MAP SENSOR PIPES
Insert canister pipe (5) onto the vertical head intake manifold union and fasten it using clamp (2).
Insert map sensor pipe (6) onto the vertical head manifold union and fasten it using clamp (2).
Insert canister pipe (3) onto the horizontal head intake manifold union and fasten it using clamp (2).
Insert map sensor pipe (4) onto the horizontal head manifold union and fasten it using clamp (2).
Connect connector (A) to Purge valve (1).

POSITIONING THE CANISTER PIPES


(A) Big self-locking tie Canister support

Pipe from canister to purge valve
Warning

REFITTING THE STARTER MOTOR CABLE AND OIL PRESSURE SWITCH
Connect oil pressure switch connector (1).

Position starter motor cable (5) on starter motor and start nut (3) placing washer (4) in-between.
Tighten nut (3) to a torque of 5 Nm ± 10%, and refit cap (2).

REFITTING THE EXHAUST SYSTEM
Fit the gaskets (20) on the stud bolts of the vertical head, orientating them as shown in the figure.
Fit the vertical exhaust manifold (19) on the vertical head stud bolts and fix it by starting nuts (18).
Position vertical heat guard (17) and start screw (15) with washer (16) on the RH side of the motorcycle.
Working on the LH side of the motorcycle, start screws (15) on vertical heat guard (17).
Start vertical exhaust oxygen sensor (14) on vertical exhaust manifold.
Tighten the vertical exhaust oxygen sensor (14) to a torque of 24.5 Nm ± 10%.
Connect vertical exhaust oxygen sensor connector (13) and secure it to the frame clip using relevant ties (Branch 7).
Position rear brake master cylinder fluid reservoir (11) and start screw (10).
Fit the gaskets (9) on the stud bolts of the horizontal head, orientating them as shown in the figure.
Position the horizontal exhaust manifold (4) inserting it on the horizontal head stud bolts and start nut (5).
Refit the pre-silencer (2) fully home on the vertical exhaust manifold and inserting it on the horizontal exhaust
manifold.
Start screw (8) that retains pre-silencer (2) to the con-rod of the side stand plate.
Start nuts (5) securing the horizontal exhaust manifold (4).
Connect the horizontal oxygen sensor connector (7).
Using the self-locking tie (6) fasten horizontal oxygen sensor cable to oil pressure switch support.
Apply the specified product to ties (1).
Position ties (1) securing pre-silencer (2) on vertical (3) and horizontal (4) exhaust manifolds, aiming them as shown
in the figure, and tighten them to a torque of 5 Nm ± 10%.

REFITTING THE LH FRONT FOOTPEG HOLDER PLATE ASSEMBLY
Connect side stand connector (14).

Fasten the side stand cable (14) to the Quick-Shift control connector, using self-locking tie (15).
Position the LH front footpeg holder plate assembly (12) and start screws (10) and screws (11).
Refit the special ties (5), securing the Quick-Shift control cable to the sump guard bracket (4) (Branch 6).


REFITTING THE RH FRONT FOOTPEG HOLDER PLATE ASSEMBLY
Connect rear brake switch connector (5) and secure it to the rear speed sensor connector, refitting rubber tie (B), as
Using self-locking tie (A), fasten the rear stop sensor cable to the rear brake master cylinder / ABS control unit pipe.

Position bracket (2) and start screws (1).

REFITTING THE SILENCER
Apply the indicated product to tie (6) thread.

Refit silencer (7) by driving it fully home against the pre-silencer and aiming clip (6) as shown in the figure.
Tighten clip (6) to a torque of 10.5 Nm ± 10%.
Place washer (6) between silencer and silencer support bracket and start screw (4).
On the opposite side, screw nut (5) on the threaded end of screw (4).
Position full heat guard (2) by inserting pin (B) in rubber block (A) and start screws (1), placing washers (15) between
the full heat guard (2) and the silencer, as shown in the figure.

REFITTING THE AIRBOX ASSEMBLY
If previously removed, fit ties (18) in the seats of intake manifolds, aiming them as shown in the figure.
Apply the indicated product to the seats (L) of intake manifolds.
Refit the airbox assembly (14) on motorcycle, routing drain pipe (16) as shown in the figure.
During this procedure, make sure that the fuel pipe (H) is not squeezed between frame and airbox assembly.
Exert a pressure on the airbox assembly (14), making sure that the sleeves of the throttle body are correctly inserted
and fully home on horizontal and vertical head intake manifolds.
Working on both heads, tighten ties (18) to a torque of 2.5 Nm ± 10%.
Using self-locking ties (F), fasten the GAC hose (17) to the fuel pump wiring branch (G), as shown in the figure.
From the indicated point, refit the self-locking ties (B), fastening the main wiring branch (C) to the clips (D) on the
airbox assembly (14).
Connect connector of the secondary air valve (15).
Refit the main wiring harness (A) on the airbox assembly (14) and connect the air temperature sensor connector (13).
Position main wiring harness cover (9) on the airbox assembly and start the screws (8).

Connect the vertical head Map Sensor connector (4).
Connect the injector connector (2) and the potentiometer connector (3).
Warning
(B).

REFITTING SECONDARY AIR SYSTEM VALVE PIPES AND COILS
Working on the horizontal head, position the pipe support bracket (12), aiming it as shown in the figure, and start
screw (11).
Tighten the lower screw (11) to a torque of 10 Nm ± 10%.
Insert the horizontal coil (10) and start screw (3) with washer (4).
Reconnect the secondary air system pipe (9) to the horizontal cylinder head cover union and secure it in place using tie
(1).
Connect horizontal coil connector (C) and fasten it using button tie (B) (Branch 6).
Fit hose grommet (8) onto frame bracket, as shown in the figure.
Working on the vertical head, position the wiring support bracket (7) and start screws (6).
Position the main wiring harness on the vertical head.
Insert the vertical coil (5) and start screw (3) with washer (4).
Reconnect the secondary air system pipe (2) to the vertical cylinder head cover union and secure it in place using tie
(1).
Connect the vertical coil connector (G) and fasten it to the wiring support bracket.
Refit the self-locking ties (A), fastening the main wiring (D), starter motor cable (E) and negative battery cable (F)
from the wiring support bracket (7), as shown in the figure.

REFITTING THE BLOW-BY PIPE
Refit the blow-by pipe (2) on the motorcycle, aiming it as shown in the figure, inserting it in the blow-by valve union
and in the airbox.
Tighten clamp (3) to a torque of 1.5 Nm ± 10%, aiming it as shown in the figure.
Fasten the blow-by pipe (2) to the airbox using tie (1).

REFITTING THE WATER RADIATOR ASSEMBLY
Refit the water radiator assembly (2) on the motorcycle, inserting pins (D) of RAD-DUCT into rubber blocks (E) of the
lower headlight cover and start screws (7).
Connect the right (B) and left (C) electric fan connectors and position them on the relevant frame brackets.
Position water radiator/pump hose (5) and radiator/head hose (4) and tighten ties (3) to a torque of 3 Nm ± 10%,
aiming them as shown in the figure.
Insert expansion reservoir hose (1) in water radiator (2) and secure it with tie (A).

REFITTING THE SUMP GUARD
If previously removed, position the RH bracket (6) on the clutch cover stud bolt, aiming it as shown in the figure and
start the screw (7).
Refit clip (8) on RH bracket (6).
If previously removed, position the LH bracket (9) on the generator cover, aiming it as shown in the figure and start
screw (10).
Tighten screw (10) to a torque of 13.5 Nm (Min. 12.5 Nm – Max. 14.5 Nm).
Refit clip (11) on LH bracket (9).
Fit the sump guard (5) on motorbike, as shown in the figure.
Working on either sides of the motorcycle, start screws (3) and lower screw (4).

POSITIONING THE FUEL TANK PIPES
Fuel tank jointing pipe
Note
All clamps must be aimed as shown in the figures.
Insert fuel tank jointing pipe centreline inside hose grommet (A).
Fuel tank drain and breather pipes
• DRAIN pipe (1).

• Pipe from Y-shaped union to presetting for rear tank (7).
Warning
• DRAIN pipe (1).


button tie cable



branch

branch

Airbox drain hose




Generator cable


connector


branch

branch

Airbox drain hose




Generator cable

button tie cable

Side stand cable


branch

branch

Airbox drain hose




(F) L = 82 mm (3.23 in) Airbox drain hose Turn the oxygen sensor connection towards the
connector



Test to check correct positioning of fuel tank drain and breather pipes
During disassembly and reassembly of the fuel tank, the fuel tank breather and drain pipes may not be positioned
correctly, causing bottlenecks that could result in vacuum inside the tank.
After refitting the fuel tank, perform the following check for possible bottlenecks in the breather and drain pipes.
Note
The procedure to check the fuel breather pipe is described below; repeat the same procedure for the drain pipe.
Open the tank plug (D), ensuring that the fuel level is below the funnel of the tank plug.
Apply a workshop syringe (E) to the canister filter breather pipe (3) as shown in the figure.
Press the plunger of the syringe (E) and release it.
Test outcome:
• Positive: syringe plunger remains stationary after compression (pipe NOT obstructed).
• Negative: syringe plunger returns back due to back pressure (pipe obstructed).
In the event of a negative result, reposition the fuel tank breather pipe to clear any bottlenecks and repeat the test.

REFITTING THE TANK
Refit fuel tank (2) on the motorcycle and connect the breather pipe (10) and the drain pipe (11).
Warning
To prevent detachment of the two pipes (10) and (11), when reassembling the tank, do NOT lubricate the two
couplings.
Connect the tank ground connector (9).
Working on the LH side of the motorcycle, connect fuel level sensor connector (8).
Connect the fuel pipe quick coupling (6) and the fuel pump connector (7) to the fuel pump.
Connect hose (5) to taps (3) and secure it by tightening clamps (4) to a torque of 1 Nm ± 10%.
Open taps again (3).
Start the screws (1) retaining the fuel tank (2) on the front and back.

REFITTING THE UNDERSEAT AND FRAME COVERS
Working on the motorcycle LH side, position the LH frame cover (7) engaging the tooth (A) into the cavity (B) in the LH
footpeg holder plate (8).
Fit the LH underseat cover (6) over the LH frame cover (7) and start the screw (2).
Fasten the upper part of the LH underseat cover (6) using the self-locking tie (7), with the closing device pointing
inwards.
Working on the RH side of the motorcycle, position RH frame cover (5) and start screw (4).
Fit the RH underseat cover (3) over the RH frame cover (5) and start the screw (2).
Tighten screw (2) and screw (4) to a torque of ± 5 Nm 10%.
Fasten the upper part of the RH underseat cover (3) using the self-locking tie (1), with the closing device pointing
inwards.

REFITTING THE SIDE CONVEYORS
Position the LH conveyor (2) by inserting it on rubber block (A) pre-fitted on the fuel tank.
Start the screw (1) on the LH conveyor (2).
Position the RH conveyor (3) by inserting it on rubber block (A) pre-fitted on the fuel tank.
Start the screw (1) on the RH conveyor (3).

REFITTING THE TANK CENTRAL COVER
Position the central tank cover (2) by inserting the special rubber block (A) into the cavity (B) and the pin (C) on the
rubber block (D), as shown in the figure.
Start the screws (1) on the tank central cover (2).

REFITTING THE STEERING DAMPER
Position the steering damper (4) on its support and start the screws (3).
Start the screws (1) that retain the steering damper support (2) to the steering head.

REFITTING THE SIDE FAIRINGS
The procedure below describes how to refit one side fairing but it applies to both.
Position LH side fairing (6) on the motorbike by engaging pins (B) on rubber blocks (C), pin (D) on rubber block (E)
and special rubber block (7) in the slot (F), as shown in the figure.
Check that the pre-applied threadlocker is still present on the threads of screws (2) and screw (4). A maximum of
Fit nylon washer (3) onto screw with short collar (2).
Secure the LH side fairing (6) by starting the screw (2) with nylon washer (3) at the top and the screw (2) on the
inside.
Insert the threaded bushing (5) into the rear hole of the special rubber block (7) and start the screw with long collar
(4) on the threaded bushing (5).
Tighten screw (4) to a torque of 5 Nm ± 10% by holding threaded bushing (5) on the opposite side.
Connect the LH front turn indicator connector (1) to LH front turn indicator wiring branch.
Using the rubber tie (A) secure the LH front turn indicator cable and the LH front turn indicator wiring branch together.
Position the LH front turn indicator wiring behind the headlight, as shown in the figure.

REFITTING THE WINDSCREEN
Apply the specified product to the shank (A) of screws (1).

Fit Plexiglas windscreen (2) on front fairings and start screws (1).

REFITTING THE PASSENGER SEAT
Refit passenger seat (4), inserting tabs (A) inside seats of rear subframe.
Position the spacers with collar (5) between the passenger seat (4) and the seat support plate, aiming them as shown
in the figure and start screws (3).

REFITTING THE RIDER SEAT

Removing the oil pump
Empty the lubrication system (Changing the engine oil and filter cartridge).
Remove the clutch cover (A) (Removing the clutch cover).
Remove the hub, clutch plate pack and clutch housing unit (B) (Removing the clutch).
Remove the primary drive gear (C) (Removing the primary drive gear).
Remove the snap ring (1) and shim (2).

Slide out oil pump gear (3) and collect rotation pin (4).
Loosen the screws (5a) and screw (5b), then remove the oil pump cover assembly (6).
Remove oil pump outer rotor lobe (7) from crankcase.
Disassembling the oil pump gear
Remove the oil pump (Removing the oil pump).
Remove circlip (1) and collect shim (2).

From the opposite side pull out the pump shaft (4), collect the inner rotor (3) and pull out the roller (5), if required.
Undo the plug (6), collect the spring (7) and the by-pass valve (8).
Reassembling the oil pump gear
Insert roller (5) inside the hole made on pin (4).

Insert inner rotor (3) on pin (4), driving it fully home.
Insert pin (4) with the just fitted inner rotor (3) in the pump cover.
Insert shim (2) on pin (4) and lock pin by inserting snap ring (4).
Check that the pin (4) moves freely.
Apply the recommended product to the plug thread (6).
Insert by-pass valve (8), spring (7) and start plug (6).
Refit the oil pump (Refitting the oil pump).

Refitting the oil pump
Apply the indicated product on the seat of the oil pump on clutch side crankcase.
Apply the indicated product on the inner and outer surfaces (7) of oil pump outer rotor lobe and insert it inside the
seat on clutch side crankcase with the reference (E) facing inside the crankcase.
Check that the two reference pins (8) are present on crankcase.
Apply the indicated product to the oil pump inner rotor lobe (9).
Fit the assembled oil pump cover assembly (6) (Reassembling the oil pump gear) and centre it following the mandatory
positions given by:
• Crankshaft seat (D) on crankcase.

• Inner rotor lobe (9) with outer rotor lobe.
• Reference pins (8).
Start the fastening screws (5a) and (5b) of oil pump cover assembly.
Tighten the screws (5a) and (5b) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm), following the indicated sequence.
Insert rotation pin (4) inside pump shaft.

Fit gear (3) by inserting pin (4) inside its seat (E).
Fit shim (2) and snap ring (1) inside shaft.
Refit the primary drive gear (C) (Refitting the primary drive gear and checking backlash).
Refit the clutch housing, clutch plate pack and hub unit (B) (Refitting the clutch).
Refit the clutch cover (A) (Refitting the clutch cover).

Removing the water tank
Remove the side fairings and conveyors (Removing the front half-fairing).
Note
To help your understanding of the procedure, some parts are not shown.
Working on the LH side of the motorcycle, loosen screws (3) and screw (4) retaining the expansion reservoir (5).
Remove button ties (C), (D), (E) and (F).
Remove button tie (B) and pull out pipe (6).

Remove expansion reservoir (5) complete with hoses (1) and (6).
Loosen clamps (7) to remove hoses (1) and (6) from the expansion reservoir (5).
Refitting the water tank
Fit the vibration damper (8) into the indicated hole of expansion reservoir (5).
On the indicated side, insert the spacer with collar (9) in the vibration damper (8).
Fit pipes (1) and (6) on expansion reservoir (5) and fasten them using clamps (7).
Pipe length:

• Pipe (6) length 872 mm (34.33 in).
Note
If it proves hard to fit the tubes in the relevant unions, it is recommended to use RUBBER LUBRICANT, and apply some
on the unions.
Note
Fit the expansion reservoir (5) on motorcycle, routing pipe (6) as shown in the figure.
Use the button tie (B) to secure the pipe (6) to the frame.
Refit button ties (C), (D), (E) and (F), as shown in the figure.


button tie cable



branch

branch

Airbox drain hose




Generator cable


connector


branch

branch

Airbox drain hose




Generator cable

button tie cable

Side stand cable


branch

branch

Airbox drain hose





(F) L = 82 mm (3.23 in) Airbox drain hose Turn the oxygen sensor connection towards the
connector



Apply the specified product to screws (3) and screw (4).

Start screws (3) and screw (4) on the expansion reservoir (5).
First tighten screws (3) and then screw (4) to a torque of 5 Nm ± 10%.
Refit the sump guard (Refitting the sump guard).
Refit the side fairings and conveyors (Refitting the front half-fairing).
Removing the water radiator
Remove the side fairings and conveyors (Removing the front half-fairing).
Note
Loosen tie (3) and disconnect thermostatic valve/vertical head hose (4).
Remove the right (B) and left (C) electric fan connectors from the frame brackets.
Disconnect the right (B) and left (C) electric fan connectors.
Working on either sides of the motorcycle, loosen screws (7) and remove the water radiator assembly (2) from the
motorcycle by releasing the RAD-DUCT pins (D) from the rubber blocks (E) of the headlight lower cover.

REMOVING THE RAD DUCT ASSEMBLY
Loosen the screws (8) and remove the RAD DUCT (9) from the water radiator assembly (2).
Loosen screws (8) and remove the protection grille of the radiator (10) from the RAD DUCT (9).

INSPECTING THE WATER RADIATOR
Visually inspect the water radiator assembly (2). Replace it at any sign of damage or leaks. Check also that the air flow
through the radiator fins are not obstructed by leaves, insects, mud, etc.
Important
Excessive coolant temperature can be caused by a partial obstruction of the radiator fins.
Carefully check the condition of the radiator fins.

Replacing the electric fan

REMOVING THE ELECTRIC FANS
Loosen the screws (1), nut (2) and remove the RH electric fan (3) from the RH bracket (4).
Repeat the operation to remove the LH electric fan.
Loosen the screws (5) with elastic washers (6) and washers (7) and remove the RH bracket (4) from the water radiator
(8).
Proceed in the same way to remove the left-hand bracket.

REFITTING THE ELECTRIC FANS
Insert elastic washers (6) and washers (7) on the screws (5).
Fit the RH bracket (4) on the water radiator (8) and start screws (5).
Proceed in the same way to refit the left-hand bracket.
Fit the RH electric fan (3) on RH bracket (4) and start screws (1) and nut (2).
Tighten screws (1) and nut (2) to a torque of 5 Nm ± 10%.
Repeat the operation to refit the LH electric fan.
Refitting the water radiator
Note

PRE-FITTING THE WATER RADIATOR ASSEMBLY
Fit vibration dampers (11) in the indicated positions of water radiator (12).
Insert the spacers with collar (13) in the vibration dampers (11), orienting them as shown in the figure.
Fit the vibration dampers (11) in the relevant holes of the lower bracket (14).
Fit the lower bracket (14) in the water radiator (12) inserting the stud bolts (F) into the vibration dampers (11), as

REFITTING THE RAD DUCT ASSEMBLY
Position the protection grille of the radiator (10) in the RAD DUCT (9), aiming it as shown in the figure, and start
screws (8).
Fit the RAD DUCT (9) on the water radiator assembly (2) and start screws (8).

REFITTING THE WATER RADIATOR ASSEMBLY
Refit the water radiator assembly (2) on the motorcycle, inserting pins (D) of RAD-DUCT into rubber blocks (E) of the
lower headlight cover and start screws (7).
Connect the right (B) and left (C) electric fan connectors (C) and position them on the relevant frame brackets.
Connect water radiator/pump hose (5) and radiator/head hose (4) and tighten ties (3) to a torque of 3 Nm ± 10%,
aiming them as shown in the figure.
Refit the side fairings and conveyors (Refitting the front half-fairing).
Removing the cooling system hoses and unions
Important
Periodically check the connection unions for leaks. Hoses that are cracked, swollen, or hardened due to dry sleeves
should be replaced.
The cooling system consists of the following hoses:
1 Water pump to horizontal head hose.

2 Water pump to vertical head hose.
3 Thermostatic valve to vertical head hose.
4 Thermostatic valve to horizontal head hose.
5 Water radiator to water pump hose.
6 Water radiator to thermostatic valve hose.
7 Thermostatic valve.
Remove the LH side fairing and conveyor (Removing the front half-fairing).
Loosen clamp (8) and disconnect the water radiator/thermostatic valve hose (6).
Loosen clamp (8) and disconnect the water radiator/pump hose (5).
Loosen clamp (9) and disconnect thermostatic valve/vertical head hose (3) from the vertical head union.
Loosen clamp (9), clamp (10) and disconnect the horizontal head / thermostatic valve hose (4) from the horizontal
head unions.
Loosen clamp (8) and disconnect the water radiator/pump hose (5).
Disconnect water temperature sensor connector (11).
Loosen clamps (12) and remove the water pump to horizontal cylinder hose (1).
Loosen clamps (12) and remove the water pump to vertical cylinder hose (2).
Loosen clamp (8) and disassemble the thermostatic valve (7) from the hose (6).
Loosen clamps (6) and remove the thermostatic valve (7) from the vertical head hose (3) and horizontal head hose
(4).
Note
Working on the horizontal head, loosen screw (15), stud bolt (14) and remove the water union (13) recovering seal
(17).
Working on the vertical head, undo the screws (15) and remove the water union (16) recovering seal (17).
Refitting the cooling system hoses and unions
If previously removed, refit adaptor bushing (18) to the horizontal cylinder connector.
If previously disassembled, refit vertical head hose (3), horizontal head hose (4) and hose (6) on thermostatic valve
(7), as shown in the figure and fasten them using clamps (9) and clamp (8).
Tighten clamps (9) and clamp (8) to a torque of 3 Nm ± 10%, aiming them as shown in the figure.
Make sure that seals are not damaged, if worn out or damaged, replace them with new ones.
Install a gasket (17) in the seat of the vertical head union (16), as shown in the figure.
Repeat the same procedure on the horizontal head union.
Working on the vertical head, position water union (16) making sure that seal (17) stays inside its seat, and start
screws (15).
Tighten the screws (15) to a torque of 6 Nm (Min. 5 Nm. - Max. 7 Nm).
Check that the pre-applied threadlocker is still present on the threads of screw (15) and stud bolt (14). A maximum of
Working on the horizontal head, position water union (13) making sure that seal (17) stays inside its seat, start screw
(15) and stud bolt (14).
Tighten screw (15) and stud bolt (14) to a torque of 6 Nm (Min. 5 Nm. - Max. 7 Nm).
If previously removed, apply the specified product to the thread of the water temperature sensor (19).
Start water temperature sensor (19) on union (13), placing washer (20) in-between.
Tighten water temperature sensor (19) to a torque of 23 Nm (Min. 20 – Max. 26).
Refit water pump hose to vertical cylinder (2) aiming clips (12) as shown in the figure.
Tighten the clamps (12) to a torque of 2.5 Nm (Min. 2 Nm. - Max. 3 Nm).
Refit water pump hose to horizontal cylinder (1) aiming clips (12) as shown in the figure.
Tighten the clamps (12) to a torque of 2.5 Nm (Min. 2 Nm. - Max. 3 Nm).
Working on the horizontal head, insert thermostatic valve / horizontal head hose (4) in the horizontal head bleeding
union and tighten clamp (10) to a torque of 1 Nm ± 10%.
Insert the thermostatic valve/horizontal head hose (4) in the water union and tighten clamp (9) to a torque of 3 Nm ±
10%.
Working on the vertical head, insert thermostatic valve / vertical head hose (3) in the water union and tighten clamp
(9) to a torque of 3 Nm ± 10%.
Reconnect water temperature sensor connector (11).
Insert the water radiator / thermostatic valve hose (6) in the water radiator and tighten clamp (8) to a torque of 3 Nm
± 10%.
Insert the water radiator / pump hose (5) in the water radiator and tighten clamp (8) to a torque of 3 Nm ± 10%.

Refit the LH side fairing and conveyor (Refitting the front half-fairing).
Removing the water pump

Loosen clamps (G) and (H) and disconnect the hoses from water pump cover (3).
Loosen screws (1) with washers (2) and remove water pump cover (3) from the generator cover.
Collect bushes (5) from the generator cover (4).

Clean the pump housing from any coolant scale.
Check the bearing wear by turning the impeller shaft (6); in case of excessive clearance, it is necessary to replace
them as follows.
Remove the generator cover by following the reference procedure (Removing the generator cover).
Working on the inside of generator cover, remove snap ring (7).

Working from the outside of generator cover, slide out the impeller (6) with its mechanical seal (9) and counter-washer
(14).
Working from the inside of generator cover, loosen and remove screws (10) and washers (11).
Working on the outside of generator cover (4), use a suitable drift to press on the inner ring of end bearing (12) until it
can be extracted from the generator cover (4).
Remove shielded bearing (13) from generator cover (4) in the same way.
Remove internal spacer (15) from generator cover (4).
Check the condition of the mechanical seal components (9) and of the counter-washer (14): there should be no signs
of deformation, cracking, or excessive wear.
In case of damage, both components must be replaced.
Refitting the water pump
Apply the indicated product inside the seat (C) of the bearings of generator cover (4).
Working on generator cover (4) internal side, insert the inner spacer (15) with the sharp edge (D) outwards.
Use a commercial drift and bring inner spacer (15) fully home on generator cover (4).
Refit shielded bearing (13), with shielded side (E) facing the cover, as shown in the figure.
Refit the bearing (12), driving it fully home on shielded bearing (13).
Apply the specified product to screws (10) thread.
Start screws (10) with washers (11) on the generator cover.
Thoroughly clean the parts to be reused and the impeller shaft (6).
Apply the specified product to seal (A) of mechanical seal (9).
Install the mechanical seal (9) on impeller shaft (6), aiming it with seal (A) facing the impeller (6); pay utmost
attention to ensure not to damage seal (A) on edge (B).
Bring the mechanical gasket (9) fully home on impeller.
Apply the specified product to counter-washer (14).
Working from the outside of generator cover, refit the counter-washer (14) fully home on the generator cover.
The gasket (14) must be positioned so that the white side is facing upwards.
Clean the counter-washer (14) from the excess of lubricant.
Install the water pump impeller (6) driving it fully home on counter-washer (14).
With the suitable equipment, install the snap ring (7) in the relevant groove on the impeller shaft (6), as shown in the
figure.
Turn the impeller (6) and make sure that it can rotate freely, without excessive resistance.
Thoroughly clean the mating surfaces of the water pump cover (3) and generator cover (4) (Cleaning and applying the
silicone rubber sealant on work surfaces).
Refit centring bushes (5) to the generator cover (4).
Apply an even and continuous bead (F) of sealing compound on the generator cover by respecting the shown path.
Warning
An excessive quantity of sealant may cause the water pump impeller to block.
Important
Fit water pump cover within 5 minutes from sealant application.
Important
All aluminium screws during refitting must be replaced with new ones.
Fit water pump cover (3) on the generator cover, centring it on the bushings.
Refit the water pump cover (3) fully home on the generator cover and start the screws (1) with washers (2).
Tighten the screws (1) to the torque specified below, following the sequence shown in the figure:
• First tightening: 3 ÷ 3.5 Nm.

• Final tightening: 90º.
• Torque check: 5 ÷ 10 Nm.
After tightening, remove any excessive sealing compound.
Refit water pipes to the pump cover (3).

Fasten water hoses by tightening clamps (G) and (H) to a torque of 3 Nm ± 10%, aiming them as shown in the figure.
Checking and adjusting the valve clearance

Remove the water radiator (Removing the water radiator).
Disconnect the secondary air system pipes from the head covers (Removing the secondary air system).
Remove spark plugs (Replacing the spark plugs).
Remove the external belt covers (Removing the timing belt external covers).
Undo the screws (1) to remove the inspection cover (2) over the end of the crankshaft and collect the gasket.
Bring the vertical cylinder piston to the TDC (combustion stage).

Then, all valves are closed and the camshafts are in rest position, i.e. free to rotate.
Note
frame.

CHECKING THE CLOSING CLEARANCE
Using a feeler gauge, check the clearance between the closing rocker arm (A) sliding shoe and the highest point of the
camshaft lobe (B).


INTAKE 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)

EXHAUST 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)
Should the values be other than those indicated in the table, remove the closing shim (3), as described in chapter
Note

CHECKING THE OPENING CLEARANCE
Using a feeler gauge, check the clearance between the opening rocker arm (C) and the lowest point of the camshaft
lobe (D).


INTAKE 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)

EXHAUST 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)
Note
Reach the same condition with the horizontal head by rotating the crankshaft in order to have the piston in the TDC in
combustion stage. Repeat the above-mentioned operations.
Make sure that the O-ring (5) is installed on the cover (2).
Refit cover (2) on generator cover and start screws (1).

Refit the external timing belt covers (Refitting the timing belt external covers).
Refit the spark plugs (Replacing the spark plugs).
Connect the secondary air system pipes to the head covers (Refitting the secondary air system).
Checking valve lift

Note
For clarity, the figures show the engine removed from the frame.
Move the piston of the cylinder being checked to TDC upon combustion stage: in this condition, all valves are closed
and the camshafts come in rest position and, therefore, free to rotate; check the valve lift.
Position the tool (G) part no. 88765.1518 on the head: support (S) of tool with the intake indication must be
positioned on the exhaust side whereas support (T) of tool with the exhaust indication must be positioned on the
intake side.
Seat the plate (E) and tighten the screws (F).
Set the opening valve clearance to zero when the camshafts are in rest position by fitting a feeler gauge, of suitable
thickness, between the upper rocker arm and the opening shim.
Lock dial gauge (V) into the seat support (T) and position probe (R) against the face of the closing shim.
Set the dial gauge to zero when the valve is fully closed.
Rotate the intake camshaft so as to allow the intake valves to lift fully.
Check on the dial gauge that the measured value corresponds to the prescribed one.
Repeat the same operation for the exhaust valves, using dial gauge (V) in support seat (S) and probe (U).
Specified values:


Intake

Exhaust
Closing 7° A.T.D.C.


Intake Valves 11.3 mm (0.44 in)

Exhaust Valves 9.6 mm (0.38 in)
Checking the engine timing
Remove the rider and passenger seats (Removing the seat).

Remove the water radiator lower retainer from the engine (Removing the water radiator).
Remove the coils (Replacing the spark plugs).
Disconnect the secondary air units of the head covers (Removing the secondary air system).
Remove the timing belt covers (Removing the timing belt external covers).
Note
Move the piston of the cylinder being checked to TDC upon combustion stage: in this condition, all valves are closed
and the camshafts come in rest position and, therefore, free to rotate.
Install tool part no. 88765.1188 (A) in the spark plug bore to determine the piston TDC, the gauges (B) on tool part
no. 88765.1518 and the timing check tool (C) part no. 88765.1635 (degree wheel with graduated disk).
Set the opening valve clearance to zero when the camshafts are in rest position by fitting a feeler gauge, of suitable
thickness, between the upper rocker arm and the opening shim.
Check that in this condition the camshaft can rotate. If it moves stiffly, use a thinner feeler gauge.
In this condition, with the piston of the horizontal cylinder at TDC with the valves fully closed as confirmed by the
reading on gauge (A), set the gauges (B) to zero.
Tension the belts to the value indicated below.
Turn the degree wheel (C) counter clockwise until the gauge dial (B), on the exhaust side, shows a lift of 1 mm (0.039
in).
Check that the value of the angular displacement read on the degree wheel (C) is the specified one (Timing
system/Valves).
Continue to rotate in the same direction until you obtain a lift of 1 mm (0.039 in) on the intake side.
Check the angular value on the degree wheel.
Continue to rotate until you obtain an intake valve lift of 1 mm (0.039 in) on the gauge (B), during closure of the valve
for the compression stroke.
Check the angular value with the prescribed one (Timing system/Valves).
Continue to rotate the degree wheel (C) counter clockwise until you obtain a lift of 1 mm (0.039 in) of the exhaust
valve, when opening or closing the valve.
Check again the angular value with the prescribed one (Timing system/Valves).
Repeat the procedure for the vertical cylinder.
A tolerance of ±3° is allowed in the values detected with the described procedure compared to the specified ones.
Remove the installed tools to check timing. Then tension the belts to the operation value indicated below.
In case of values different from the specified ones, loosen the fastening screws (D) of the timing belt rollers and
correct the value detected by turning the ring nut of the camshaft with the wrench supplied with tool (E) part no.
88713.1806.
Then lock the three screws (D) securing the timing system belt roller to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm)
and mark the new position on the components.

BELT TENSIONING VALUES

status value

115)

Used


Intake

Exhaust
Closing 7° ± 3° A.T.D.C.


Intake 11.3 mm (0.44 in)

Exhaust 10.1 mm (0.39 in)

Valve diameters

Intake valve diameter 35.5 mm (1.40 in)

Exhaust valve diameter 28.8 mm (1.13 in)

Valve clearance adjustment values

Assembly value Check value

Opening rocker arm - intake 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)

Opening rocker arm - exhaust 0.13 ÷ 0.18 mm (0.0051 in ÷ 0.0071 in) 0.10 ÷ 0.25 mm (0.0039 in ÷ 0.0098 in)

Closing rocker arm - intake 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)

Closing rocker arm - exhaust 0.05 ÷ 0.10 mm (0,002 in ÷ 0,004 in) 0.05 ÷ 0.15 mm (0.0020 in ÷ 0.0059 in)
Refit the timing belt covers (Refitting the timing belt external covers).
Connect the secondary air units of the head covers (Refitting the secondary air system).
Refit the coils (Replacing the spark plugs).
Refit the passenger seat and the rider seat (Refitting the seat).
Removing the timing belt covers

Remove blow-by hose (Removing the airbox and throttle body).
Loosen screws (1) and remove the vertical head belt central cover (2).
Loosen screws (1) and remove the vertical head belt upper cover (3).
Loosen screws (1) and remove horizontal head belt cover (4).
Removing the mobile tensioner-timing belt
Remove spark plugs from the heads (Replacing the spark plugs).
Remove the timing belt external covers by following the reference procedure (Removing the timing belt external covers).
Loosen the nut (1), remove the washer (2) and the mobile tensioner (3) from the pin (4) on the cylinder head.
Remove the timing belt (5) from the horizontal head.
Important
If the belts are to be re-used, mark the direction of rotation with an arrow and also mark the piston-cylinder assy they
belong to.
Perform the same operations to remove the vertical head timing belt.
Removing the cylinder head pulley/fixed tensioner
Note
Remove the mobile tensioners and timing belts (Removing the mobile tensioner/timing belt).

FIXED TENSIONERS
Working on the vertical head, undo the nut (1), collect washer (7) and remove fixed tensioner (2).
Repeat the same procedure to remove the fixed tensioner from horizontal head.

HEAD PULLEYS
Insert tool (A) part no. 88713.1806 in the pulleys to lock their rotation and use the supplied bush to loosen the fixing
ring nuts (3) of the pulleys.
Important
Upon reassembly, always use new ring nuts.
Remove the ring nuts (3) and the pulleys (4) from the camshafts.
Repeat the same procedure to remove the pulleys from horizontal head.
Removing the tensioner pins
Note
Use tool part no. 88713.1821 to remove tensioner pins (1) from both heads.
Removing the timing layshaft pulleys
Note
Using tool (A) part no. 88713.5644 block the rotation of the driving belt rollers on the crankcase.
Important
If this operation is carried out with the engine installed in the frame, block the driving belt rollers rotation using tool
part no. 88713.2011 fitted on generator cover
Loosen the self-locking ring nut (10) using the socket supplied with the tool.
Remove the self-locking ring nut (10), the spacer (11), the outer pulley (12) and the key (13).
Remove the spacer (14) and the inner pulley (15).
Remove the inner spacer (16) and key (17) from the timing layshaft.
Remove the snap ring (18) located on the timing layshaft.
Refitting the timing layshaft pulley
Note
Insert snap ring (18) paying attention not to scratch the timing layshaft of pulleys.
Refit key (17) on the timing layshaft.

Fit the inner spacer (16) to timing layshaft, aiming it with groove (A) facing the inside of the engine.
Fit the inner pulley (15) and the washer (14).
Fit the outer pulley (12) and the spacer (11) on the timing layshaft.
Apply the indicated product on self-locking ring nut (10) thread, then screw it to timing layshaft.
Important
To prevent the ring nuts from loosening and consequent serious engine damage, always use new self-locking ring nuts
on all the timing belt rollers.
Use tool part no. 88713.5644 to lock timing belt roller rotation and tighten self-locking ring nut (10) to a torque of 71
Nm (Min. 64 Nm - Max. 78 Nm) using the insert supplied with the wrench together with a torque wrench.
Refit the mobile tensioners and timing belts (Refitting the mobile tensioner/timing belt).
Refitting the tensioner pins
Note
Apply specified product to the bigger thread of tensioner pins (1).

Insert the tensioner pins (1) on the heads and start them with tool part no. 88713.1821.
Tighten tensioner pins (1) to a torque of 50 Nm (Min. 45 Nm – Max. 55 Nm).
Refitting the cylinder heads pulleys/idler pulleys
Note

HEAD PULLEYS
Make sure that seat (D) is free of damage or burr.

Check that key (B) is properly installed to keyway (D) on each camshaft.
Refit belt roller (4) on camshaft (5), inserting key (B) in the pulley slot (C).
Apply the indicated product to the thread of the camshaft (5).
Carry out the same operations on the other camshaft.
Insert tool (A) part no. 88713.1806 in the pulleys to block its rotation.
Apply the indicated product to the mating face of the ring nut (3).
Fit the ring nut (3).
Carry out the same operations on the other camshaft.
Important
Always fit new nuts on reassembly.
Using the bush supplied with tool (A) part no. 88713.1806, together with a torque wrench, lock the ring nuts (3) of
pulleys (4) to a torque of 71 Nm (Min. 64 Nm - Max. 78 Nm).

FIXED TENSIONERS
Fit the fixed tensioner (2), with its bearing, to its pin on vertical head.
Apply the indicated product to the nut thread (1).
Tighten nut (1) on the vertical head pin, placing washer (7) in-between.
Tighten nut (1) to a torque of 25 Nm (Min. 22 Nm – max. 28 Nm).
Repeat the same procedure to refit the fixed tensioner to horizontal head.
Refitting the timing outer covers
Fit the horizontal head belt cover (4) and start the screws (1).
Fit the vertical head belt upper cover (3) and start the screws (1) without fully tightening them.
Fit the vertical head belt central cover (2) and start the screws (1).
Refit the blow-by hose (Refitting the airbox and throttle body).
Disassembling pulleys/camshafts
Undo and remove the screws (1).

Slide off the washer (2).
Slide out pulley (3) from hub (4).
Reassembling the pulleys/camshafts
Fit pulley (3) on hub (4), making the pulley reference point (A) coincide with the hub reference mark (B).
Fit washer (2) fully home on the pulley, aligning the reference mark (C) with pulley reference point (A) and hub
reference mark (B).
Start screws (1) in the hub threaded holes (D).
Tighten the screws (1) to a tightening torque of 14 Nm (Min. 12.5 Nm. - Max. 15.5 Nm).
Refitting the timing belts
Note
Undo the screws (1) to remove the inspection cover (2) over the end of the crankshaft and collect the gasket.
Position tool (A) part no. 88765.1635 (without degree wheel) so as to be able to rotate the crankshaft.
Engage the sixth gear.
Position the horizontal cylinder to TDC (combustion stage) by following the procedure below:
Rotate the crankshaft so that the reference on the driving pulley (3) is aligned with the reference on the clutch cover
(4), as shown in the figure.
Remove tool part no. 88765.1635 previously fitted.

Fit tool (B) part no. 88713.2011 on the generator cover to prevent the rotation of the crankshaft and block it with the
suitable pin. Then tighten the screw of the tool. To do this, the two pins (D) on tool must engage into the two housings
(E) on crankshaft.
Align the two vertical head camshafts as shown in the figure.
Insert tool (C) part no. 88765.1623 on pulleys to prevent rotation, inserting teeth (F) into the seats (G) of the
camshafts.
Important
Make sure that tool is installed in the correct direction, as shown in the figure.
Loosen the six screws (5) securing the pulleys (6).
Loosen pulleys (6) anticlockwise until they get fully home.
Using your hands only fit the vertical timing belt (7) acting as follows:
• Fit the belt (7) on the timing system layshaft pulley (8), adjust it on the fixed tensioner (9) and, without skipping
the teeth (that is while the belt is tensioned), fit it on vertical head pulleys (6).
• To fit the belt correctly onto the cylinder head pulleys, the pulleys must be rotated slightly and aligned with the
first useful tooth of the belt.
Apply the indicated product to the shaft thread (12).

Insert mobile tensioner (9), secure it in place by starting nut (10) and placing washer (11) in-between.
Screw nut (10) without tightening it to torque.
Turn the mobile tensioner (9) eccentric clockwise to tension the vertical timing belt.
Use tool (H) part no.97900.0253 to check correct tensioning of vertical timing belt.
During tensioning, comply with the values in the table below.
When belt has been tensioned, tighten nut (10) to a torque of 25 Nm (Min. 22 - Max. 28).

status value

115)

Used
Tighten screws (5) to a torque of 14 Nm (Min. 12.5 – Max. 15.5).
Remove tool part no. 88765.1623 previously fitted.
Repeat the same procedures to refit the horizontal head timing belt.
Remove tool (B) part no. 88713.2011.
Position timing inspection cover (2) and start screws (1).

Tighten screws (1) to a torque of 5 Nm (Min. 4.5 – Max. 5.5).
Refit spark plugs in the heads (Replacing the spark plugs).
Removing the camshafts

Remove the timing belts (Removing the mobile tensioner/timing belt).
Note
frame.

HORIZONTAL HEAD
Loosen screw (19) and remove pipe support bracket (20).
Working on the horizontal head, undo the special screws (3), the stud bolt (21) and remove the O-rings (4) from head
cover (5).
Remove the horizontal head cover (5).
Remove gaskets (6) and (7) from the horizontal head cover (5).
Undo and remove the screws (9) securing the camshaft supports (10) and (11).
Withdraw the camshaft supports (10) and (11) straight out from the horizontal head, taking care not to damage the
machined faces and centring dowels (12).
For an easier removal of the camshaft supports, work on the indicated points.
Remove the exhaust side camshaft assy (13) and intake side camshaft assy (14) and slide out sealing rings (15)
positioned at their ends.

VERTICAL HEAD
Move the main wiring from the vertical head, loosen screws (2) and remove wiring support bracket (1).
Working on the vertical head, undo the special screws (3), the screw (8) and remove the O-rings (4) from head cover
(18).
Remove the vertical head cover (18).
Remove gaskets (6) and (7) from the vertical head cover (18).
Undo and remove the screws (9) securing the camshaft supports (10) and (11).
Withdraw the camshaft supports (10) and (11) straight out from the vertical head, taking care not to damage the
machined faces and centring dowels (12).
For an easier removal of the camshaft supports, work on the indicated points.
Remove the exhaust side camshaft assy (13) and intake side camshaft assy (14) and slide out sealing rings (15)
positioned at their ends.
Check of the camshafts and supports
Remove the camshafts (Removing the camshafts).
Check the cam contact surfaces for scratches, grooves, steps and waving.
Worn cams are frequently the cause of poor timing, which leads to loss of engine power.
Place the camshaft between two opposite centres and check the run-out on the areas indicated using two dial gauges.
Service limit: 0.1 mm (0.004 in).
Visually inspect the camshaft tracks for scoring and abnormal wear.
If any of the above defects are found, the camshaft should be replaced.
If you find scoring or excessive wear, check the operation of the engine lubrication circuit.
Refit the camshafts (Refitting the camshafts).
Refitting the camshafts
Note
frame.
Note
The described operations regard the horizontal cylinder head. For the vertical head, follow the same procedure.

IDENTIFYING THE CAMSHAFTS
The meaning of the first two letters punched in the highlighted area of the camshaft is as follows:
• The first letter indicates the cylinder head to which the camshaft belongs (“V” Vertical; “O” Horizontal).
• The second letter indicates the head side (“A” Intake, “S” Exhaust).

Stamped letters Shaft type

Head Side

VA Vertical Intake

VS Vertical Exhaust

OA Horizontal Intake

OS Horizontal Exhaust
Use specified product both on the cylinder head and on supports (10) and (11), to lubricate the seats of the camshafts
(see green areas).
Fill reservoirs (A) with specified product.
Apply the specified product at the four points of the support (11) shown in red in the figure.
Clean off any excess of sealant.
Apply sealant only on the timing side support (11) and not on support (10).
Install the intake camshaft (16) and exhaust camshaft (17) in their housings on cylinder head, and rotate them to
distribute the lubricant evenly.
Check that the centring dowels (12) are present.
Refit the supports (10) and (11) aimed as shown in the figure, so that they are perfectly seated on the cylinder head,
checking that the number stamped in zone (B) of the cylinder head is the same as the number stamped in the support
zone (C).
Start screws (9) on supports (10) and (11).
Pre-tighten the screws (9) to a torque of 10 Nm (Min. 9 Nm. - Max. 11 Nm).
Note
Pre-tighten one cap at a time in the sequence indicated in the figure.
Note
Tighten one cap at a time in the sequence indicated in the figure.
Remove any excess of sealant from between the cylinder head and the cap (11).
Turn the camshafts (16) and (17) by hand to check that they rotate freely.
Note
The first screw to be tightened must the one indicated in the figure (intake and timing side).
Important
Now, proceed checking the valve clearance.
Check valve clearance by following the reference procedure (Checking and adjusting the valve clearance).

SEALING RINGS
Note
Before installing seal rings (15) make sure that the relevant seats (B) on the head are perfectly clean.
Remove any excess of previously applied lubricant.
Lubricate the indicated seats (B).

Only in case the ring has not been previously lubricated, lubricate the internal diameter of seal rings (15) with
GREASE C, or lubricate the cap external diameter with engine oil (better if wrapping the cap in a cloth soaked in
engine oil).
Note
Always make sure that the cap, the seal rings and their seats are free from surface flaws (dents, scratches, etc.) and
dirt (dust, other solid residues).
Fit seal rings (15) on camshafts (16) and (17) using tool (F) part no. 88713.1906.
Note
Once installed, the seal rings must be positioned as indicated. Clean any excess of lubricant with a clean cloth.

CYLINDER HEAD COVER
Note
Apply the indicated product at the points (C) of the horizontal head cover (5), as shown in the figure.
Fit the gaskets (6) and (7) on the horizontal cylinder head cover (5), as shown in the figure.
Cylinder head cover identification: the vertical head cover (18) has a tooth (A) on the left-hand side (exhaust side),
whereas cover (5) has a tooth (B) on the right-hand side (exhaust side).
Apply a bead (F) of at least 2 mm (0.08 in) (max. 4 mm (0.16 in)) of sealant on the four areas (D) of head surface (E)
(approximately in the middle of the cap machined surface, as indicated), by respecting the values and position (G), i.e.
10 ÷ 11 mm (0.40 ÷ 0.43 in) from the cap edge.
Value (M) is approximately 19 mm (0.75 in).

HORIZONTAL HEAD
Working on the horizontal head, refit horizontal head cover (5) on the head, with pre-fitted gasket, as shown.
Centre the cover in the four fixing holes.
Fit O-rings (4) on the special screws (3) and on the stud bolt (21).
Start the special screws (3) and the stud bolt (21) on horizontal head cover (5).
Tighten the special screws (3) and the stud bolt (21) to a torque of 10 Nm (Min. 9 Nm – Max. 11 Nm), following the
indicated sequence.
Thoroughly remove any excess of previously applied sealant between cylinder head and cover.
Position the pipe support bracket (20), aiming it as shown in the figure and start the screw (19).

VERTICAL HEAD
Working on the vertical head, refit vertical head cover (18) on the head, with pre-fitted gasket, as shown.
Centre the cover in the four fixing holes.
Fit O-rings (4) on the special screws (3) and on the screw (8).
Start the special screws (3) and the screw (8) on vertical head cover (18).
Tighten the special screws (3) and the screw (8) to a torque of 10 Nm (Min. 9 Nm – Max. 11 Nm), following the
indicated sequence.
Thoroughly remove any excess of previously applied sealant between cylinder head and cover.
Position the wiring support bracket (1) and start screws (2).
Position the main wiring harness on the vertical head.
Refit the timing belts (Refitting the mobile tensioner-timing belt).

Removing the intake manifold and water union

REMOVING THE INTAKE MANIFOLD

Disconnect the canister pipes and map sensor (Removing the Canister filter).
Working on the vertical head, loosen screws (2) retaining vertical head intake manifold (1).
Loosen nut (3) and remove the vertical head intake manifold (1).
Repeat the same operation on the horizontal head intake manifold.

REMOVING THE WATER UNIONS
Remove the involved hoses (Removing cooling system hoses and unions).
Working on the horizontal head, loosen screw (9), stud bolt (10) and remove the water union (7) recovering seal (11).
Working on the vertical head, undo the screws (12) and remove the water union (13) recovering seal (14).
Refitting the intake manifold and water union

REFITTING THE INTAKE MANIFOLD
Working on the vertical head, position the vertical head intake manifold (1) on the head and start screws (2) and nut
(3).
Tighten the screws (2) and the nut (3) to a torque of 10 Nm (Min. 9 Nm. - Max. 11 Nm).
Repeat the same operation on the horizontal head intake manifold.
Connect the canister pipes and map sensor (Refitting the Canister filter).

REFITTING THE WATER UNIONS
Make sure that seals (11) and (14) are not damaged, if worn out or damaged, replace them with new ones.
Install seal (14) in its seat on the vertical head water union (13), paying attention to position the protrusion (B) in the
groove (C).
In the same way, install seal (11) on horizontal head water union (7).
Working on the vertical head, position water union (13) making sure that seal (14) stays inside its seat, and start
screws (12).
Check that the pre-applied threadlocker is still present on the threads of screw (9) and stud bolt (10). A maximum of
Working on the horizontal head, position water union (7) making sure that seal (11) stays inside its seat, start screw
(9) and stud bolt (10).
Tighten screw (9) and stud bolt (10) to a torque of 6 Nm (Min. 5 Nm. - Max. 7 Nm).
If previously removed, apply the specified product to the thread of the water temperature sensor (6).
Start water temperature sensor (6) on union (7), placing washer (8) in-between.
Tighten water temperature sensor (6) to a torque of 23 Nm (Min. 20 – Max. 26).
Connect the relevant hoses (Refitting cooling system hoses and unions).
Removing the cylinder heads
Remove the airbox (Removing the airbox).

Remove the underseat covers (Removing the side body panels and the tail guard).
Disconnect the secondary air system pipes from the cylinder heads (Removing the secondary air system).
Disconnect the canister filter pipes (Removing the canister filter).
Remove the cooling system hoses and unions from the engine block (Removing cooling system hoses and unions).
Remove the rear brake control lever (Removing the complete rear brake control).
Remove the gear shift lever (Removing the gear shift).
Remove the exhaust system (Removing the exhaust system).

REMOVING THE ABS SUPPORT
Working on either sides of the motorcycle, loosen screws (2) that fix the ABS support to the frame.

REMOVING THE SCREWS SECURING FOOTPEG HOLDER PLATES TO ENGINE
Loosen screws (1) securing the RH front footpeg holder plate assembly (2) to the engine and collect the bushings (3).
Loosen screws (4) securing the LH front footpeg holder plate assembly (5) to the engine.

LOWERING THE ENGINE
Position tool (A) part no.88713.3220 below the engine as shown in the figure.
Working on the RH side of the motorcycle, loosen the special screws (1) while holding nuts (2) from the opposite side.
Lower tool (A) part no. 88713.3220 and the engine will turn towards the front end.
Tilt the engine until the vertical head can be easily removed.

VERTICAL HEAD
Undo the nuts (1), with washers (2) and remove the complete vertical cylinder head (3) by sliding it out of its stud
bolts.

HORIZONTAL HEAD
Undo the nuts (1), with washers (2) and remove the complete horizontal cylinder head (4) by sliding it out of its stud
bolts.
Removing the valves
Remove the complete heads from the engine (Removing the engine heads).
Remove the timing pulleys (Removing the cylinder head pulley/fixed tensioner).
Remove the cylinder head covers, the camshaft supports and the camshafts (Removing the camshafts).
Raise rocker arm (3) and remove the opening shim (4) from the valves with a pair of pliers.
Push down the closing rocker arms (5) and (6) and the closing shim (7).
Remove the split rings (8) from the valves with a magnetic screwdriver.
Extract the closing shims (7) from the valve using a pair of pliers.
Withdraw the valves (9) and (10) from underhead of the cylinder head.
Repeat the same procedures for the other cylinder head.
Refitting the valves
Note
Carefully clean the two intake valve seats (A) and the two exhaust valve seats (B).
Lubricate the stems of the two intake valves (5) and the two exhaust valve stems (4) with engine oil.
Fit the valves in their seats on cylinder head, fully home.
If previously removed, fit the seal rings before installing the valves.
Lubricate seals (6) with the specified product; use tool part no. 88713.2442 to drive the four seals (6) in their seats
on valve guides.
Important
Pay attention not to lubricate the ring seats.
Note
Position the seal ring as shown in the figure.
Fit the closing rocker arms as described in chapter (Refitting the rocker arms).
Insert closing shims (2) in the valve stem.
Insert the two split rings (3) in the valve seat.
Using suitable tools, quickly push the closing rocker arm to bring the shim (2) into seat.
Fit the opening shims (1).
Repeat the same procedure for the other valves.
Refit the camshafts, the camshaft supports and the head covers (Refitting the camshafts).
Refit the timing pulleys (Refitting the cylinder head pulleys/fixed tensioner).
Refit the complete cylinder heads in the engine (Refitting the engine cylinder heads).
Removing the valve rocker arms
Remove the complete heads from the engine (Removing the engine heads).
Remove the timing pulleys (Removing the cylinder head pulley/fixed tensioner).
Remove the cylinder head covers, the camshaft supports and the camshafts (Removing the camshafts).
The procedure below refers to one head but it applies to both coils.
Loosen blanket plugs (1) and collect seals (2).

REMOVING THE OPENING ROCKER ARMS
Use suitable tools to slide out shafts (3) of the opening rocker arms (4) both on intake and exhaust side.

REMOVING THE CLOSING ROCKER ARMS
Using a commercial pawl, slide springs (6) out of the closing rocker arms (5).
Withdraw the shafts (7) of the closing rocker arms on the exhaust and intake sides.
Remove the closing rocker arms (5), the springs (6) with the spacers (8).
Refitting the valve rocker arms
Check the rocker arm conditions: they must feature no scratches or breakage.
The closing and opening rocker arm shafts are different.
The closing rocker arm shafts feature a 10 mm (0.39 in) diameter, whereas the opening rocker arm shafts feature a 9
mm (0.35 in) diameter.

REFITTING THE OPENING ROCKER ARMS
Fit the opening rocker arm shafts (7) using suitable tools.
Insert a spacer (8) on closing rocker arm shaft (7), aiming it as shown in the figure.
Fit spring (5) on spacer (8), as shown in the figure, by engaging one end (A) in the relevant seat on the cylinder head.
Place the closing rocker arm (5) in its seat having care that the through hole is aligned with the closing rocker arm
shaft (7).
Fit the closing rocker arm shaft (7) fully home.
Using a commercial pawl, engage springs (6) on the closing rocker arms (5).
Follow the same procedure to refit the closing rocker arms.
Note
Always install the closing rocker arms on the exhaust side before those on the intake side.
Warning
Take care not to damage the shoe of the closing rocker arm with the intake spring during assembly.

REFITTING THE CLOSING ROCKER ARMS
Fit the opening rocker arm shafts (3) using suitable tools.
Fit the opening rocker arm (4) and drive the shaft (3) fully home.
Follow the same procedure to refit the opening rocker arms.
If not installed before, lift the opening rocker arms (4) and insert the opening shim as described in chapter "Refitting the
valves".
Refit the camshafts (Refitting the camshafts) and check the valve opening clearance (Checking and adjusting the valve
clearance).
Insert the gaskets (2) on the plugs (1), orienting them (preferably) with the square edge side facing the cylinder head.
Check that the pre-applied threadlocker is still present on the plugs (1). If it is not so, apply the indicated product on
the first two plug threads, spreading it for the half circumference (about 180°).
Tighten plugs to a torque of 15 Nm (Min. 14 Nm – max. 16 Nm).
Note
After tightening, remove any excessive sealant.
Refit the camshaft supports and the head covers (Refitting the camshafts).
Refit the timing pulleys (Refitting the cylinder head pulleys/fixed tensioner).
Refit the complete cylinder heads in the engine (Refitting the engine cylinder heads).
Overhauling the cylinder head components

CYLINDER HEADS
Remove any carbon deposits from the combustion chamber and its ducts.
Remove any scale from the coolant ducts.
Check for cracking and inspect the sealing surfaces for scoring, steps or other damage.
Check that the cylinder mating surfaces of the cylinder head are free of carbon deposits and scale. If this is not the
case, spread diamond lapping paste (6÷12 micron thickness) on a reference surface and slide the cylinder head on the
surface as shown in the figure until a flat surface is obtained.
Important
Since it is absolutely necessary that the machining is extremely precise, we recommend having it performed by
operators specialised in grinding operations.

MAINTAINING THE VALVE SEAT
Visually inspect the valve seats: there must be no pitting or cracks.

Minor damage can be repaired by grinding with special 45°, 60° and 70° single-blade grinders. Grind the valves and
check the seal.
Check that the outer diameter of the valve seat contact surface.
Standard: exhaust
Standard: intake
"Minor" damage can be repaired by grinding with special α (1) and β (2) single-blade grinders.
Grind the valves and check the seal.

Valve Grinder

α β

Intake 45° 60°

Exhaust 45° 70°
Remove the least possible quantity of material from the seat.
If the valve seats are excessively damaged, fit oversize seats. Replacement seats are available with 0.03 and 0.06 mm
(0.0012 and 0.0024 in) oversized outside diameters.
Warning
Check that there are no leaks by filling the intake and exhaust pipes with a suitable product. In case of leaks, check
the repair quality with Prussian blue.

REPLACING THE VALVE SEAT
Important
When you change the valve seats, change the valve guides as well.
Change the valve guides as follows:
• Remove the worn out seats by grinding them carefully.

• Check the diameter of cylinder head housings and choose the oversized valve seat that will give an interference fit
of 0.04 ÷ 0.10 mm (0.0016 ÷ 0.0039 in).
• Heat the cylinder head gradually and evenly up to 150 °C and chill the new valve seats in dry ice.
• Drive the seats perfectly square into their housings using the appropriate installers part no. 88713.2846 and
88713.2847.
• Allow the cylinder head to cool down and grind the seats to the following dimensions:
Important
Do not use any lapping compound after final grinding.

Valve

Intake (CA) Ø 35.09 ± 0.05 mm (1.381 ± 0.002 in)

Exhaust (CS) Ø 28.39 ± 0.05 mm (1,157 ± 0,002 in)

D 0.984 ÷ 1.618 mm (0.039 in ÷ 0.064 in) x 45°

E 5.85 mm (0.23 in) x 45°

H 1.049 ÷ 1.548 mm (0,041 in ÷ 0,061 in) x 45°

L 5.9 mm (0.232 in) x 45°
It is advisable to lap the radius between the intake valve seats and the intake ducts (F = before; G = after).
Lubricate valve seats with the indicated product.

VALVE GUIDES
Check the internal surface of the valve guides: there should be no signs of deformation or cracking.
Thoroughly check the dimensions of the valve guide.

Measure the inside diameter with a suitable gauge.
Measure the diameter at different positions of the valve guide.
The clearance upon fitting must be: maximum detected value - minimum detected value = 0.003 ÷ 0.045 mm (0.0001
÷ 0.0018 in).
The maximum permissible wear limit is 0.08 mm (0,003 in).
Change the valve guides when the ovality exceeds permissible limit or the valve stem clearance is outside the
tolerance range.
When you change the valve guide, you must also change the valve.
Change the valve guides as follows:
• Heat up the cylinder head gradually and evenly up to 150 °C.

• Remove the original valve guides using tool part no. 88713.2842.
• Allow the cylinder head to cool down and check the condition of the seats.
• Choose suitable valve guides to obtain an interference fit in the cylinder head of 0.022 ÷ 0.051 mm (0.0009 ÷
0.002 in).
• Heat up the cylinder head again and chill the new valve guides in dry ice.
• Lubricate the seats in the cylinder head and install the valve guides using the appropriate service tools and with
reference to the dimensions given in the figure.
INTAKE (A)= 27.8 ± 0.3 mm (1.09 ± 0.01 in).
EXHAUST (B)= 21.05 ± 0.3 mm (0.83 ± 0.01 in).

CHECKING THE VALVE
Check that the stem and the valve seat contact surface are in good condition.
There must be no pitting, cracks, deformations or signs of wear.
Warning
The valves cannot be ground.
Perform the following checks:
Measure the diameter of the valve stem at various points along the section that runs in the valve guide.
Check the valve stem for buckling. Place it on a "V" reference and measure deformation with a dial gauge.
Service limit: 0.053 mm (0,002 in).

Check the valve stem for buckling. Place the valve on a "V" reference block, set a dial gauge perpendicular to head and
measure concentricity of valve face at 45°:
• Nominal concentricity: 0.01 mm (0.0004 in).

• Service limit: 0.03 mm (0.0012 in).
Use Prussian blue or a mixture of minium and oil to check that the contact surface (W) between valve and seat is 1.4
÷ 1.6 mm (0.055 ÷ 0.063 in) (1.05 ÷ 1.35 mm (0.041 ÷ 0.053 in) when new).
Grind the seat if the dimension measured is greater than the above limit.

CHECKING THE VALVE SEALING
Note
Lubricate valve stems in the indicated area, only.
After grinding the seats it is important to check the seal between valve face and seat: if the seat contact area (S) on
the valve is wider than the 45° band (W) this could lead to poor sealing.

CHECKING THE ROCKER ARMS
Check for signs of wear, grooves or chrome flaking off.

Check the condition of rocker arm bore and shaft.
Clearance upon fitting: 0.025÷0.049 mm (0,001÷0.0019 in).
Wear limit: 0.08 mm (0,003 in).

OPENING AND CLOSING SHIMS – SPRINGS
Check the condition of the contact surfaces of the valve opening and closing shims (C): there must be no signs of
wear.
Check the conditions of the return springs (D) of the closing rocker arms: no cracks, deformations or failure must be
present.
Refitting the cylinder heads
Warning
To prevent oil leaks in the contact area between cylinders and crankcase, each time the head is removed, cylinder and
piston must be removed as well to clean the mating faces of crankcase and cylinder and restore the worn gaskets and
O-rings and apply again sealing compound.
Working on the vertical head, refit the centring bushes (7) in the vertical cylinder.
Refit the new gasket (6) on the vertical cylinder, aiming it so that the side with the stamped part no. (B) is aimed
upwards as shown in the figure.
Warning
Whenever removed, seals must be replaced by new ones of the same type on refitting.
Note
The shape of the gasket prevents incorrect fitting, provided that the fluid flow holes are aligned with those on the
cylinder.
Repeat the same procedure to fit the gasket to horizontal head.

VERTICAL HEAD
Lower the complete vertical cylinder head (3) carefully over the stud bolts. Take care not to damage the threads.
Apply the indicated product on the underhead of nuts (1) and on the stud bolt thread.
Fit washers (2) on stud bolts and screw nuts (1).
As a first step, tighten the nuts (1) to a torque of 20 Nm, following the sequence shown in the figure.
Pre-tighten the nuts (1) to a torque of 40 Nm (Min. 38 Nm - Max. 42 Nm), following the sequence shown in the figure.
Tighten the nuts (1) to a torque of 60 Nm (Min. 57 Nm - Max. 63 Nm), following the sequence shown in the figure.

HORIZONTAL HEAD
Check that the cylinder head gasket is fitted on the mating surface between horizontal head and cylinder.
Warning
Lower the complete horizontal cylinder head (4) carefully over the stud bolts. Take care not to damage the threads.
Apply the indicated product on the underhead of nuts (1) and on the stud bolt thread.
Fit washers (2) on stud bolts and screw nuts (1).
As a first step, tighten the nuts (1) to a torque of 20 Nm, following the sequence shown in the figure.
Pre-tighten the nuts (1) to a torque of 40 Nm (Min. 38 Nm - Max. 42 Nm), following the sequence shown in the figure.
Tighten the nuts (1) to a torque of 60 Nm (Min. 57 Nm - Max. 63 Nm), following the sequence shown in the figure.

POSITIONING THE ENGINE
Raise tool (A) part no. 88713.3220, bringing the engine in its original position.
Apply the indicated product to the stem, underhead and thread of special screws (1).
Working on the RH side of the motorcycle, start the special screws (1) on frame, driving them fully home.
On the opposite side, start nuts (2) on the thread of special screws (1).
Tighten special screws (1) securing the engine to the frame to a torque of 60 Nm ± 5%, while holding nuts (2).
Remove tool (A) part no. 88713.3220.

REFITTING THE SCREWS SECURING FOOTPEG HOLDER PLATES TO ENGINE

Start screws (4) securing the LH front footpeg holder plate assembly (5) to the engine.

Start screws (1) in the RH front footpeg holder plate assembly (2) placing bushings (3) between footpeg holder plate
and engine.

REFITTING THE ABS SUPPORT
Working on either sides of the motorcycle, start screws (2) that fix the ABS support to the frame.
Refit the timing belts (Refitting the mobile tensioner-timing belt).
Refit the exhaust system (Refitting the exhaust system).
Refit the rear brake control lever (Refitting the complete rear brake control).
Refit the gear shift lever (Refitting the gear shift).
Refit the cooling system hoses and unions on the engine block (Refitting the cooling system hoses and unions).
Connect the canister filter pipes (Refitting the canister filter).
Connect the secondary air system pipes to the cylinder heads (Refitting the secondary air system).
Refit the underseat covers (Refitting the side body panels and the tail guard).
Removing the cylinder/piston assembly
Note
Note
frame.
Remove the heads from the engine block (Removing the engine heads).
Loosen clamps (1) and remove the hose (2) from the vertical cylinder (3) and from the water pump cover.
Loosen clamps (1) and remove the hose (4) from the horizontal cylinder (15) and from the water pump cover.
Remove the gasket (6) from the vertical cylinder.
Remove the centring bushes (7).

Engage the sixth gear.
Use tool (A) part no. 88765.1635 to bring the piston of the vertical cylinder to the TDC.
Since insertion of piston in the cylinder is a difficult operation to perform at the time of reassembly, remove the piston
together with the barrel as described below.
Position a rag on crankcase opening so as to prevent gudgeon pin retainers from falling inside it.
Carefully lift the cylinder (8) off the crankcase, keeping it vertical. If necessary, rock the cylinder slightly using both
hands or tap its base gently with a rubber mallet.
Continue to lift the cylinder until you can access the gudgeon pin (9).
Block the crankcase opening with a rag or soft paper to prevent foreign material from falling inside.
Working on clutch side, remove the snap ring (10) from the gudgeon pin (9).
Drive out the gudgeon pin (9) sufficiently to release the connecting rod.
Lift the cylinder-piston assembly (8) and (12) clear of the crankcase stud bolts.
If work is to be carried out on the piston, carefully withdraw it from the cylinder.
Remove seal (11) from the crankcase unit.
Remove the centring bush (13) and gasket (14).

Repeat the above procedures to remove the horizontal cylinder-piston assembly.
Important
Mark the pistons to show from which cylinder they were removed:
V= Vertical - O= Horizontal.
Overhauling the cylinder/piston components

OVERHAULING THE CYLINDER
Check that the walls of the cylinder are perfectly smooth. Measure the cylinder diameter at 50 mm (1.97 in) from the
top face and determine the size class to which it belongs in accordance with the values specified in chapter
"Cylinder/piston".
Repeat measurement of the diameter at three heights "A" (10 mm (0.394 in) from the upper surface), "B" (50 mm
(1.97 in) from the upper surface) and "C" (100 mm (3.94 in) from the upper surface) and in two directions at 90°
between them; check that the measurements of taper and oval fall within the range specified in chapter
"Cylinder/piston".
In order for the liner to be conforming, the following conditions must be true:
ØA<ØB<ØC
Ø C – Ø A = 0.015 mm (5.90 in)
In the event of damage or excessive wear the cylinder must be replaced as it has a silicon carbide coating (which
provides the cylinder walls with excellent anti-friction and anti-wear properties) and therefore cannot be ground.
The cylinders are marked with letters (stamped between the two oil return ways) indicating their size class.
Always match piston with cylinder from the same size class.

OVERHAULING THE PISTON
Clean the piston crown and piston ring grooves, removing any carbon deposits.
Visually inspect the piston and check its dimensions carefully: there must be no signs of scuffing, scoring, cracks, or
other damage.
The piston diameter must be measured at 7.5 mm (0,295 in) from the bottom of the skirt and in perpendicular
direction to the gudgeon pin axis.
The pistons must always be replaced as a pair.

CHECKING THE PISTON-CYLINDER COUPLING
The pistons are marked with a symbol (selected letter (L) punched onto the piston crown) that indicates the size class
to which they belong.
Always match piston with cylinder from the same size class.
(F): arrow that indicates the exhaust side.
For the correct values, refer to chapter "Cylinder/piston".

OVERHAULING THE GUDGEON PINS
Gudgeon pins must be perfectly smooth without signs of scoring, steps, or blueing due to overheating.
The well-lubricated gudgeon pin must slide smoothly inside the piston without stiffness.
For the coupling clearance values with the piston and the connecting rod, see chapter "Cylinder/Piston".
If a new gudgeon pin is fitted, you must also change the connecting rod small end bush.

OVERHAULING THE PISTON RINGS
The piston rings must not show any signs of scuffing or scoring.
Spare pistons are supplied complete with piston rings and gudgeon pin.

CHECKING THE PISTON RING-GROOVE COUPLING
The maximum permissible wear limit is 0.15 mm (0.0059 in) for the top ring (1st ring "S") and 0.10 mm (0.0039 in)
for the others (2nd ring "T" and oil scraper ring "R").
The piston rings must always be fitted with markings (M) facing upwards.
First ring (S).
Second ring (T).
Oil scraper ring (R).

CHECKING THE PISTON RING/CYLINDER COUPLING
Insert the piston ring 50 mm (1.97 in) from the top face of the cylinder; make sure that the ring is positioned perfectly
square to the cylinder axis by checking with a gauge at several points around the ring that the top surface of the ring
is 50 mm (1.97 in) from the cylinder top face.
Measure the piston ring gap (A):

Distance (A) Wear limit

Upper piston ring 0.2 ÷ 0.4 mm (0,008 in ÷ 0.016 in) 0.8 mm (0,031 in)

Intermediate piston ring 0.3 ÷ 0.5 mm (0.012 in ÷ 0.02 in) 0.8 mm (0,031 in)

Oil scraper ring 0.2 ÷ 0.7 mm (0,008 in ÷ 0.028 in) 1.0 mm (0,039 in)
Refitting the cylinder/piston assembly
Note
Note
frame.
If new parts are used, it is necessary to match cylinders and pistons of the same selection (see chapter "Overhauling the
cylinder/piston components").
Note
If the pistons have been separated from their cylinders, before reassembling these components, position the piston
ring gaps at 120° from one another (the markings must always face the piston crown).
Use a universal tool to carefully insert the piston into the cylinder (first lubricate the inside of the cylinder with engine
oil). Position the cylinder with the smallest valve recess is on the side of the exhaust.
Remove any deposits and degrease the contact surfaces of the crankcase half and the cylinders.
Refit the centring bush (13) and gasket (14) to crankcase.
Apply the indicated product to both sides of gasket (11), as shown in the figure.
Fit gasket (11) on crankcase stud bolts, aimed so that “top inlet” stamping is visible by the operator.
Position the gasket (11) in contact with the casing.
Warning
Apply engine oil on the shank of gudgeon pin (9).
Bring the connecting rod small end close to TDC and slide the cylinder-piston assembly (12) and (8) onto the
crankcase stud bolts.
Push the connecting rod small end into the piston (12) close to the hole and insert the gudgeon pin (9).
The gudgeon pin must slide smoothly in the connecting rod small end bush and in the piston (12).
Close the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the snap ring (10).
Important
Always fit new circlips upon reassembly.
Push the cylinder (8) down until it seats against the crankcase.
Refit the centring bushes (7) in the vertical cylinder.
Refit the new gasket (6) on the vertical cylinder, aiming it so that the side with the stamped part no. (B) is aimed
upwards as shown in the figure.
Warning
Note
The shape of the gasket prevents incorrect fitting, provided that the fluid flow holes are aligned with those on the
cylinder.
Repeat the above procedures to refit the horizontal cylinder-piston assembly.
Refit the hose (4) on the connectors of the horizontal head (15) and water pump cover.
Position the clamps (1) aiming them as shown in the figure and tighten them to a torque of 2.5 Nm (Min. 2 Nm. - Max.
3 Nm).
Refit the hose (2) on the connectors of the vertical head (3) and water pump cover.
Position the clamps (1) aiming them as shown in the figure and tighten them to a torque of 2.5 Nm (Min. 2 Nm. - Max.
3 Nm).
Refit the engine cylinder heads (Refitting the engine cylinder heads).
Description of the clutch assembly
Note
The clutch has the important function to immediately disconnect the gearbox primary shaft from the crankshaft.
Working on clutch lever (1) the master cylinder (2) is pressurized and pushes on the control rod (3). Therefore the
pusher plate (4) is moved and detaches the driven plates from the driving ones.
The clutch consists of a housing (5) that rotates freely on the primary shaft (6).
Inside the clutch housing there the driving plates (7) and the driven plates (8).
The driving clutch plates move together with housing (5) and crankshaft (10) by means of gear (9).
While the driven plates move together with the clutch hub (11) that is fixed to the gearbox shaft (6).
The entire system is moved by the pressure on the hub springs.
Working on the clutch lever, thanks to the pusher plate mechanism, the clutch will be detached and the plates will
rotate freely with no connection to housing and hub.
This will allow the detachment of crankshaft and gearbox shaft.
The following is a list of possible causes of clutch malfunction.
A clutch which does not disengage may be caused by:
• Excessive play of the control lever.

• Distorted clutch plates.
• Incorrect spring tension.
• Faulty clutch release mechanism.
• Excessive wear of the hub or clutch housing.
A clutch which slips may be caused by:
• No backlash of the control lever.

• Worn clutch plates.
• Weakened springs.
• Faulty clutch release mechanism.
• Excessive wear of the hub or clutch housing.
A noisy clutch may be caused by:
• Excessive backlash between the primary drive gears.

• Damaged primary drive gear teeth.
• Excessive clearance between driving plate tabs and the clutch housing.
• Worn gear/clutch housing bearings.
• Presence of metal particles (filings) on the gear teeth.
Removing the clutch
Remove the sump guard unit (Removing the sump guard)

Remove the clutch cover (Removing the clutch cover).
Note
frame.
Undo the fixing screws (1) and remove the ring (2) and the springs (3) from the pusher plate (4).
Slide out pusher plate (4) taking care not to damage snap rings (C).
Remove the clutch control pin (6) and bearing (7) from pusher plate (4).
Lock the clutch housing with tool (A) part no. 88713.3408, loosen the retaining nut (7) and collect the lower washer
(8).
Slide the plate assy (9) with hub out of clutch housing (10), marking them so as to be able to later refit them in the
same position.
Remove the spacer (11) from the clutch housing (10).
Remove the clutch housing (10) from the primary shaft.
Collect the spacer (12) from the primary shaft.

The plate pack (9) consists of:
• 6 driven plates (A) with 1.6 mm (0.06 in) thickness.

• 1 driven plate (B) with 2 mm (0.08 in) thickness.
• 5 drive plates (C) with 3 mm (0.12 in) thickness.
• 3 drive plates (D) with 3 mm (0.12 in) thickness.
• 1 Belleville washer (E) with 0.8 mm (0.03 in) thickness.
• 1 shimming plate (F).
Checking and overhauling the components

CLEARANCE BETWEEN THE CLUTCH HOUSING AND FRICTION PLATE
Insert a friction plate (E) in the clutch housing (F) and measure the clearance (S) with a feeler gauge.
Clearance "S" must not exceed 0.6 mm (0.02 in).
If it does, replace the plates and, if necessary, the clutch housing.

OVERHAULING THE CLUTCH PLATES
The clutch plates must not show any signs of blackening, grooves or deformation.
Measure the thickness of the friction plates; it should not be less than 2.6 mm (0.10 in).
The rated thickness of the plates pack must be 35.6 +0.80mm (1.40+0.030 in).
Place the plate on a flat surface and check the amount of deformation with a feeler gauge.
Max. flatness error: 0.2 mm (0,007 in).

OVERHAULING THE PUSHER PLATE
Check bearing (7) conditions: replace the bearing if the play is excessive.
Check the mating surface of the last driven plate; if extremely scored, polish it in the same manner as described
previously for the cylinder head surface (Overhauling the cylinder head components).
Check the condition of the spring guide seats of pusher plate (4) and of snap rings (5).

OVERHAULING THE PUSHER PLATE SPRINGS
Measure the length "L" of each spring.

Free length: 43.6 mm (1.72 in).
Working length: 25.8 mm (1.01 in).
Replace any springs that are shorter than the above limit value.
Refitting the clutch
If the plate assy (9) was disassembled, take special care with the positioning of the clutch plate upon reassembling.
Insert the clutch plate pack on hub.
The plate pack (9) consists of:
• 6 driven plates (A) with th. 1.6 mm (0.06 in).

• 1 driven plate (B) with th. 2 mm (0.08 in).
• 5 drive plates (C) with th. 3 mm (0.12 in).
• 3 drive plates (D) with th. 3 mm (0.12 in).
• 1 Belleville washer (E) with th. 0.8 mm (0.03 in).
• 1 shimming plate (F).
Refit the spacer (12) onto the primary shaft.

Note
frame.
Refit the housing (10) onto the primary shaft.

Fit the spacer (11) to the clutch housing (10).
Fit the clutch plate pack (9) with hub inside the clutch housing (10).
Fit lock washer (8) on primary shaft, driving it fully home inside clutch unit.
Apply the indicated product on nut (7) mating surface and on primary shaft thread, then tighten nut driving it fully
home by hand inside primary shaft.
Lock the clutch hub with tool (A) part no. 88713.3408 (Clutch hub reaction tool), so as to hold it when tightening nut
(7).
Remove tool (A) part no. 88713.3408 (Clutch hub reaction tool).
Refit the clutch control pin (6) and bearing (7) on pusher plate (4).
Fit the pusher plate (4) on the clutch hub.
Fit snap rings (D) on pusher plate (4).
Fit the springs (3) on pusher plate (4).

Fit ring (2) to pusher plate (4) and start screws (1).
Refit the clutch cover (Refitting the clutch cover).
Removing the clutch cover

Remove the silencer heat guard (Removing the silencer).
Loosen screws (1) and remove the clutch cover (2).
Loosen screws (3) and slide rear brake master cylinder assembly (4) out of rod (5).
Using a service clamp (C), fasten the right front footpeg holder plate assembly (7) to the right rear footpeg holder
plate assembly, as shown in the figure.
Loosen screws (10) and remove sump guard support bracket (11).
Loosen screws (12) and special stud bolts (13) retaining the clutch cover (14).
Remove the clutch cover (14).
Disassembling the clutch cover

OIL FILLER CAP
Loosen oil plug (1) and collect O-ring (2).

INSPECTION SIGHT GLASS
Operating from the inside of the clutch cover with a suitable drift, remove the oil inspection sight glass (3).

CLUTCH PLUG
Loosen plug (4) and collect seal (5).

CRANKSHAFT CENTRING BUSHING
Remove snap ring (6), shim (7), sealing ring (8) and crankshaft bushing (9).

SOUNDPROOFING METAL SHEET
Loosen the retaining screws (10).

Remove the sounddeadening sheet (11) and the soundproofing panel (12) from clutch cover.
Reassembling the clutch cover

SOUNDPROOFING METAL SHEET
Insert the soundproofing panel (12) fully home against clutch cover, aiming it as shown in the figure.
Fit the sound-deadening sheet (11) inside clutch cover, positioning it as shown in the figure.
Start and tighten the screws (10) to a torque of 12 Nm (Min. 10 Nm. - Max. 14 Nm).

CLUTCH PLUG
Fit washer (5) on plug (4).
Start cap (4) on the clutch cover.

CRANKSHAFT CENTRING BUSHING
Apply the indicated product to the bushing seat (9).

Drive bushing (9) using a suitable drift.
Clean seal (8) using the specified product.
Using the specific tool, drive seal (8), with the spring side facing out, as shown in the figure.
Fit spacer (7) and snap ring (6).
At the end of fitting operations, make sure that the snap ring is completely inside the seat of clutch cover.

INSPECTION SIGHT GLASS
Apply the indicated product to the inspection sight glass (3) and position it on clutch cover, as shown in the figure.
Using a suitable drift, fit the inspection sight glass to X = 47.5 +0.50 mm (1.87 0.010 in).
Make sure that two of the four holes (A) inside the sight glass are parallel to the cover bottom (B).

OIL FILLER CAP
Refit O-ring (2) in cap (1).

Start cap (1) on the clutch cover.
Tighten cap (1) to a torque of 5 Nm (Min. 4.5 Nm – max. 5.5 Nm).

Refitting the clutch cover
Clean and degrease clutch cover and casing mating surfaces. Check that the casing features the centring bushing (A).
Apply the specified product to crankshaft (B).
Thoroughly clean contact surfaces of clutch cover (14) and RH crankcase half (Cleaning and applying the silicone rubber
sealant on work surfaces) and apply an even and continuous bead of sealing compound on clutch cover (14) by following
the path shown in the figure.
Warning
An excessive quantity of sealant may cause the internal components of the clutch cover to block.
Warning
Fit clutch cover within five minutes from sealant application.
Important
Move clutch cover (14) fully home on crankcase.

Start screws (12) and special stud bolts (13) on clutch cover (14).
Tighten the screws (12) to the torque specified below, following the sequence shown in the figure:

Tighten special stud bolts (13) to a torque of 13.5 Nm (Min. 12.5 Nm – Max. 14.5 Nm).
Position sump guard support bracket (11) on the special stud bolt, aiming it as shown in the figure and start screw
(10).
Remove the service clamp (C) of the RH footpeg holder plate assembly (7).
Position the rear brake master cylinder assembly (4) and start screws (3).
Position clutch cover (2) and start screws (1).
Check that rear brake pedal has a free play (X) = 2 ÷ 5 mm (0.08 ÷ 0.19 in) before the brake bites.
If not, modify the length of the control rod (5) of the master cylinder as follows:
• Slacken off the lock nut (15) on the master cylinder rod.
• Tighten the lock nut (15) to a torque of 7.5 Nm ±10%, and check play again.
Refit the silencer heat guard (Refitting the silencer).
Removing the primary drive gears
Remove the sump guard unit (Removing the sump guard)

Remove the cover (Removing the clutch cover).
Remove the clutch unit (Removing the clutch).
Lock the primary sprocket (1) with holding tool (A) part no.88713.3417 and loosen the ring nut (2) securing sprocket
using bushing (B) part no. 88713.3406.
Remove the ring nut (2) and the lock washer (3).
Remove the primary sprocket (1) using tool (C) part no. 88713.4882.
Collect the key (4).
Refitting the primary drive gears and checking backlash
Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear.
Make sure that key (4) is positioned on crankshaft.
Fit the primary sprocket (1) onto the crankshaft with the oil pump drive sprocket facing the crankcase.
Position washer (3).
Apply the indicated product on the ring nut (2) thread.
Start the ring nut (2) on the crankshaft.
Lock the primary sprocket (1) with holding tool (A) part no. 88713.3417.
Using bushing (B) part no. 88713.3406, tighten ring nut (2) to a torque of 190 Nm (Min. 171 Nm - Max. 209 Nm).
Refit the clutch unit (Refitting the clutch).
Removing the gearchange mechanism
Remove the gear shift ().

Remove the water hoses (Removing cooling system hoses and unions).
Note
For better clarity, some of the following figures show the engine removed from the frame.
Loosen screws (1) and (2) and remove the complete gearchange mechanism (3), collecting spacer (4).
Visually inspect the gear selector fork (5) for wear, particularly around the area where it contacts the selector drum.
Remove the snap ring (14) and collect the washer (13).
Separate the selector fork (5) from the gearbox shaft (7). Remove the spring (12).
Remove the circlip (11).

Collect in order shim (10), centring bush (9), stop plate (8), spring (6) and gearbox shaft (7).
Disassembling gear interlock plunger and ratchet

Remove the clutch cover ().
Undo the clutch-side crankcase half screw (5) and remove the ratchet (6), the washer (7) and the spring (8).
Refitting the gear interlock plunger and ratchet
On the special screw (5), fit the gear ratchet (6), orienting it as shown in the figure, the washer (7) with the square
edge side (D) facing the clutch-side crankcase half, and the spring (8), positioning it so that the hook end (A) is facing
the gear ratchet.
Locate the hook (A) of the spring on the gear ratchet as shown in the figure.
Apply the indicated product to screw (5) thread.
Start screw (5) on the casing.
Position end (B) of the spring so that it rests against rib (C) of the crankcase half, as shown in the figure.
After tightening, remove the excess of threadlocker.
Manually move the gear ratchet to check for proper spring operation.
Refitting the gearchange mechanism
Note

PRE-ASSEMBLING THE GEARCHANGE MECHANISM ASSEMBLY
Insert spring (6) inside gearbox selection shaft (7), aiming it as shown in the figure.
Fit the limit stop plate (8), the centring bush (9), aiming them as shown in the figure.
Fit shim (10) and snap ring (11).
Insert selector fork (5) inside gearbox selection shaft (7), fitting spring (12) as shown in the figure.
Fit washer(13) and snap ring inside fork (14).
Make sure that gearbox is in "neutral" position, otherwise move the gearbox shafts with a service lever until reaching
this condition.
Remove centring bush (A).
Apply the indicated product in the chain-side casing seat and on the complete gearchange mechanism (3) pin.
Position the complete gearchange mechanism (3) on chain-side casing, insert teeth (B) on pins (C) of selector drum
and secure it in place by positioning plate (4) and screwing screws (1) and (2) without tightening.
Position tool (D) part no. 88713.0022, as shown in the figure, securing it to the casing with pin (E).
Insert tool pin (F) inside selector fork.
In this position, first tighten screw (2) to a torque of 36 Nm (Min. 34 Nm - Max. 38 Nm) and then screw (1) to a
torque of 16 Nm (Min. 15 Nm - Max. 17 Nm).
Remove tool (D).
Warning
Make sure that the gearchange mechanism fixing screws are those indicated in our spare part catalogues. They must
be screws of class 12.9 in order to respect the tightening torque indicated above.
Check for the correct operation of the complete gearchange mechanism, trying to engage all gears both in upshifting
and downshifting, making sure that there are no hard spots.
With the gearbox in neutral, check that the lever travel is the same when shifting up and down. The same should apply
when a gear is engaged.
Operate the gearchange lever and turn the front sprocket at the same time to check that all the gears engage when
shifting up and down.
Remove the previously installed lever and sprocket.
Refit centring bush (A).

Refit the water hoses (Refitting cooling system hoses and unions).
Refit the gear shift (Refitting the gearbox unit).
Removing the gearbox assembly
Remove the engine from the frame (Removing the engine).

Remove the timing pulleys (Removing the timing layshaft pulleys).
Remove the complete cylinder head assembly (Removing the engine heads).
Remove the complete cylinder/piston assembly (Removing the cylinder/piston assembly).
Remove the generator side cover (Removing the generator cover) and the complete generator (Removing the
flywheel/generator assembly).
Remove the starter motor (Removing the starter motor).
Remove the primary drive gear (Removing the primary drive gear).
Loosen screw (5) and remove gear selector drum flange (6).
Separate the crankcase halves (Separating the crankcase halves).
Withdraw the selector fork shafts (1).

Move forks (2) and (3) so as to disengage pins (B) from the seats in the gear selector drum (4).
Slide out gear selector drum (4) and remove magnet holder (7).
Remove gear selector forks (2) and (3).
Remove the gearbox primary (9) and secondary (10) shafts complete with gears, taking care to recover the shim
washers on the ends of the shafts.
If the bearing inner rings (A) are left on the shafts, slide them off the ends of the gearbox primary (9) and secondary
(10) shafts (Separating the crankcase halves).
Disassembling the gearbox shafts
Place the shaft in a vice in such a way to facilitate the disassembly operations.
Important
Take care not to invert the shim position upon reassembly: this would potentially lead to jamming when using the gear
selector control, making it necessary to reopen the crankcase.

DISASSEMBLING THE GEARBOX SECONDARY SHAFT
Slide out shim (1) from the secondary shaft.
Remove the first speed driven gear (3) with the needle roller bearing cage (4) and the shim (5).
Remove the fifth speed driven gear (6).
Use two flat blade screwdrivers to remove the snap ring (7) from its seat, taking care not to damage the shaft surface.
Slide off the splined washer (8).

Remove the fourth speed driven gear (9) with its roller bearing cage (10).
Remove the third speed driven gear (11) with its roller bearing cage (10) and splined washer (8).
Remove the snap ring (7).
Remove the sixth speed driven gear (12).

Slide out the splined washer (8) and the second speed driven gear (13).
Withdraw the roller bearing cage (10). All the components have thus been removed from gearbox secondary shaft (2).

DISASSEMBLING THE GEARBOX PRIMARY SHAFT
Slide out shim (16) from the primary shaft.

Remove the second speed driving gear (17) and remove the snap ring (18).
Important
Take care to avoid damaging the surface of the shaft while removing the snap ring.
Remove the splined washer (19) and the sixth speed driving gear (20) with its roller bearing cage (21).
Slide off the splined washer (19).
Remove snap ring (18) and slide out the third and fourth speed driving gear (22).
Slide out the splined washer (19), the fifth speed driving gear (23) with the relevant roller bearing cage (21) from the
primary shaft (15).
Overhauling the gearbox
Check the condition of the front coupling dogs of the gears. They must be in perfect condition and with no sign of wear
on the edges of the teeth.
The idler gears must rotate freely on their shafts.
When refitting, make sure the circlips are correctly positioned.
Check the needle roller bearings for wear.
The threads and splines of the shafts must be in perfect condition.
Also check that the component parts of the gear selector mechanism are in good condition.
Engage the gears and check that the gearchange mechanism does not stick (selector fork-gear groove, and fork pin-
desmodromic drum groove) due to incorrect end float.
Restore the correct end float by shimming the gearbox shafts and the selector drum with suitable shims (Gearbox).
Inspecting the gear selector forks
Visually inspect the gear selector forks. Bent forks must be replaced as they may lead to difficulties in gear changing or
may suddenly disengage when under load.
Use a feeler gauge to check the clearance of each fork in its gear groove.
If the service limit has been exceeded, check whether or not it is necessary to replace the gear or the fork by referring
to the limits specified for each part (Gearbox).
Inspecting the fork selector drum
Use a gauge to measure the clearance between fork pin and the groove on the selector drum.
If the service limit has been exceeded, determine which part must be replaced by comparing these dimensions with
those of new components.
Also check the wear on the drum support pins; these must not show any signs of scoring, burrs, or deformation.
Turn the drum in the crankcase to establish the extent of radial play.
If play is excessive, change whichever part is most worn (Gearbox).
Reassembling the gearbox shafts

REASSEMBLING THE PRIMARY SHAFT
Apply the indicated product on the roller bearing cage (21).

Fit roller bearing cage (21), fifth speed gear (23) and splined washer (19) on the primary shaft (15).
Refit the snap ring (18), insert the third and fourth speed gear (22) and the snap ring (18).

Fit the splined washer (19), the roller bearing cage (21), the sixth speed gear (20) and the washer (19).
Refit the snap ring (18), insert the second speed gear (17) and the shim (16).

REASSEMBLING THE GEARBOX SECONDARY SHAFT

Fit the roller bearing cage (10) on the secondary shaft (2); fit the second speed gear (13) and the splined washer (8).
Refit snap ring (7) and insert the sixth speed gear (12).
Refit the snap ring (7).

Fit the splined washer (8), the roller bearing cage (10) and the third speed gear (11).
Fit the roller bearing cage (10), the fourth speed gear (9) and the splined washer (8).
Refit the snap ring (7).

Insert the fifth speed gear (6).
Fit shim (5), roller bearing cage (4) and first speed gear (3).
Refit shim (1) on the secondary shaft.

Reassembling the gearbox assembly
To refit the gearbox components follow the procedure under chapter "Closing the crankcase" relating to the reassembly
of the crankcase.
As a final practical test, ensure that with the gearbox in neutral the front coupling dogs (A) of sliding gears (B) are
equidistant on both sides with respect to the corresponding coupling dogs on the fixed gears (C).
Check also that there is always a small amount of clearance between fork (D) and relative groove (E) on sliding gear
(B) when engaging the gears.
Close the crankcase halves (Closing the crankcase).
Position the gear selector drum flange (6) on the selector drum, centring the slot (F) on the pin (G) and aiming the
machined tooth (which identifies the gearbox "Neutral” position) on the gear interlock ratchet (12).
Apply the indicated product to screw (5) thread.
Start screw (5) of the gear selector drum flange (6).

Refit the primary drive gear (Refitting the primary drive gear and checking backlash).
Refit the starter motor (Refitting the starter motor).
Refit the complete generator (Fitting the flywheel/generator assembly) and the generator side cover (Fitting the generator
cover).
Refit the complete cylinder/piston assembly (Refitting the cylinder/piston assembly).
Refit the complete cylinder head assembly (Refitting the cylinder heads).
Refit the timing pulleys (Refitting the timing layshaft pulley).
Refit the engine in the frame (Refitting the engine).
Removing the generator cover
Undo the screws (1) to remove the timing inspection cover (2) in correspondence of the crankshaft and collect the
gasket.
Remove the gear shift con rod (Removing the gear shift).
Remove the clutch slave cylinder unit (Removing the clutch assembly).
Remove the front sprocket cover (Removing the front sprocket cover).
Remove the gear/neutral sensor (Gear/neutral sensor).
Loosen the screw (3) and remove the bracket (4).

Loosen screws (5), screws (6) and special stud bolts (10) that retain the generator cover (8).
Fit tool part no. 88713.1749 (D) on the generator cover (8), fastening it to holes (A).
Turn the tool slowly until the cover (8) detaches from the left crankcase half, remove it and support it properly as it is
still connected with the wiring to the vehicle.
There is a sealing ring (9) on the cover (8) at the gearchange lever shaft that may be damaged when removing the
generator cover.
Always check the condition of this sealing ring and replace it if damaged.
If you wish to remove the generator cover from the motorbike, proceed as follows:
• Remove the fuel tank (Removing the fuel tank).

• Disconnect the generator wiring connector (G) from the voltage regulator by removing the retaining ties (Branch
10).
Disassembling the generator cover
Undo screws (1) that retain the stator (2).

Remove the stator (2) and the plate (3).
Remove the circlip (4).

Remove the bearing (5) using a universal puller.
If necessary, remove the water pump components (Removing the water pump).
Reassembling the generator cover
Apply the indicated product on the seat (G) of the bearing (5) on the generator cover.
Refit the bearing (5) to generator cover, aiming it with the shielded side opposite to the cover.
Secure the bearing (5) with the circlip (4), ensuring that it is correctly fitted in its seat in the generator cover.
Check that the pre-applied threadlocker is still present on the screws (1). Otherwise, use the indicated product.
Refit stator inside the generator cover, so that the cable exit point faces downwards and towards the recess.
Start screws (1) on the stator.
Tighten the screws (1) to a torque of 13.5 Nm (Min. 12.1 Nm. - Max. 14.9 Nm).
Check that rubber element (A) is correctly inserted in the relevant seat on the generator cover.
Insert the lower tabs (B) of plate (3) in the generator cover grooves (C).
Push plate (3) downwards along the guides having care that the stator cable (D) is correctly positioned under the plate
(with the three cables aligned in order to create as little thickness as possible) until the upper tabs (E) reach the
grooves (F).
Push plate outwards with respect to the cover and engage the tabs (E) in the grooves (F) until fully home.
If previously removed, fit the water pump assembly (Refitting the water pump).
Refitting the generator cover
Thoroughly clean contact surfaces (Cleaning and applying the silicone rubber sealant on work surfaces) and apply an even and
continuous bead of sealing compound on generator cover (8) by following the path shown in the figure.
Warning
An excessive quantity of sealant may cause the internal components of the generator cover to block.
Important
Fit generator cover within five minutes from sealant application.
Refit the centring bushes (11).

Apply the indicated product to the idle shaft (D), the crankshaft (E) and the gearchange lever pin (F).
Important
Move generator cover (8) fully home on crankcase.

Position bracket (4) on generator cover (8), aiming it as shown in the figure and start screw (3).
Start screws (5), screws (6) and special stud bolts (10) that retain the generator cover (8).
Tighten screw (3) and special stud bolts (10) to a torque of 13.5 Nm (Min. 12.5 Nm - Max. 14.5 Nm), following the
sequence shown in the figure.
Tighten the screws (5) and (6) to the torque specified below, following the sequence shown in the figure:


Insert seal (9) on driving tool (B) part no. 88700.5749, aiming it as shown in the figure and insert them on gearbox
driving shaft.
Fit the seal (9) fully home with tool (C) part no. 88700.5749 in the generator cover (8).
If the generator wiring has been removed from the motorcycle, proceed as follows:
• Fit the generator wiring on the motorbike, as shown in the figure.

• Connect the generator wiring connector (G) to the voltage regulator by restoring the retaining ties (Branch 10).
• Refit the fuel tank (Refitting the fuel tank).
Refit the gear/neutral sensor (Gear/neutral sensor).
Refit the front sprocket cover (Refitting the front sprocket cover).
Refit the clutch slave cylinder unit (Refitting the clutch unit).
Refit the gear shift con-rod (Refitting the gearbox unit).
Make sure that the O-ring (12) is installed on the timing inspection cover (2).
Refit timing inspection cover (2) on generator cover and start screws (1).
Removing the flywheel/generator assembly

Remove the cooling system hoses (Removing cooling system hoses and unions).
Note
Fit tool (A) part no. 88713.3367, as shown in the figure, by starting screws (B) on crankcase half lower holes (C).
Tighten the screws (B) to a torque of 13.5 Nm (Min. 12.5 Nm. - Max. 14.5 Nm).
Drive screws (D) fully home on flywheel, so as to prevent it from rotating.
Unscrew the generator-flywheel retaining nut (1).
Remove tool (A).
Warning
While unscrewing the nut, apply axial pressure to the socket to avoid damage or injury in the event of the wrench
suddenly slipping off the nut.
Remove nut (1), washer (2) and flywheel assembly (3) complete with driven gear (4) from crankshaft.
Remove the inner ring (5), the needle roller bearing cage (6) and the washer (7).
Check the inner ring (5), the needle roller bearing cage (6) and the washer (7) for wear.
Replace if worn.
Overhauling the flywheel/generator assembly
Inspect the inner part of generator rotor (1) for signs of damage.
Check that the starter clutch is working properly and that the roller races do not show signs of wear or damage of any
kind.
Disassemble the unit if you find faulty operation.

DISASSEMBLING THE FLYWHEEL/GENERATOR ASSEMBLY
Note
Remove the driven gear (2) from starter clutch (7).

Unscrew the screws (4) and remove the generator rotor (1) from the flywheel (3).
Unscrew the screws (5) and remove the flange (6) from the flywheel (3).
Remove starter clutch (7) from flywheel (3).
The starter clutch is a slight interference fit on the flange.
Use a suitable drift to remove it.

REASSEMBLING THE FLYWHEEL/GENERATOR ASSEMBLY
Fit starter clutch (7) in flywheel (3) by taking starter clutch edge (A) fully home on the flywheel (3).
Position flange (6) on the flywheel (3) and start the four screws (5).
Refit generator rotor (1) on flywheel (3) and start screws (4).
Apply the indicated product to the race (B) of driven gear (2).
Fit the driven gear (2) on the starter clutch (7), ensuring it is properly seated.
Check that the driven gear (2) can rotate freely in the direction of the green arrow but not in the direction of the red
arrow.
If either of these two conditions is not met, this means that the starter clutch (7) has not been fitted correctly (or that
parts are non-conforming).
Note
To help insertion, turn the driven gear in the direction indicated by the "green" arrow.
Refitting the flywheel/generator assembly
Note
Apply the indicated grease on washer (7).

Pre-assemble the roller bearing cage unit (6) with washer (7) and internal race (5).
Install the roller bearing cage (6), washer (7) and inner race (5) assembly on the crankshaft.
Make sure that washer (7) stays in its correct position inside its seat.
Insert the flywheel assembly (3) complete with driven gear (4) inside crankshaft.
Fit the washer (2) on the end of the crankshaft.
Apply the indicated product to the thread (E) of the crankshaft and on nut (1).
Fit tool (A) part no. 88713.3367, as shown in the figure, by starting screws (B) on crankcase half lower holes (C).
Tighten the screws (B) to a torque of 13.5 Nm (Min. 12.5 Nm. - Max. 14.5 Nm).
Drive screws (D) fully home on flywheel, so as to prevent it from rotating.
Start and tighten nut (1) to a torque of 330 Nm (Min. 313 Nm – Max. 346 Nm).
Remove tool (A).
Refit the cooling system hose (Refitting cooling system hoses and unions).
Refill the engine oil (Changing the engine oil and filter cartridge).
Removing outer components

Remove the timing lay gear (Removing the timing gear pulleys).
Remove the gearchange mechanism (Removing the gearchange mechanism).

REMOVING THE BLOW-BY VALVE
Loosen the screws (1) and remove flange (2).

Remove the oil breather valve (3) union from the engine.
Remove gasket (4).

Undo screw (8) and remove spacer (9).
Remove reed valve (10).
Loosen screw (5) and remove lower flange (6).

Collect the two O-rings (11).
Check the condition of the two O-rings (11) and replace them if necessary.

REMOVING THE OIL FILTER CARTRIDGE SUPPORT NIPPLE
Remove oil filter cartridge by following the reference procedure (Changing the engine oil and filter cartridge).
Loosen and remove the nipple (12).

REMOVING THE CYLINDER/HEAD STUD BOLTS
Remove the cylinder head stud bolts (19) with the aid of an appropriate tool.

REMOVING THE TIMING SENSOR
To remove the timing sensor (15), undo the screw (16) and collect the washer (17).
Check the condition of O-rings (13) on the crankcase and replace them if necessary.

REMOVING THE CLUTCH FLUID FLOWRATE ADJUSTMENT VALVE DOWEL
Loosen nut (21).

Loosen special dowel (23), collect washer (22), spring (26), buffer (24) and ball (25).
Remove seal (28) from special dowel (23).
Refitting the external components
Note

REFITTING THE CLUTCH FLUID FLOWRATE ADJUSTMENT VALVE DOWEL
Insert buffer (24) inside spring (26), until it engages in place.

Insert O-ring (28) in its seat on special dowel (23).
Fit ball (25), spring (26) with buffer (24) and screw special dowel (23) with O-ring (28) on chain-side casing.
Fit washer (22) and screw nut (21) inside special dowel (23), until driving it fully home.
Move special dowel (23) to the indicated position (X) = 4.1 ± 0,5 mm (0.16 ± 0.02 in).

REFITTING THE TIMING SENSOR
Make sure that the O-rings (13) are fitted on the crankcase.
Position rpm sensor (15), fit the washer (17) and start the screw (16).
Tighten the screw (16) to a torque of 10 Nm (min. 9 – max. 11).
Use a feeler gauge to check the clearance between timing sensor (15) and timing gear (23).
The value must be between 0.6 and 0.8 mm (0.02 and 0.03 in).

REFITTING THE BLOW-BY VALVE
Fit two new O-rings (11) after having lubricated them with the indicated product.
Fit the lower flange (6) on the crankcase and start screw (5).
Fit reed valve (10), spacer (9), and start screw (8).
Tighten the screw (8).
Refit gasket (4) on lower flange, aiming it as shown in the figure.

Position blow-by valve coupling (3), flange (2) on the crankcase and start screws (1).
Tighten the screws (1) to a torque of 1.2 Nm (Min. 1 Nm. - Max. 1.4 Nm).

REFITTING THE OIL FILTER CARTRIDGE SUPPORT NIPPLE
Apply the indicated product to the thread of nipple (12).

Start the nipple (12) in the crankcase half.
Tighten nipple (12) to a torque of 42 Nm (Min. 38 Nm - Max. 46 Nm).
Refit the engine oil filter cartridge (Changing the engine oil and filter cartridge).

REFITTING THE CYLINDER/HEAD STUD BOLTS
Now fit the stud bolts (19) on the crankcase halves, applying the indicated product to the thread of stud bolts (19) and
tightening to a torque of 30 Nm (Min. 28 Nm - Max. 32 Nm).
Use the appropriate commercial tool for this operation.
Refit the gearchange mechanism (Refitting the gearchange mechanism).

Refit the starter motor idler gear (Refitting the starter motor gear).
cover).
Refit the timing lay gear (Refitting the timing gear pulley).
Refit the timing belts (Refitting the mobile tensioner/timing belt).
Removing the starter motor idler gear

Slide out the transmission pin (1) with gear (2) and spacer (3).
Warning
Be careful when positioning the spacer as it could fall inside the crankcase half.
At this point, it is possible to remove the starter motor (Starter motor).
Refitting the starter motor idler gear
Insert pin (1) inside starter gear (2).

Insert spacer (3) on pin (1) (crankcase side) and drive it fully home on starter gear (2).
Apply the indicated product to pin (1) threaded end (A).
Fit the starter motor transmission gear assembly (1) on crankcase, as shown in the figure.
Removing the timing gears

Slide out the driving gear (7) of the timing gear pair (1) and remove the tab (2).
Straighten out the lock washer (3) of nut (4).

Restrain the timing gear by inserting a pin in one of the holes, and unscrew the locking nut (4).
Remove nut (4), washer (3), timing driven gear (6) and tab (5) from the timing layshaft.
Refitting the timing gears
Before reassembling the removed parts, check timing gears for wear. Change, if necessary.
Important
The timing gears must always be replaced as a pair.
Check that tab (5) is present and correctly fitted on the timing layshaft.
Check that tab (2) is present and correctly fitted on the crankshaft.
Refit the driven gear (6) and the driving gear (7) by timing the engraved points as shown in the figure.
Note
Check that, in this position, the horizontal cylinder piston is at TDC.
Apply the indicated product to the nut thread (4).

Fit washer (3) and screw nut (4) on timing layshaft.
Stake washer (3) against nut (4) in such a way as to prevent the nut from working loose.

Removing the starter motor

Working on the RH side of the motorcycle, remove cap (C), loosen nut (A), collecting washer (B) and slide out the
starter motor cable (1).
Loosen the rear screw (2) retaining the starter motor (4).
Working on the LH side of the motorcycle, loosen the retaining screws (3) and (6).
Remove starter motor (4).
Refitting the starter motor
Visually check the gasket (5) for wear and replace it if necessary.
Check that the pre-applied threadlocker is still present on the screws (3) and (6). Otherwise, use the indicated
product.
Fit the starter motor (4) on crankcase, as shown in the figure.
Start the fastening screws (3), and (6) on the starter motor (4).
Tighten the screws (3) and (6) to a torque of 13.5 Nm (Min. 12.5 Nm. - Max. 14.5 Nm).
Start the rear screw (2) retaining the starter motor (4).
Apply the specified product to nut (A).
Position starter motor cable (1) on starter motor and start nut (A) placing washer (B) in-between.
Tighten nut (A) to a torque of 5 Nm ± 10%, and refit cap (C).
Important
Fill the protection cap with protective grease before fitting it on the starter motor.
Refit the starter motor idler gear (Refitting the starter motor idler gear).
Separating the crankcase halves

Remove the timing lay gear (Removing the timing gear pulleys).
Remove the oil filter (Changing the engine oil and filter cartridge).
Remove the gearchange mechanism (Removing the gearchange mechanism).
To better identify the position of each component, the casing has been divided into four areas:
• A) generator side, external part.

• B) generator side, internal part.
• C) clutch side, internal part.
• D) clutch side, external part.
Use a commercial tool to remove the snap ring (1) from the timing layshaft (9) on the clutch-side crankcase half (Side
D).
Warning
Take care to avoid scoring the surface of the shaft while removing the snap ring.
Remove the gear selector drum flange (G) (Removing the gearbox unit).
Working on the generator side of the casing (Side A) and the clutch side (Side D) loosen screws (1), (2), (3) and
special screw (16).
Reuse the generator cover or a service cover with puller (A) no. 88713.1749 duly fitted.
Secure cover to crankcase half with some of the original screws and begin separation by turning the central pin of the
tool.
Tap the end of the gearbox secondary shaft with a plastic mallet to separate the crankcase halves.
Note
Take care not to lose the shim washers on the shafts and on the selector drum.
Working on the crankcase half internal side (Side B) remove the gearbox shafts (6) and the gear selection drum (7)
from the crankcase halves as described in chapter "Removing the gearbox assembly".
Drive out the crankshaft (8) using a plastic mallet, taking care not to lose the snap ring.
Remove the timing layshaft (9).
On both cases, loosen screw (10), remove the lubrication valve (11) and collect the O-ring (12).
Overhauling the crankcase halves
Important
If crankcase halves have to be replaced, they are supplied as a new spare part set.
Warning
When overhauling an engine it is good practice to replace all the crankcase bearings.
Visually inspect the engine crankcase halves.

Check that the surfaces of the crankcase halves are perfectly flat using a reference surface.
Check that the oilways are free of restrictions or clogging.
Check the condition of centring bushes. If apparently distorted or loose in their seats, change them using proper tools.

To replace the main bearings, refer to chapter "Main bearings".

GENERATOR SIDE, INTERNAL PART (SIDE B)
SECONDARY SHAFT BEARING (1).

Undo the two retaining screws (2) and recover spacers (3).
Remove the bearing (1).
PRIMARY SHAFT BEARING (4).

Remove the internal ring (5).
Remove the sealing ring (6).
TIMING LAYSHAFT BEARING (7).

SELECTOR DRUM NEEDLE ROLLER BEARING CAGE (10).

Loosen the retaining screw (11) and collect the washer (12).
Slide out the needle roller bearing cage (10).
GEARCHANGE MECHANISM STOP SCREWS (13).

Loosen and remove gearchange mechanism stop screws (13).

GENERATOR SIDE, EXTERNAL PART (SIDE A)
SECONDARY SHAFT OIL SEAL (9).

Remove oil seal (9).
NEEDLE ROLLER BEARING (10) FOR SWINGARM SHAFT.
Remove the following components in the following sequence:
• sealing ring (11);

• needle roller bearing (10);
• snap ring (12).

CLUTCH SIDE, INTERNAL PART (SIDE C)
Undo the two retaining screws (15) and recover spacers (16).
Remove bearing (14) and tab (17).
Remove the internal ring (19).

GEARBOX DRUM BEARING (22).

Undo the two retaining screws (23) and recover washers (24).

CLUTCH SIDE, EXTERNAL PART (SIDE D)

Remove the following components in the following sequence:

• needle roller bearing (22);
• snap ring (24).
TIMING SHAFT SEAL RING (26).
Remove the sealing ring (26).

Main bearings

REMOVING MAIN BEARINGS
Remove the crankshaft bearing shells (14) and (15) using tool (A) part no. 88713.4145, set drift inside the crankcase
half and the cap on the outside.
Tighten screw (B) fully home.

FITTING MAIN BEARINGS
Crankshaft is supplied in classes ranging from "A" to "D".
The crankshaft markings are positioned on one side at point (C) and are identified by three numbers and three letters.

Number Pin identification

1 Clutch side journal for the main bearings

2 Generator side journal for the main bearings

3 Crank pin
Depending on the type of supplier, the con-rod markings are positioned at point (D) as shown in the figure.
Both casings are clearly marked with main journal size class.
Important
As shown in the figure, the size class of the two main journals is punched on the crank web and CLUTCH side and
CHAIN side are clearly indicated.
Important
As shown in the figure, both casings are clearly marked with main journal size class.


CRANKSHAFT CRANKCASE CRANKCASE HOLE SIZE SHELL SHELL THICKNESS
CRANK PIN SIZE [mm]
MARKING CLASS [mm] COLOUR [mm]

48.980÷48.988 (1.9283 1.990÷1.995 (0.0783
C PURPLE
÷ 1.9680 in) ÷ 0.0785 in)
44.992÷45.000 (1.7713
A
÷ 1.7716 in)
48.988÷48.996 (1.9286 1.990÷1.995 (0.0783
D PURPLE
÷ 1.9289 in) ÷ 0.0785 in)

48.980÷48.988 (1.9283 1.994÷1.999 (0.0785
C RED
÷ 1.9680 in) ÷ 0.0787 in)
44.984÷44.992 (1.7710
B
÷ 1.7713 in)
48.988÷48.996 (1.9286 1.994÷1.999 (0.0785
D RED
÷ 1.9289 in) ÷ 0.0787 in)

48.980÷48.988 (1.9283 1.998÷2.003 (0.0786
C BLUE
÷ 1.9286 in) ÷ 0.0788 in)
44.976÷44.984 (1.7707
C
÷ 1.7710 in)
48.988÷48.996 (1.9286 1.998÷2.003 (0.0786
D BLUE
÷ 1.9289 in) ÷ 0.0788 in)

48.980÷48.988 (1.9283 2.002÷2.007 (0.0788
C YELLOW
÷ 1.9286 in) ÷ 0.0790 in)
44.968÷44.976 (1.7703
D
÷ 1.7707 in)
48.988÷48.996 (1.9286 2.002÷2.007 (0.0788
D YELLOW
÷ 1.9289 in) ÷ 0.0790 in)



SANSERA CON-ROD

CON-

CLASS

45.019÷45.025
1.478÷1.483/1.482÷1.487 (0.0581
A (1.7724 ÷ 1.7726 RED/BLUE
÷ 0.0583 / 0.0583 ÷ 0.0585)
41.996÷42.004 in)
A (1.6533 ÷ 1.6537
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 RED 1.478÷1.483 (0.0581 ÷ 0.0583 in)
in)

45.019÷45.025
1.482÷1.487/1.486÷1.491 (0.0583
A (1.7724 ÷ 1.7726 BLUE/YELLOW
÷ 0.0585 / 0.0585 ÷ 0.0587 in)
41.988÷41.996 in)
B (1.6530 ÷ 1.6537
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 BLUE 1.482÷1.487 (0.0583 ÷ 0.0585 in)
in)

C 41.980÷41.988 45.019÷45.025
1.486÷1.491/1.490÷1.495 (0.0585
(1.6527 ÷ 1.6530 A (1.7724 ÷ 1.7726 YELLOW/BLACK
÷ 0.0587 / 0.0586 ÷ 0.0588 in)
in) in)

SANSERA CON-ROD

CON-
CLASS

45.013÷45.019
B (1.7721 ÷ 1.7724 YELLOW 1.486÷1.491 (0.0585 ÷ 0.0587 in)
in)

45.019÷45.025
1.490÷1.495/1.494÷1.499 (0.0586
A (1.7724 ÷ 1.7726 BLACK/GREEN
÷ 0.0588 / 0.0588 ÷ 0.0590 in)
41.972÷41.980 in)
D (1.6524 ÷ 1.6527
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 BLACK 1.490÷1.495 (0.0586 ÷ 0.0588 in)
in)


Position the new main bearing shells (14) and (15) in the drift of tool (A) part no. 88713.4145 and insert bushing (C)
fully home.
Apply the specified product to tool (A) part no. 88713.4145.

Fit the main bearing shells using the tool drift part no. (A) 88713.4145 and positioning the shell parting line at a right
angle to cylinder centreline, as shown in the figure.
Drive screw (B) fully home.
Remove tool (A) part no. 88713.4145 and check that the main bearing shells (28) have been correctly fitted.
Close the crankcases by following the reference procedure (Closing the crankcase).
Reassembling the crankcase halves

The crankcase halves must be in good condition and perfectly clean.

The mating surfaces must be perfectly flat and free from burrs.
To fit the bearings we recommend heating up the casings to a temperature between 95 °C and 110 °C.
Note
Bearings do not have a specific mounting position (except main bearings), however it is good practice to install the
bearings so that the written side is facing inwards.

GENERATOR SIDE, INTERNAL PART (SIDE B)
GEARCHANGE MECHANISM STOP SCREWS (13).

Start and tighten screws (13) to a torque of 22 Nm (Min. 20– Max. 24).
SELECTOR DRUM NEEDLE ROLLER BEARING CAGE (10).

Apply the indicated lubricant to the needle roller bearing cage (10).
Fit the needle roller bearing cage (10) in the crankcase half.
Check that the pre-applied threadlocker is still present on the screw (11). Otherwise, use the indicated product.
Start screw (11) on the casing.
Tighten screw (11) to a torque of 10 Nm (Min. 9– 11).

Insert bearing (1) with the marks facing up.
Fit spacers (3) onto screws (2).
Start screws (2) on the casing.
Tighten screws (2) to a torque of 10 Nm (Min. 9 – Max. 11).

Fit the oil seal (6) by respecting the values indicated in the figure.
Important
While heating the casing, if the seal ring is heated to a temperature above 120 °C loses its properties.
Apply indicated product on the bearing (4).

Fit ring (5) in bearing (4) with the marks facing up.
Fit bearing (7) and fix it with snap ring (8).
Note
The closed side of the plastic cage must be facing towards the crankcase half.

GENERATOR SIDE, EXTERNAL PART (SIDE A)
SECONDARY SHAFT OIL SEAL (9).
Apply the indicated product to oil seal (9).

Fit the oil seal (9) by respecting value (X) 88 ± 0.2 mm (3.46 ± 0.008 in), as shown in the figure.
NEEDLE ROLLER BEARING (10) FOR SWINGARM SHAFT
Fit snap ring (12) inside its seat of crankcase half.

Apply the indicated product on crankcase housing.
Insert seal (11) by driving it fully home on snap ring (12), and aiming it as shown in the figure.
Insert the needle roller bearing (10) driving it fully home on seal (11) and aiming it so that the side with marks (A) is
positioned as shown in the figure.
Insert seal (11) by driving it fully home on needle roller bearing (10), aiming it as shown in the figure.

CLUTCH SIDE, INTERNAL PART (SIDE C)
GEARBOX DRUM BEARING (22).

Fit bearing (22) in the crankcase half.
Insert washers (24) on the thread of screws (23).

Insert bearing (14) with the marks facing up. Fit tab (17) in the groove on the crankcase.
Fit spacers (16) onto screws (15).

Apply indicated product on the bearing (18). Fit ring (19) in bearing (18) with the marks facing up.
Insert bearing (18) in the crankcase half with the marks facing up.
Fit the internal ring (19) in the bearing (18).
Fit bearing (20) and fix it with snap ring (21).

CLUTCH SIDE, EXTERNAL PART (SIDE D)
Fit snap ring (24) inside its seat of crankcase half.

Apply the indicated product on crankcase housing.
Insert seal (23) by driving it fully home on snap ring (24), and aiming it as shown in the figure.
Insert the needle roller bearing (22) driving it fully home on seal (23) and aiming it so that the side with marks (A) is
positioned as shown in the figure.
Insert seal (23) by driving it fully home on needle roller bearing (22), aiming it as shown in the figure.
TIMING SHAFT SEAL RING (26).
Fit seal ring (26) by respecting the indicated values (X) 69.2 ± 0.2 mm (2.72 ± 0.008 in).
Shimming the shafts
Before assembling the crankcase halves, it is necessary to check the size of the shims that determine the end float of
the gearbox shafts.
The following shims are supplied as spare parts.

Shimming the gearbox shafts

The following shims are supplied as spare parts: one for each shaft

Gearbox primary shaft (1) Chain side 1.6 mm (0.06 in)

Gearbox secondary shaft (2) Clutch side 3.15 mm (0.12 in)
Closing the crankcase
Thoroughly clean the crankcase half contact surfaces ("Cleaning and Applying the silicone rubber sealant on work surfaces").
If previously removed, fit the lubrication valves (11).

Install the O-ring (12) in its seat in the crankcase half.
Apply the specified product to screw (10).
Start the screw (10) on the lubrication valve (11).
Repeat the operations described above with the other valve.
If previously removed, apply the indicated threadlocker to dowel thread (46) and tighten to a torque of 20 Nm (Min. 18
Nm - Max. 22 Nm).
Make sure that the two centring bushes (A) are correctly fitted on the crankcase.
The gearbox assembly inner races (41) of gearbox shafts end bearings are fitted in the bearings themselves.
Note
When refitting used components, before installing the gearbox assembly in the crankcase half, make sure that the
inner races of the gearbox shaft end bearings are fitted into the correct bearings and have not been left on the shafts.
Ensure that the corresponding shim (14) is preassembled to gearbox primary shaft.
Couple the gears of the two shafts (4) and insert them in the relevant seats in the generator-side casing.
Check the gearbox shafts movement.
Apply the specified product on the surface (A) of the selector drum (5) and on the diameter (B) of the magnet holder
(15), ensuring that the product is distributed all around the pin.
Insert magnet holder (15) on selector drum (5), driving it fully home.
Remove any excess product between the magnet holder (15) and the selector drum (5).
Important
Assemble the magnet holder within 5 minutes form sealant application. Wait 15 minutes for complete curing of the
product.
Warning
Installation is correct when the sealant (X) is visible around the entire circumference of the contact surface between
the magnet holder and the selector drum, as shown in the figure.
Insert the forks of 1st - 4th and 2nd - 3rd speed (42) inside the sliding grooves of the secondary shaft driven gears.
Insert the fork of 5th - 6th speed (43) inside the primary shaft driven gear.
Insert the pins (44) in the gearbox forks.
Apply the specified product in the area (C) of the selector drum (5).
Install selector drum (5) on casing, aiming it as shown in the figure.
Apply the specified product in the areas (D) of gearbox shafts.

Ensure that shim (18) is preassembled on the secondary shaft.
Insert pins (E) of forks (42) and (43) in their seats on selector drum (5).
Turn selector drum (5) to help this procedure.
Drive both pins fully home.
Check the gearbox shafts movement.
Apply the specified product to the crankshaft (8), in the areas indicated in the figure.
Fit crankshaft (8) inside generator-side casing, positioning connecting rods in the relevant seats of the cylinders, as
Fit the timing layshaft (9) into the generator-side casing.
Important
Make sure that the connecting rods are correctly positioned in the relevant cylinder seats. Incorrect positioning of the
connecting rods at this stage will inevitably lead to the need to re-open the crankcase halves.
Fit the O-ring (17) after having lubricated it with the indicated product.
Apply an even and continuous bead of sealing compound to clutch-side casing mating surface respecting the path
Warning
An excessive quantity of sealant may cause the internal components of the casings to block.
Important
Match the casings together within five minutes from sealant application.
Bring the crankcase halves (20) and (21) together, tapping with a rubber mallet in the area of the shafts if necessary.
Check that the sealing ring (F) is correctly positioned in relation to the timing layshaft (9) and that the inner lip has not
come out.
Fit the snap ring (1) in the groove on the timing layshaft (9).

Ref. Q.ty Description Notes

1 7 screws M8 x 75 mm GREASE B

2 2 screws M6 x 75 mm

3 7 screws M6 x 35 mm

16 1 special screw M6 x 35 mm

Start screws (1) on generator-side casing.
Pre-tighten screws (1) at first to a snug torque of 19 Nm (Min. 17 Nm - Max. 21 Nm), following the indicated
sequence.

Start screws (1) on clutch-side casing.
Pre-tighten screws (1) at first to a snug torque of 19 Nm (Min. 17 Nm - Max. 21 Nm), following the indicated
sequence.
Working on clutch-side casing, tighten screws (1) to a torque of 25 Nm (Min. 22 Nm - Max. 28 Nm), following the
indicated sequence.
Working on generator-side casing, tighten screws (1) to a torque of 25 Nm (Min. 22 Nm - Max. 28 Nm), following the
indicated sequence.
Tighten screws (2), (3) and special screw (16) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm), following the indicated
sequence.
Working on the crankcase half clutch side, refit the gear selector drum flange (G) (Reassembling the gearbox assembly).
If previously removed, apply the indicated product on dowel thread (17), and tighten it to a torque of 20 Nm (Min. 18
Nm - Max. 22 Nm).
During this operation, respect the indicated value (F): 1 ± 0.2 mm (0.0393 ± 0.0078 in).
Refit the gearchange mechanism (Refitting the gearchange mechanism).
Refit the oil filter (Changing the engine oil and filter cartridge).
Refit the starter motor idler gear (Refitting the starter motor gear).
cover).
Refit the timing lay gear (Refitting the timing gear pulley).
Refit the timing belts (Refitting the mobile tensioner/timing belt).
Removing the connecting rod assembly

After separating the crankcase halves, remove the crankshaft (1) complete with connecting rods (2).
Disassembling the connecting rod assembly

Remove the connecting rod assembly from the crankcase halves (Removing the connecting rod assembly).
To disassemble the connecting rod assembly, loosen screws (3) and separate connecting rods (2) from crankshaft (1).
Important
Take care not to mix up components of different connecting rods and maintain the original orientation.
Overhauling the connecting rod assembly
Remove the engine from the motorcycle (Removing the engine).

Remove the connecting rod assembly from the crankcase half (Removing the connecting rod assembly).
Disassemble the connecting rod assembly (Disassembling the connecting rod assembly).
Make the following dimensional checks on the connecting rods:

CHECKING AND REPLACING THE CON-ROD SMALL END BUSH
In case of excessive wear, replace the connecting rod. The small end bush must be in good condition and firmly driven
into its seat. Check the parallelism error measured at 100 mm (3.94 in) from the connecting rod longitudinal axis:
it must be H-h lower than 0.02 mm (0.00078 in) (H standard height when new is 122.5 mm (4.82 in)); change the
con-rod if it is not so.
Connecting rod big-end diameter must be within the specified limits.
It is preferable to use crankshafts and connecting rods of the same size class.

REPLACING CON-ROD BIG END BEARINGS
It is good practice to replace the big end bearings (4) each time the engine is overhauled.
Spare bearings are supplied ready for fitting and they must not be reworked with scrapers or emery cloth.
The bearings are comprised of an external steel ring, the inner face of which is electroplated with a lead-based
compound.
All dimensional classes are identified with a different colour (S) on the big end bearings (4).
For their replacement, refer to chapter "Reassembling the connecting rod assembly".
SANSERA con-rod

OVERHAULING THE CRANKSHAFT
The journals for main bearings (A) and crank pin (B) should not be scored or grooved.
The threads, keyways, and slots must be in good condition.
Check for fretting or burrs in the fillet between journal and shoulder.
Fillet radius on journals for main bearings: 1.5 mm (0.0591 in).
Fillet radius on crank pin: 3 mm (0.1181 in).
Use a micrometer to measure oval and taper of the crank pin. Measure oval and taper in several different directions.
Use a dial gauge to measure the alignment of the main journals by positioning the crankshaft between two centres.
To carry out this operation, use a heat gun able to reach 150 °C.
Loosen the plug (4) of the crankshaft, heating the latter, if necessary, to remove the sealant applied upon assembly.
Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues
that may have accumulated and may be restricting the oil flow.
Apply the indicated product and tighten the dowels (5) and the special screw (6) to a torque of 13 Nm (Min. 11 Nm -
Max. 15 Nm).
Apply the indicated product and tighten plug (4) M20x1 to a torque of 50 Nm (Min. 45 Nm - Max. 55 Nm).
Warning
Do not chamfer plug after assembly.
Refit the connecting rod assembly (Refitting the connecting rod assembly).
Refit the connecting rod assembly inside crankcase half (Refitting the connecting rod assembly).
Refit the engine in the vehicle (Refitting the engine).
Reassembling the connecting rod assembly
Important
Always order the crankshaft and con-rod part numbers with the same weight selection.
SANSERA con-rod
It does not feature centring pins between shank and cap.
Note
Use the following tables for correct crankshaft and con-rod assembly.


CRANKSHAFT
CRANKCASE CRANKCASE HOLE SIZE SHELL SHELL THICKNESS
CRANK PIN SIZE [mm]
MARKING CLASS [mm] COLOUR [mm]

48.980÷48.988 (1.9283 1.990÷1.995 (0.0783
C PURPLE
÷ 1.9680 in) ÷ 0.0785 in)
44.992÷45.000 (1.7713
A
÷ 1.7716 in)
48.988÷48.996 (1.9286 1.990÷1.995 (0.0783
D PURPLE
÷ 1.9289 in) ÷ 0.0785 in)

48.980÷48.988 (1.9283 1.994÷1.999 (0.0785
C RED
÷ 1.9680 in) ÷ 0.0787 in)
44.984÷44.992 (1.7710
B
÷ 1.7713 in)
48.988÷48.996 (1.9286 1.994÷1.999 (0.0785
D RED
÷ 1.9289 in) ÷ 0.0787 in)

48.980÷48.988 (1.9283 1.998÷2.003 (0.0786
C BLUE
÷ 1.9286 in) ÷ 0.0788 in)
44.976÷44.984 (1.7707
C
÷ 1.7710 in)
48.988÷48.996 (1.9286 1.998÷2.003 (0.0786
D BLUE
÷ 1.9289 in) ÷ 0.0788 in)

48.980÷48.988 (1.9283 2.002÷2.007 (0.0788
C YELLOW
÷ 1.9286 in) ÷ 0.0790 in)
44.968÷44.976 (1.7703
D
÷ 1.7707 in)
48.988÷48.996 (1.9286 2.002÷2.007 (0.0788
D YELLOW
÷ 1.9289 in) ÷ 0.0790 in)



SANSERA CON-ROD

CON-
CLASS

45.019÷45.025
1.478÷1.483/1.482÷1.487 (0.0581
A (1.7724 ÷ 1.7726 RED/BLUE
÷ 0.0583 / 0.0583 ÷ 0.0585)
41.996÷42.004 in)
A (1.6533 ÷ 1.6537
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 RED 1.478÷1.483 (0.0581 ÷ 0.0583 in)
in)

45.019÷45.025
1.482÷1.487/1.486÷1.491 (0.0583
A (1.7724 ÷ 1.7726 BLUE/YELLOW
÷ 0.0585 / 0.0585 ÷ 0.0587 in)
41.988÷41.996 in)
B (1.6530 ÷ 1.6537
in) 45.013÷45.019
B (1.7721 ÷ 1.7724 BLUE 1.482÷1.487 (0.0583 ÷ 0.0585 in)
in)

C 41.980÷41.988 45.019÷45.025
1.486÷1.491/1.490÷1.495 (0.0585
(1.6527 ÷ 1.6530 A (1.7724 ÷ 1.7726 YELLOW/BLACK
÷ 0.0587 / 0.0586 ÷ 0.0588 in)
in) in)

SANSERA CON-ROD

CON-
CLASS

45.013÷45.019
B (1.7721 ÷ 1.7724 YELLOW 1.486÷1.491 (0.0585 ÷ 0.0587 in)
in)

45.019÷45.025
1.490÷1.495/1.494÷1.499 (0.0586
A (1.7724 ÷ 1.7726 BLACK/GREEN
÷ 0.0588 / 0.0588 ÷ 0.0590 in)
41.972÷41.980 in)
D (1.6524 ÷ 1.6527
in)
45.013÷45.019
B (1.7721 ÷ 1.7724 BLACK 1.490÷1.495 (0.0586 ÷ 0.0588 in)
in)


After having performed the overhaul of con-rod assembly (Overhauling the con-rod assembly) and checked correct
crankshaft/con-rod/big end bearing assembly.
Before starting, check that the crankshaft main bearing and big-end journals are free of burrs or evident signs of
machining: if necessary, clean the surfaces with very fine emery cloth and oil.
Check that the grooves are in perfect condition with no signs of forcing.
Thoroughly clean the crank pin (7) on the crankshaft (1) and lubricate it with specified product.
Proceed as follows for correct crankshaft/con-rod coupling:

WEIGHT CLASS CHECK
Important
The crankshaft and con-rod must always have the same weight class.
Check the stamping on the crankshaft and con-rod at points (A) and (B) as shown in the figure, the stamping must be
the same.
SANSERA

DIAMETER CHECK
Once the weight class has been identified, check the crankshaft and con-rod diameters.
Always use the tables at the beginning of this chapter to select the bearings.
Crankshaft is supplied in classes ranging from "A" to "D".
The crankshaft markings are positioned on one side at point (C) and are identified by three numbers and three letters.

Number Pin identification

1 Clutch side journal for the main bearings

2 Generator side journal for the main bearings

3 Crank pin
Depending on the type of supplier, the con-rod markings are positioned at point (D) as shown in the figure.
SANSERA

FITTING
Proceed with the assembly after identifying the couplings.
Insert the bearing shells (4) in the connecting rod seats matching the tooth (H) of the bearings with the corresponding
marks on the connecting rod cap (F) and on the connecting rod small end (G). It is essential that the tooth (H) adheres
perfectly to its own seat.
Apply the indicated product to bearing shells (4) fitted on shank.
Fit connecting rods inside crankshaft.

Join the connecting rod cap (F) with the corresponding connecting rod small end (G), ensuring that the laser marking
(M) of the progressive number stamped on the two pieces is the same, as shown in the figure.
Warning
The grease utilised is irritant in contact with the skin; wear protective gloves.
Important
Lubrication of con-rod bolts is essential to obtain the correct coupling and to prevent breakage of the parts.

COUPLING THE BIG-END BEARINGS-CRANK PIN
In order to correctly couple big-end bearings and crank pin, proceed as follows:
- apply a strip (A) of GREEN "Plastigauge PG-1" to the crank pin;

- fit the connecting rod and the original big-end bearings.
Tightening procedure
Tighten the connecting rod bolts (Class 14.9) as described below:
• Apply the specified product to screws (3) thread and underhead.

• Tighten to 35 Nm.
• Snug torque to 20 Nm.
• Tighten to 105°±1°.
• Torque check 80÷110 Nm.
Continue the coupling procedure as described below:
• Loosen the screws and remove the connecting rod.

• Check the thickness of the strip of "GREEN Plastigauge PG-1" (A), using the suitable reference scale (B).
• The thickness measured with scale (B) represents the actual clearance: if it is not within the specified limits
(Crankshaft), it is necessary to replace the big end bearings or the crankshaft and repeat the procedure.
• If the clearance value complies with the established limits, carefully remove the strip of "GREEN Plastigauge PG-1"
(A) from the crankshaft and repeat the tightening procedure as described.
Tighten the screws (3) fully home by hand.
If this proves difficult or if the screws jam, undo them and lubricate them again.
Remove any excess grease. Tighten the screw by hand until the head seats against the connecting rod.
Temporarily fit the gudgeon pin (L) to align the connecting rods.
Using a feeler gauge (S) make a first con-rod shimming, then place the fork feeler gauge (T) of tool part no.
88765.1000 (thickness 0.1 mm (0.0039 in)), part no. 88765.1005 (thickness 0.2 mm (0.0079 in)) or part no.
88765.1006 (thickness 0.3 mm (0.0118 in)) between the con-rods to eliminate the end float.
Using a torque wrench as shown in the figure, tighten screws (3) to the values specified here below:
• Tighten to 35 Nm.
• Tighten to 105°±1°.
• Torque check 80÷110 Nm.
Remove the feeler gauge and check that connecting rods/crankshaft end float is: 0.15 ÷ 0.30 mm (0.0059 in ÷ 0.0118
in).
Refit the connecting rod assembly inside crankcase half (Refitting the connecting rod assembly).
Refit the engine in the vehicle (Refitting the engine).
01
1
2
05
05
9-B
9-B
11
02 8-A
02
9-J
3
04 7-E
04 7-D
05 6-B
03 8-D
10
03 8-C
4
07
07
07
07
07
07
07
07
03
02
02
02
06
04
9-J
7-C
1-D
1-D
3-A
3-G
3-G
6-G
5-G
4-G
8-G
8-G
8-G
10-G
03
03
03
8
8-F
8-E
8-D
02
9-J
5
06 8-G
05 6-H
05 7-H
05 3-I
05 5-I
03 1-B
07 7-G
07 2-G
03 1-B
03 4-H
03 6-H
07 10-C
07 8-G
07 4-G
07 3-G
07 9-C
06
7
9-C
07 10-G
05 8-H
05 9-H
05 9-H
07 6-G
07 5-G
02
12
8-C
01
01 1-F
05 3-B
05 3-B
01 5-E
01 1-C
03 2-A
33
2-A
03
13
32 1 2 3
14
2
1
31
15
30
16
29
AMP
3 2 1
17
18
3
3
2
2
1
1
19
3
3
2
2
1
1
3 2 1
3 2 1
23
24
3 2 1
3 2 1
22
2
21 20
1
01 6-E
1
26 01 6-E
28 27 25
03
34
9-F
06
6-H
2-D
7-D
7-D
4-E
4-E
7-G
7-G
4-E
4-E
05
05
07
07
07
01
01
01
01
01
05 5-H
05 8-H 35
05 4-I 01 9-I
1
AMP
2
36
01 9-H
1
AMP
2
7-G
39
07
3
AMP
2
1
01 6-E
02 7-B
38
02 9-J
01 9-H
37
01 9-H
04
42
01 5-E
40
01 8-C
41
01 8-C
06 9-C
05
AMP
2
1
44
43
45
01 9-J
01 6-B
01 5-B
46
01 9-J
07 10-C
58
07 10-C
59
47
03 6-B
01 9-J
48
01 9-G
01 7-D
49
01 9-G
03 8-C
03 6-B
50
01 9-H
51
8
3
7
2
5 6
1
52
AMP
03 6-B
53
01 9-G
9-J
9-J
02
02
54
03 8-E
55
57 56
06
60 61 62 64
65
9-G
6-E
01
01
68
66
67
07
05 8-C
77 01 9-I
01 6-E
69
01 9-J
05 8-C
78 01 9-I
06 9-D
01 9-I
01 6-F
70
01 5-F
8
3
7
2
5 6
1
03 8-C
01 9-H
03 8-C
71
03 4-F
01 5-E
72
01 6-J
01 5-E
01 6-J
73
01 6-E
74
01 9-I
03 8-C
01 5-E
75
01 9-I
01 6-E
01 9-H
76
Key to wiring diagram
Power line BBS line CAN line
1 Battery 34 Black Box System (BBS) 60 Inertial platform (IMU)
2 Key switch 35 RH fan 61 ABS
3 Fuse box 1 36 LH fan 62 Bluetooth
4 Fuse box 2 37 Fuel pump 64 BBS
5 Rectifier 38 Fuel pump relay 65 Diagnostic socket
6 Generator 39 Fuel level sensor 66 Instrument panel
7 IMU 67 ECU
8 Relay / dip switch ABS line 68 ECU CAN
9 Starter motor 40 ABS control unit
10 Cold-start relay 41 Front speed sensor Accessories
11 Main fuse 42 Rear speed sensor 69 Bluetooth
70 Alarm
Engine line Instrument panel line 71 Auxiliary fuel pump
12 Engine ECU 43 Instrument panel 72 GPS navigation system
13 Throttle 44 Immobilizer 73 USB
14 Gear sensor 45 Front left turn indicator 74 Left additional spotlight
15 Quick Shift (DQS) 46 Front right turn indicator 75 Right additional spotlight
16 Horizontal TPS 47 Headlight 76 12 V socket
17 Horizontal oxygen sensor 48 Rear left turn indicator 77 LH heated handgrip
18 Map sensor 2 49 Rear right turn indicator 78 RH heated handgrip
19 Map sensor 1 50 Tail light
20 Coil 2 51 Alarm Wire colour coding
21 Coil 1 52 Oil temperature sensor B Blue
22 Ambient temperature 53 Number plate light W White
23 Front brake switch 54 Instrument panel temperature sensor V Violet
24 Rear brake switch 55 Horn Bk Black
25 Purge Valve 56 Left-hand switch Y Yellow
26 Secondary air valve 57 Right-hand switch R Red
27 Engine Temperature 58 LH heated handgrip Lb Light blue
28 Pick- up 59 RH heated handgrip Gr Grey
29 Side stand switch G Green
30 Injection
Bn Brown
31 Clutch switch
O Orange
32 Vertical oxygen sensor
P Pink
33 Main Relay
Check List for
Scheduled Maintenance
Customer Name: Model: Plate number:
Frame number (VIN): Registration date: Mileage:
Current date: Work Order Number: Service type:
Scheduled Maintenance Check List for Desert X

Check the boxes close to the performed service operations
Annual Service *
Performed
Replaced
Desmo Service *
Oil Service *
First Service 1000*
Reading of the error memory with DDS 3.0 and check of technical updates and recall campaigns on DCS 12
Change engine oil and filter 24
Check and clean air filter 24
Change air filter
Change timing belts 60
Check and/or adjust valve clearance
Replace spark plugs
Change coolant 48
Change front fork fluid every45,000km/27,000mi
Visually check the front fork and rear shock absorber seals 12
Check brake and clutch fluid level 12
Change brake and clutch fluid 24
Check front and rear brake disc and pad wear. Replace, if necessary 12
Check the proper tightening of brake calliper bolts and front and rear brake disk screws 12
Check spoked wheel as indicated in the workshop manual 12
Check front and rear wheel nuts and rear sprocket nut tightening 12
Check frame-to-engine, frame-to-swinging arm and frame-to-rear shock absorber fasteners tightening 12
Check the wheel hub bearings 12
Check silentblocs on rear sprocket and lubricate the rear wheel shaft
Check chain, rear sprocket and sprocket wear and check final drive chain tension, lubrication and stretch. Measured stretch
value:__________ (cm) 12
NOTE: It is recommended to change the final drive chain kit within 20,000 km/12,000 mi.
Check steering tube bearing clearance 12

Check the freedom of movement and tightening of the side stand 12
Check that all gaiters and visible hoses (i.e. fuel, brake and clutch, cooling system, bleed, drain hoses, etc.) are not cracked, are
12
tight and properly housed
Check rear brake lever free play and handlebar lever and pedal control lubrication 12
Check tyre pressure and wear 12
Check the operation of all electric safety devices (side stand and clutch sensor, front and rear brake switch, engine stop switch,
12
gear/neutral sensor)
Check lighting devices, turn indicators, horn and controls operation 12
Final test and road test of the motorcycle, testing safety devices (e.g. ABS and DTC), electric fans and idling 12
Visually check the coolant level and circuit for damage 12
Softly clean the motorcycle 12
Service coupon registration with turning off of Service warning light on instrument panel with DDS 3.0 and, if provided, filling
12
in of the on-board documentation (Service Booklet)
* First Service 1000 must be performed after the first 1,000 km/600 mi.
The Oil Service must be performed every 15,000 km/ 9,000 mi or every 24 months.
The DESMO SERVICE must be performed every 30,000 km/18,000 mi.
The Time Service must be performed every 12 months.
Thank you! Your Ducati Technician: Ed.05/2022

Check List for bike delivery to customer
Model: Customer Name:

VIN number: Warranty activation date:
Plate number: Vehicle delivery date:
Congratulations on the purchase of your Ducati!

In order to get maximum satisfaction, it is important that you, as a Customer, are aware of the technical features
as well as of the rules of use and maintenance in order to take maximum care of your new motorcycle!
General information and use precautions

Vehicle compliance in accordance with purchasing contract (correct model version, any installed accessories, and aesthetic compliance)
Keys and their functions (active and passive depending on the model)
Customer ergonomics (where applicable):
- rider and passenger seat height (assembly/removal operation)
- windscreen height
- instrument panel tilt
- rear-view mirrors (opening/closing operation)
- brake lever and clutch lever
Tools supplied with the motorcycle (e.g. tyre repair kit, chain tensioning tool, etc.)
Power sockets (where present), USB socket, lead or Lithium battery charging and maintenance socket
Side panniers and Top Case:
- assembly/removal and opening/closing
- precautions for the use of the side panniers and the Top Case (e.g. maximum speed, maximum load, etc.) and operation
of the tilting system, where applicable
Handlebar controls
Instrument panel (e.g. Setting Menu, Pin Code, Riding Mode, etc.)
Rider seat, passenger seat and handgrip heating, where applicable
Driving aid systems: ABS cornering (Antilock Braking System), DTC (Ducati Traction Control), DWC (Ducati Wheelie
Control), DSC (Ducati Sliding Control), DPL (Ducati Power Launch) and VHC (Vehicle Hold Control), where applicable
Mechanical or electronic suspension with auto-levelling function, where applicable
DQS Up&Down (Ducati Quick Shift) system, where applicable
Operation and limits of Cruise Control (CC), Active Cruise Control (ACC) and Blind Spot Detection (BSD) systems, where
applicable
Bluetooth interface for connecting the phone and intercom, where applicable
Ducati Connect App, Sygic GPS Navigation App and smartphone connection to the motorcycle, where applicable
Download and explanation of My Ducati App (my garage, scheduled maintenance, news, etc.)
Presentation of the Service Manager and the Service workshop
Use precautions:
- first period of use of the motorcycle (engine speed during the first 1,000km/600mi)
- procedure for final drive chain cleaning, tensioning check and lubrication
- periodic tyre pressure check
- engine oil level and brake and clutch fluid level check and topping up, where applicable
Scheduled Maintenance chart of the motorcycle (mileage and time services) and service coupon digital recording through
the diagnosis instrument on the Ducati official network
Delivery of the vehicle registration document, the Owner's Manual, the equipment supplied with the motorcycle and the
duly filled out Warranty Certificate (possibility of extending the Warranty through the Ever Red programme and the risks
and limitations of the validity of the warranty in case of installation of non-original Ducati spare parts and/or accessories).
Tick on the information communicated to the Customer
The Customer declares that he/she has read and agrees with the general information
and use precautions of the motorcycle.
Dealer signature Customer signature

Ducati Service specific tools
Ed.09/2022

This document and its contents, including, for example, trademarks and images, are owned by Ducati Motor Holding SpA, Sole shareholder company - an Audi Group Company
(hereinafter "Ducati"). Any reproduction, publication, distribution and/or disclosure to third parties of this document without prior written consent of Ducati is expressly prohibited.
Ducati reserves the right to make changes to this document without notice. Ducati reserves the right to pursue legal action against anyone who does not comply with these
conditions or who damages Ducati's reputation.
Ducati Service specific equipment
This document groups all Ducati Service specific equipment. The list specifies the following for
each tool: part number, description, picture and application.
Additional information:
 887xxxxxx (part no. is in bold): tool is mandatory
 887xxxxxx (part no. is not in bold): tool is not mandatory.
The figures above the part number indicate the tool position in the wall cabinet or in the tool
box; if no figure is shown, the tool has no specific position.
The items marked with the symbol (*) in the "PART NO." column are "end-of-series" and will no
longer be restocked.
REFERENCE
FIGURE TOOL DESCRIPTION – POSITION
SERVICE BULLETIN
Left-hand side of the wall cabinet (1)
Right-hand side of the wall cabinet (1)

SVC-14-012
Both areas of the wall cabinet (1)
Left-hand side of the wall cabinet (2)
First right-hand side of the wall cabinet (2) SVC-15-020
Second right-hand side of the wall cabinet (2) SRV-SRB-17-018
Panigale tool chest - Module A
Panigale tool chest - Module B SVC-12-003
Panigale tool chest - Module C
Panigale tool chest - Module D SVC-13-026
Panigale V4 tool chest - Module E SRV-SRB-18-003

No. PART NO. DESCRIPTION IMAGE APPLICATION
Technical specification binder
See MY2007-MY2011
language part
number Part no.91717361A - English
1 Part no.91717361B - Italian
Optional tool Part no.91717361C - Spanish
Part no.91717361D - Japanese
(*) Part no.91717361E - German
Part no.91717361F - French
MY2012 and MY2013

Technical Specification
See
Update
language part
number
Part no.91717391A - English
2
Part no.91717391B - Italian
Optional tool
Part no.91717391C - Spanish
Part no.91717391D - Japanese
(*)
Part no.91717391E - German
MY2014 and MY2015

See Technical Specification
language part Update
number
3 Part no. 91717392A - English
Optional tool Part no. 91717392B - Italian
Part no. 91717392C - Spanish
(*) Part no. 91717392E - German
Part no. 91717392F - French
MY2016 and MY2017

number
4 Part no. 91717393A - English
Optional tool Part no. 91717393B - Italian
Part no. 91717393C - Spanish
(*) Part no. 91717393E - German
Part no. 91717393F - French
MY2018 and MY2019

number
5 Part no.91717394A - English
Optional tool Part no.91717394B - Italian
MY2020 and MY2021

number
6 Part no.91717395A - English
Optional tool Part no.91717395B - Italian
4 Ducati Service specific equipment Ed.09-2022

Service Collection
7 91471131B
2009 - 2011
Service Collection
8 91471131A
1988 - 2008
Wall cabinet
DUCATI SERVICE
9 88710231B
(Minimum quantity
for one workshop: 2)
Tool stickers for

wall cabinet
10 984160071 For the correct application

of stickers, refer to
the Technical Bulletin
SVC-14-012
Update of Model Year 2015

tool sticker
for wall cabinet
11 984160072
For the correct application
SVC-15-020
Update of Model Year 2017

tool sticker
for wall cabinet
12 984160073
For the correct application
SRV-SRB-17-018
Ducati Service specific equipment Ed.09-2022 5

Work bench
887138831A
DUCATI SERVICE
13
Optional tool
(Q.ty 2)
889450142
Fairing holder
14
cart
Optional tool
Ducati Service
Work folders
15 91740611A
(Q.ty 20)
TecMate
Power supply unit
16 979000286
5101H681A
Motorbike connection cable

with Euro 4 - Euro 5
diagnostic socket
SPARE PART of
Part no.979000286
EUR version power cable for

17.1 979000287
TecMate power supply unit

US/CAN version power cable

17.2 979000288 for TecMate power supply
unit
UK version power cable for

17.3 979000289
India version power cable for

17.4 979000290
Japan version power cable

17.5 979000291 for TecMate power supply
unit
AU, NZ, AR version power

17.6 979000292 cable for TecMate power
supply unit
18 979000285 Serial line

diagnosis cable kit

Branch for Ducati

979000259 Performance ECU calibration
19 loading
Optional tool with MAP-KEY device
and DDS 2.0
Branch for connection of

5101F571A
EURO 5 vehicle connector to
20
DDS 2.0 diagnosis
Optional tool
instrument
KIT for diagnosis instrument

DDS 3.0
979000281
DDS 3.0 HASP Key
SPARE PART of
Part no.979000279
21 979000279
979000282
DDS 3.0 Connection cable for

Ducati 4pin socket + OBD
EU5 Bike 6pin socket
SPARE PART of
Part no.979000279
979000283
DDS 3.0 26-16 pin

adapter cable
SPARE PART of
Part no.979000279

979000284
1.5-metre male-male USB

Continue Continued
cable
21 979000279
SPARE PART of
Part no.979000279
Radar adjustment
tool kit
(Multistrada V4)
889450145
Laser
SPARE PART of
Part no.889450124
889450146
Level
22 889450124
SPARE PART of
Part no.889450124
889450147
Wheel shaft
rotating support (2 pcs.)
SPARE PART of
Part no.889450124
889450148
Mirror
SPARE PART of
Part no.889450124

DMT measurement tool

(Ducati Measurement Tool)
complete with case,
accessories and adapters
979000262
16 bar pressure probe
SPARE PART of
Part no.979000260
979000263
KEY-OFF current
measuring probe
SPARE PART of
Part no.979000260
23 979000260
979000264
DMT
Ducati Measurement Tool
SPARE PART of
Part no.979000260
979000265
Keyboard covering sticker
SPARE PART of
Part no.979000260
979000266
P1 90-degree
M/R fuel pressure union
SPARE PART of
Part no.979000260

979000267
P2 90-degree
M/R fuel pressure union
SPARE PART of
Part no.979000260
979000268
P3 straight
fuel pressure union
SPARE PART of
Part no.979000260
979000269
P4 oil pressure
union
SPARE PART of
Part no.979000260
Continued Continued
23 979000260
979000270
P5 M10 compression
test union
SPARE PART of
Part no.979000260
979000271
P6 M12 compression
test union
SPARE PART of
Part no.979000260
979000272
P7 drilled screw for

oil pressure measurement
(to be used with

Part no.979000269)
SPARE PART of
Part no.979000260

Fuel pressure
union
24 887138838
(Multistrada 1200 DVT,
Scrambler)
Adapter cable for

fuel pump - main wiring
25 887138865
(Panigale V4)
Test branch
26 5101H662A
Ducati Quick Shift (DQS)
Pressure check nozzles

27
(Testastretta 11° DVT)
887134966
Clutch fluid pressure

measuring tool
28 887132695
(Testastretta 11° 2V/4V)

measurement rod
29 887136156
(Diavel, XDiavel)


measuring tool
30 887136155
(Panigale V4)
DBA instrument
for timing belt
31 979000253
tension value
measurement
Battery charger/
battery charge maintainer
for lithium-ion batteries
(1199 Superleggera,
32 69924821A 1299 Superleggera,
Superleggera V4,
Panigale R, Panigale V4 S,
Panigale V4 Speciale and
Panigale V4R)
Adapter for battery charger/

battery charge maintainer
bike connector
for lithium-ion batteries
33 51040111A (1199 Superleggera,
1299 Superleggera,
Panigale R, Panigale V4 S,
Panigale V4 Speciale and
Panigale V4R)
TDC check tool

34
(Testastretta DVT)
887135009
TDC check tool

35
(Testastretta DVT 1262cc)
887138836

Cam
locking tool
36
887651737 (Testastretta DVT)
Cam O-ring
assembly tool
37
Head nut
tightening wrench
38
Special wrench
for vertical head
39 889450088
(Multistrada DVT –
Hypermotard)
Insert to tighten
889450144
M10 head nuts
40
Optional tool
(Testastretta 11° 937cc)
Tool for
crankshaft insertion
41 on engine shells
887135013 (Testastretta 11° 821cc)

Assembly tool
for main bearing shells
42
Reaction tool
for Adler clutch
43
887132801 (Scrambler 800cc)
Reaction tool
for clutch hub
44
887133929 (Scrambler 400cc)
Clutch overhaul kit
887134284
Reaction wrench
for clutch plates pack
45
assembly
887134287
SPARE PART of
Part no.887134287
887134285
Locking screws
SPARE PART of
Part no.887134287

887134286
Removal/assembly support
Continued Continued
45 887134287
SPARE PART of
Part no.887134287
Tool for
circlip insertion on piston pin
46
Key to remove
the vertical cylinder exhaust
47 manifold upper nut
Panigale tool chest –

Module A
48 889450117
(tools are NOT included)
Thermoformed kits for Tool

chest – Module A
49 889450118

Module B
50 889450113


chest – Module B
51 889450114

Module C
52 889450115

chest – Module C
53 889450116

Module D
54 889450115

chest – Module D
55 889450120
Panigale V4 tool chest –

Module E
56 889450115


chest – Module E
57 889450139
Fastening plate for

valve collet reaction tool
58
887134507 (1199 Superleggera)
Adapter for circlip insertion

tool
on piston pin
887134747
59
(1199 Superleggera)
Optional tool
(to be used with
Part no.887133502)
Engine support for

workbench
60 887133875 Part no.887131832
(Superquadro Engine)
Engine
rotation tool
61 887138856
(V4 engine)
Support for
engine stand
62
887133003 (V4 engine)

Oil recovery tank

63 887138855
(Panigale V4)
Unified drift for

saving bearings on
64 chain casing and clutch
887133436
Head support
on bench
65
887133004 (Panigale V4)
Head support for

timing system assembly
887134131
Valve support
66
887133422 SPARE PART of
Part no.887133422
887138834
Valve support
(1299 Superleggera)
SPARE PART of
Part no.887133422

887134132
Locking pin with hexagon

Continued Continued
nut with knob
66 887133422
SPARE PART of
Part no.887133422
Bearing driving tool

67
887133452 (Superquadro Engine)
Tool for crankshaft reset

887132574 with respect to TDC
68
Optional tool (Superquadro Engine)
(*)
Pin and punch for gearbox

shaft seal insertion
69 (12x22x5)
887133507
(1199 Panigale)
Punch and flange for

secondary gearbox seal
70 insertion (40x55x7)
887133508
Tool for fitting the barrel

bearing on secondary shaft
71
887135962
(Panigale V4)

Drift for fitting

clutch cover oil seal
72 (14x28x6.5)
887133509
Clutch slave cylinder oil seal

fitting tool
73
887138859 (V4 engine)
Crankshaft oil seal insertion

tool
74
887138864 (V4 engine)
Tool for insertion of water

pump
75 gear oil seal
887138858
(V4 engine)
Assembly tool
for gearbox shaft oil seal
76 889450093
(V4 engine with dry clutch)
Oil seal fitting tool

75x95x12mm
77 889450104

Primary gear oil seal

assembly tool
78 889450096
Valve shim control gauge

79 889450107
(V4 engine)
Retaining fork
for con-rod screw locking
80 on crankshaft
887133510
Drift for fitting

chain casing oil seal
81 (17x25x4)
887133511
(1199 Panigale)
Pushrod chain casing oil seal

fitting drift (8x14x4)
82
887133512
Flywheel reaction flange

83

Centring tool
for gearbox secondary shaft
84 on chain guard holes
887133549
Tool for fixing

gearbox to lower casing
85
887135840
(V4 engine)
Tool for inserting roller

bearing on
86 gearbox primary shaft
887138862
(V4 engine)
Needle roller bearing fitting

tool
87
887138860
(V4 engine)
Roller bearing cage assembly

tool
88 889450100
Assembly tool for

first primary drive bearing
89 889450095

Second primary bearing

assembly tool
90 889450097
Roller bearing
control gauge
91 889450103
Gear selector bushing

driving drift
92
887133758
Special screw M7x1 to

slide out rocker arm shaft
93
887133760
Ring nut tightening wrench

94
Sprocket
reaction tool
95

Reaction tool
for gear selector drum flange
96
887133853 (Superquadro Engine,
V4 Engine)
Piston mounting tool

97
887133820 (1199 Panigale)
Timing tool
for camshafts
98
887651678
Crankshaft
fastening support
99
887135389
(V4 engine)
Tightening tool for

clutch hub nut
100
887133879
Tightening tool for

clutch hub nut
101
887138852 (Panigale V4)

Tightening tool for

clutch hub nut
102 889450110
(Streetfighter V4,
Multistrada V4)
Tool for clutch hub

assembly/disassembly
103 889450092
Clutch cup
centring tool
104 889450098
Assembly tool
for clutch housing
105 889450099
Tool for
flywheel nut
106
887138853 (V4 engine)
Tightening tool for

flywheel nut
107 889450138
(Multistrada V4)

Service lever
for gearbox testing
108
(Superquadro Engine, V4
887133795
Engine)
Valve collet removing tool

109
Valve collet removal/

assembly tool
(Panigale V4R)
110 889450090
889450091
Plate
SPARE PART of
Part no.889450090
Bench valve collet removing

tool
111 889450089 for heads
(Panigale V4R)
Tool
for head removal
112 889450087
(V4 Granturismo Engine)

Tool with divider

for timing check
113
Tool for
timing check
114
887138861 (V4 engine)
Tightening tool for

valve collets
115
887133467
887134133
Reaction tool
SPARE PART of
Part no. 887133467
Flywheel
puller
116
887133880 (Superquadro 1199 Engine,
Superquadro 1299 Engine)
Flywheel
puller
117
887138854
(V4 engine)

Tool for tightening/

loosening
118 primary drive sprocket screw
887133925
Tool for liner

extraction from cylinder
887134135
Extraction hook
119 opening spring
887133878
SPARE PART of
Part no.887133878
887134134
Liner extraction hook
SPARE PART of
Part no.887133878
Generator cover
puller
120
887133922
Driving pins
for crankcase covers
121 887132933 (3pz)
(V4 engine)

Generator cover
puller
122
887138857
(V4 engine)
Tool for TDC

crankshaft locking
123
887133500
Timed crankshaft
locking tool
124
887135396
(V4 engine)
Timed camshaft
locking plate
125
887135397
(V4 engine)
Liner driving tool
126
887133923
887134136
Teflon plate
SPARE PART of
Part no.887133923

Tool for removing valve

collets with head
on vehicle
127
887133924
887134137
Reaction tool
valve collets
SPARE PART of
Part no.887133924
Engine support tool
128
887133927 To be used with Part no.
887133220
Engine
support tool
(Desmosedici Stradale
129
Engine)
887138863
To be used with Part no.
887133220
Engine
support tool
130 889450111 (V4 Granturismo Engine)
To be used with Part no.

887133220
Special screw M6x1

to slide out rocker arm shaft
131
887133943

Pin puller
132
887133517
Optional tool
Horizontal and vertical head

intake/exhaust valve lift
timing equipment KIT
(1199 Panigale)
Note The dial gauges do not

come with the tool
887651702
Dial gauge bushing support
SPARE PART of
Part no.887651632
133
887651632
Optional tool 887651703
Small rod for dial gauge
SPARE PART of
Part no.887651632
887651704
Big rod for dial gauge
SPARE PART of
Part no.887651632
Circlip insertion tool on

piston pin
134
887133502
(1199 Panigale)
Optional tool

887134139
Calliper
SPARE PART of
Part no.887133502
Continued Continued
134 887133502
887134138
Calliper
guide tube
SPARE PART of
Part no.887133502
Monolithic flywheel
extraction tool
135
(Superquadro 899 Engine,
887134257
Piston
assembly tool
136
887134308
Valve support

137 Superquadro 955 Engine)
887134314
(to be used with
Part no.887133422)
Reaction tool
for clutch hub nut
138
887134392 (Superquadro 899 Engine,

Tool base for

timing check
(899 Panigale)
139 887651718
(to be used with
Optional tool
Part no.887651632)
Circlip insertion tool

on piston pin

140
887134116 Superquadro 955 Engine)
Optional tool (to be used with

Part no.887133502)
Piston/cylinder installation
ring
141 887134968
(1299 Panigale)
Piston insertion
circlip Ø81
142
887135387 (Panigale V4)
Flange for piston insertion in

the casing
143 889450137
(Multistrada V4)
Tool for fixing

sprocket to Morse chain
144 887134970
(1299 Panigale)

Circlip insertion tool

on piston pin
887134993
145 (1299 Panigale)
Optional tool
(to be used with
Part no.887133502)
Work bench
for engine repair
146 887131832
(Includes the assembly
bracket for 2V - 4V engines)
Support for
engine removal
147 887133396
(2V - 4V)
Support for
engine removal
148 887133220
(Superquadro - Desmosedici
Stradale - V4 Granturismo)
Base for head assembly

149 887132103
(2V – 4V – Testastretta 11°)
Head support bracket

for valves with valve collets
150 887132346
(749 S/R)

Head support bracket

for valves with valve collets
151 887132863
(1098R)
Valve lift and

valve check gauges
152 887651518 (4 V)
Optional tool Note The dial gauges do not

come with the tool
(*)
Valve lift and timing

887651001 control gauge
153 Optional tool (DESMOQUATTRO)
(*) Note The dial gauges do not

come with the tool
Valve lift
887651181 control gauge
154 Optional tool (TESTASTRETTA 999 - 749)

come with the tool
TDC control gauge

887651188
(M12 spark plug hole)
155 Optional tool
(*)
come with the tool
TDC control gauge

887651297
(M14 spark plug hole)
156 Optional tool
(*)
come with the tool

Valve lift and valve

887651058 check gauge
157 Optional tool (2 V – up to MY2002)

come with the tool
Valve lift and valve

887651581 check gauge
158 Optional tool (2 V – from MY2003)

come with the tool
Valve lift
control kit
159
887133614
(Panigale V4)
Optional tool
Valve lower and upper

adjuster control spacer
160
887651322 (valve stem Ø 8 mm)
Valve lower and upper

adjuster control gauge
161
887651298 (valve stem Ø 7 mm)
Tool for
valve collet removal
162
04110551A (valve stem Ø 6 mm)

Tool for
valve collet settlement
163
04111911A (valve stem Ø 6 mm)
Valve seal
887131429
driving tool
164
Optional tool
(valve stem Ø 7 mm)
Valve seal
driving tool
165
(2V - 3V - 4V –
887132442 Testastretta 11° –
Superquadro)
Valve seal
tool
166 887132589
(Multistrada V4, Desmosedici
RR)
Assembly tool
167 for rocker arm and spring
887132916 (2V)
Wrench to tighten
15 mm hex. head nuts
168
887132096 (2V – 4V – Testastretta 11°)

Wrench to tighten
14 mm hex. head nuts
169
887132676 (2V – 4V – Superquadro)
Rocker arm shaft puller

170
(2V – 4V – Superquadro - V4
887131994 Engines)
Camshaft seal ring

insertion tool
171
887131906 (4V – Testastretta 11°)
Closing rocker arm

887132068
loading kit
172
Optional tool
(4V – Testastretta 11°)
Camshaft belt roller Z=20

tightening tool
173
887131806 (4V – Testastretta 11°)
Mobile belt tensioner

tensioning wrench
174
887133497 (Multistrada 1200)

Head belt roller Z=18

887132107
tightening reaction tool
175
Optional tool
(2 V)
Tightening tool for

driving pulley Z=20
176
887131805 (999 - 749)
Locking wrench for

887132355
pulley Z=20
177
Optional tool
(2V)
887132295 Reaction tool

178
Optional tool (3V)
Timing pulley
timing tool
179
887131791 (999 - 749)
Timing pulley
timing tool
180
887651524 (1098 - 848)

Pulley rotation tool

for timing tool
181 assembly
887133219 (4V – Testastretta 11°)
Timing pulley
timing tool
182
887651623 (4V – Multistrada 1200)
Camshaft
locking pin
183
887132257 (3V)
Split belt roller Z=18

timing pins
184
887132009 (2V – 4V)
Cam timing pin

185
(2V 1000cc and 1100cc)
887132282
Tool for TDC

crankshaft locking
186
887132011 (2V – 4V)

887134411
Continued Continued Reference insert

186 887132011
SPARE PART of
Part no.887132011
Driving pulley and

generator cover puller
187
887131749 (2V – 4V)
Degree wheel holding

tool for advance check
with degree wheel
(2V – 4V – 8V)
188
887651635 887134791
Degree wheel
for advance check
SPARE PART of
Part no.887651635
Flywheel wrench
189
887133367
Magnetic rotor
assembly tool
190
(Testastretta 11°,
887133931 Testastretta 11°DVT,
Testastretta 11°DVT 1262cc)

889450135
Brass washer
Continued Continued
190 887133931 (Q.ty 1)
SPARE PART of
Part no.887133931
Denso generator
887132101
retaining wrench
191
Optional tool
(2V – 4V)
FCC clutch hub

reaction wrench
192
887132651 (2V – 4V)
FCC wet clutch

housing
193 reaction tool
887133408 (Multistrada 1200)
ADLER clutch
reaction tool
194
887138837 (Diavel MY16-18)
Dry clutch drum housing

retaining wrench
195
887132133 (2V – 4V)

Dry clutch housing

gear
assembly socket
196
887005665 (2V – 4V –
Desmosedici stradale)
Puller for primary drive gear

and front sprocket
197
(2V – 4V –
887134882 Testastretta 11° 821cc)
Puller for primary drive

gear (dry clutch) and
887130031
front sprocket
198
(wet clutch)
Optional tool
Primary drive gear

tool
199
887138851 (V4 engine)
APTC clutch housing

reaction tool
200
887132556 (2V)
APTC clutch
plate pack pins
201
(Q.ty 3)
887132591
(2V)

Timing tool
(clutch plate set)
202
887133352 (Multistrada 1200)
Primary drive sprocket

tightening wrench
203
887132102 (999 - 749)

for primary drive gear
204
887133406 (Multistrada 1200)
887132423 Sprocket retaining tool

205
Optional tool (2V)
Timing system belt roller

retaining tool
206
887005644 (2V – 4V)
Primary drive sprocket

887130137
retaining tool
207
Optional tool
(2V – 4V)

Belt roller tightening

887133218
reaction tool
208
Optional tool
(2V)
Reaction tool
209
(Multistrada 1200)
887133417
Mobile and fixed tensioner

pin tightening wench
210
887131821 (4V – Testastretta 11°)
887132870 Con-rod guide tool

211
Optional tool (4V)
Fork feeler gauges

(0.1 – 0.2 – 0.3)
212
887651000
887651005 (999 – 749)
887651006
Fork feeler gauges

213
(2V – 4V)
887131309

O-ring
insertion tool
214
887132913 (4V)
Half-casing assembly cap

215
(2V – 4V)
887005749
Tool for O-ring

insertion on
216 engine block stud bolts
887131920 (999 - 749)
Gearbox position
sensor socket
217
887133407 (Multistrada 1200)
Spark plug wrench (14 mm)

218
(2V – 4V – Testastretta 11° –
887132877 Superquadro)
Spark plug removal/refitting

tool
219
887130023 (Multistrada 1200 DVT)

Spark plug removal/refitting

tool
220
887130024 (Monster 797)
Spark plug fitting/removal

tool
221
887133633 (V4 engine)
Oil cartridge
tightening wrench
222 887132906
(2V – 4V – Testastretta 11° –
Optional tool Superquadro)
(*)
Plate for selector fork

positioning
223
887133334 (2V – 4V – Testastretta 11°)
Gear selector
tool
224 887130022
(2V – 4V – Testastretta 11°
with gearbox pawl Part
no.82120151A)
887132775 Spoked wheel

centring tool
225 Optional tool
(Scrambler,
(*) Multistrada 1200 Enduro)

887132776
Wrench to tighten
nipples of spoked rims
226 Optional tool
(Scrambler)
(*)
Wrench to tighten
227 887132777 nipples of spoked rims to
torque
Front wheel
spoke control wrench
228 887138840
(Multistrada 1200 Enduro)
Rear wheel
spoke control wrench
229 887138841
(Multistrada 1200 Enduro)
Fuel tank
support tool
230 887138835
(Scrambler)
Chain tensioning
wrench
231
887131038 (Small hub)

Chain tensioning
wrench
232
887133211 (Large hub)
Chain elongation
233 889450134
measurement tool
Tool for final drive belt

tensioning check
234
887133930 (XDiavel)
Rear wheel
887131073 balancing tool
235
Optional tool (Small hub)
(*)
Rear wheel
887132951 balancing tool
236
Optional tool (Large hub)
(*)
Front wheel
237
shaft wrench
800070139

Fuel level
sensor plug
tightening wrench
238
(Multistrada 1200 DVT,
887133501 Multistrada 1260,
Multistrada 950)
Swingarm shaft
887131074
removal drift
239
Optional tool
887131059
Swinging arm ball bearing
assembly tool
240 Optional tool
(916 – 996 – 998)
(*)
Wrench to adjust steering

887131037 tube
241 eccentric
Optional tool
(4V)
Wrench to fit steering tube

plug
242
887131058 (2V – 4V – Testastretta 11°)
Steering tube bearing

assembly tool
243
887131062 (2V – 3V – 4V)

Swinging arm play

adjustment wrench
244
887130032 (Scrambler Desert Sled)

245
(Monster MY09-13)
887133166

M20x1
246
887133526 (Multistrada 1200)
887131515
Engine/frame support kit
247 Optional tool
(2V – 4V)
(*)
Fork leg ring nut

tightening socket
248
(SACHS fork
887134303 Multistrada 1200 MY13)
Tightening tool for

249
fork leg
887134302

Drift for oil seal

insertion
250 (SACHS fork)
887130030 (Multistrada 1200 DVT,

Multistrada 1260 DVT)
Drift for oil seal

insertion
251
(SHOWA fork
887134484
899 Panigale)
Spring support
removing tool
252
(SHOWA fork
887134485
899 Panigale)
Sleeve on fork bottom end

driving tool
253
(SHOWA fork
887134486
899 Panigale)
Plug removing tool

254
(SHOWA fork
887134487 899 Panigale)
887131096 Tool for seal overhaul/fitting

255
Optional tool (SHOWA fork)

887130957 Spacer retaining tool

256
887130958 Overhaul tool

257
Socket for
removing the plug
258 887134743
(ÖHLINS fork)
(1199 Superleggera)
Socket for
removing the plug
259
(ÖHLINS fork)
887134337
(43-mm leg diameter)
Socket for turning

spring preload hexagon
260 (ÖHLINS fork)

887134338
Plug assembly/
removal socket
261
(ÖHLINS fork)
887132854

262 Bush support bar
887132856
Bar guide tool
263 (ÖHLINS fork)
887132855 (43-mm leg diameter)
Sliding bush
removal tool
264 (ÖHLINS fork)
887132857 (43-mm leg diameter)
Sliding bush
assembly tool
265
(ÖHLINS fork)
887132858
Plug assembly/
removal socket
266
(ÖHLINS fork)
887133465
Sliding bush
assembly tool
267
(ÖHLINS fork)
887133527

Sliding bush
assembly tool
268
(ÖHLINS fork)
887133528
Bush support bar

269
(ÖHLINS fork)
887133529
Damper rod removing tool

270
(ÖHLINS fork)
887138826
Plug fitting tool

271
(MARZOCCHI fork)
887133091
Plug removal/
assembly tool
272
(MARZOCCHI fork)
887138848
(XDiavel)
Plug removal/
assembly tool
273 (KAYABA fork)
887130025 (Scrambler Desert Sled -

Multistrada 950)

Plug removal/
assembly tool
274
(MARZOCCHI fork)
887130026
(SuperSport)
Plug removal/
assembly tool
275
(KAYABA fork)
887130027
(Hypermotard 939)
Plug removal/
assembly tool
276
(KAYABA fork)
887130028
(Scrambler Cafè Racer)
Plug removal/
assembly tool
277
(KAYABA fork)
887130029
(Monster 797)
Tool for fork overhaul/seal Ø

50 mm fitting
278
887133204 (MARZOCCHI fork)
Fork overhaul tool

279
(MARZOCCHI fork)
887133203

Exhaust gas
sampling union
280 (Q.ty 2)
887131010
(2V – 4V – Testastretta 11°
Optional tool – Superquadro)
Rear stand
for pit
281 887138849
(Scrambler, Monster 797)
Tank protection kit

(Q.ty 5)
(XDiavel, Diavel, Monster,

Scrambler and Superbike)
887138847
Fuel tank protection for

XDiavel
(Q.ty 1)
SPARE PART of
Part no.887138842
282 887138842
887138845

Diavel and Multistrada V4
(Q.ty 1)
SPARE PART of
Part no.887138842
887138846
Fuel tank protection kit for

Monster
(Q.ty 1)
SPARE PART of
Part no.887138842

887138843

Scrambler
(Q.ty 1)
SPARE PART of
Part no.887138842
Continued Continued
284 887138842
887138844

Superbike
(Q.ty 1)
SPARE PART of
Part no.887138842

283 889450082 Panigale V4
(Q.ty 1)
Tail guard protection

284 889450086 Panigale V4
(Q.ty 1)

2023 Ducati Desert X

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2023 Ducati Desert X

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Symbols - Abbreviations - References

Used engine oil

General advice on repair work

1 Manufacturer: Ducati Motor Holding

1 Manufacturer: Ducati Motor Holding

• Primer: 2K White, code 873AC001, Manufacturer Palinal.

• Primer: 2K White, code 873AC001, Manufacturer Palinal.

• EPD with PPG product.

Tyre repair or replacement (Tubeless)

After the replacement of a tyre, wheel balancing is required.

Do not use levers or similar tools as they damage the rims.

Tyre repair or replacement (Tubeless)

After the replacement of a tyre, wheel balancing is required.

Do not use levers or similar tools as they damage the rims.

A) Total length: 2390 mm (94.09 in)

H) Total width (at hand guard): 960 mm (37.80 in)

Recommendations concerning oil

• Viscosity grade SAE 15W-50.

* dynamic safety-critical point; tightening torque tolerance must be Nm ± 5%.

This document contains important information for:

• Preparing the vehicle and setting it ready for the road.

Check of the supplied kit completeness

Fitting the handlebar and controls

Remove handlebar service support.

Fitting the rear-view mirrors

Place the battery inside its compartment.

Apply the indicated product to pin (D) of rider seat (2).

Switch (2) controls displaying and setting of instrument panel parameters.

Switch (3) has 3 positions:

• Position (3a) = turn indicator off.

Switch (4) controls the lights and has 3 positions:

• High beam, pushed up.

Red switch (6) controls the warning horn.

Switch (7) controls enabling/disabling of the 4 turn indicators (Hazard).

Switch (8) controls enabling/disabling of the Cruise Control function.

Switch (11) controls enabling/disabling of the ABS function.

Switch (13) controls the following:

• Enabling/disabling of the DRL function.

Switch (14) controls the engine starting.

Switch (15) controls the engine killing and has 2 positions:

Transport Mode function

The “Transport Mode” function limits instrument panel operation, in particular:

Setting menu function

• Indication of scheduled maintenance service due dates (SERVICE).

Riding Mode change function

Six riding modes are available:

• Power (Engine power).

PIN CODE function

• Back: to exit the menu and return to the previous display.

Date and time setting

This function allows setting the instrument panel language.

Setting the units of measurement

Vehicle maintenance schedule

* time not to be summed to the Desmo Service.

Prescribed time to carry out the operations of the Desmo Service:

Useful information for scheduled maintenance

To tension the final drive chain it is necessary to:

• World Wide version A = 47 ÷ 49 mm (1.85÷ 1.93 in).

• Fuse box (A) and (B) in front of the battery.

must be carried out every 15,000 km/9,000 mi.

must be carried out every 12 months.

USA, CANADA, ITALY version

Other country version