Ducati Multistrada/S/1000DS Motorcycle Repair Service Manual
Complete service repair manual with electrical wiring diagrams for Ducati Multistrada/S/1000DS Motorcycle, with all the workshop information to maintain, diagnose, repair, and servicelike professional mechanics.
Ducati Multistrada/S/1000DS Motorcycle workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Ducati
MODEL: Multistrada, Multistrada 1000DS, Multistrada ABS, Multistrada S ABS (MTS 1200, MTS 1200 ABS, MTS 1200 S Touring, MTS 1200 S ABS)
YEAR: 2003 2004 2005 2006 2007 2008 2009 2010
FORMAT: PDF
PAGES / SIZE: 912 + 592 Pages
LANGUAGE: English Italian
Section 1
1 - General 0
1 - How to use this manual 3
How to use this manual 3
Layout of the manual 4
2 - Symbols - Abbreviations - References 5
Product specifications 6
3 - Hazardous Products - Warnings 8
General safety rules 8
General maintenance indications 10
Section 2
2 - Model-specific information 0
1 - Identification data 3
Multistrada 1200 ABS identification data 3
Section 3
3 - Technical data 0
1.1 - Technical specifications 3
General 3
Colors 4
Transmission 4
Timing system/valves 5
Crankshaft 5
Cylinder/Piston 6
Gearbox 6
Cooling system 6
Front wheel 7
Front suspension (1200 ASB) 7
Front suspension (1200 S ASB) 7
Rear wheel 7
Rear suspension (1200 ASB) 8
Rear suspension (1200 S ASB) 8
Hydraulic brakes 8
Charging system/alternator 9
Injection-ignition system 9
Fuel system 9
Injection system 9
Lights/instrument panel 10
1.2 - Dimensions 11
2 - Fuel, lubricants and other fluids 12
3 - Torque settings 13
Frame torque settings 13
Engine torque settings 20
4 - Service tools 23
Specific tools for the engine 23
Specific tools for the frame 29
Section 4
4 - Maintenance operations 0
1 - Vehicle pre-delivery 3
2 - Scheduled maintenance chart 4
Operations to be carried out by the dealer 4
List of operations to be performed at 1000 km 4
Operations to be carried out by the dealer 5
List of operations to be performed every 12000 km / year (first limit reached) 5
Operations to be carried out by the customer 5
List of operations to be performed every 1000 km 5
3 - Maintenance operations 6
Reading of the error memory with DDS on the engine control units, vehicle and ABS 6
Checking the engine oil level 6
Changing the engine oil and filter cartridge 7
Checking valve clearances 14
Renew the timing belts 17
Spark plugs replacement 18
Changing and cleaning the air filters 23
Checking the coolant level 26
Change the coolant 27
Changing the brake fluid 35
Draining the brake circuit 40
Filling the brake system with fluid 42
Changing the clutch fluid 46
Draining the clutch hydraulic circuit 47
Filling the clutch circuit 49
Adjusting the steering head bearings 51
Adjusting the chain tension 52
Checking brake pad wear and changing brake pads 54
Adjusting the throttle cable 61
Adjusting the clutch lever and front brake lever 64
Adjusting the position of the gear change and rear brake pedals 65
Front fork adjustment (MTS 1200 ABS) 66
Rear shock absorber adjustment (MTS 1200 ABS) 67
Adjusting the rear ride set-up 68
5 - Fairings 0
1 - Rear-view mirrors 3
Removing the panel 4
Refitting the panel 7
Removing the headlight fairing 10
Refit the headlight fairing 17
2 - Fairings 20
Removing the front half-fairing 21
Refitting the front half-fairing 27
Removal of the fuel tank fairings 30
Refitting the fuel tank fairings 32
3 - Seat – seat cowling and side panels 34
Removal of the seat 35
Removal of the side panels and seat cowling 36
Refitting the side panels and seat cowling 38
Refitting the seat 39
4 - Front mudguard 40
Removal of the front mudguard 41
Refitting the front mudguard 42
Fitting the front semi mudguard 43
Removing the oil sump guard 45
5 - Rear mudguard - Splash guard 47
Removing the rear mudguard 48
Refitting the rear mudguard 48
Fitting the long rear mudguard 49
Removing the splash guard 50
Refitting the splash guard 51
Section 6
6 - Electric system and engine control system 0
1 - Wiring diagram 4
Wiring diagram 1200 S ABS - Key 6
Wiring diagram 1200 S ABS - Key 7
Wiring diagram colour codes 8
Key of front fuse box 8
Key of rear fuse box 9
Routing of wiring on frame 10
2 - Battery charging system 63
Checking the battery charging system 63
Recharging the battery 64
Topping up the electrolyte 65
Battery 69
Alternator 71
Rectifier-regulator 74
3 - Electric starting system 77
Electric starting system 77
Starter motor 78
Solenoid starter 83
4 - Lights and indicating devices 86
Replacing bulbs 86
Headlight aim 88
5 - Indicating devices 89
Checking the indicating system components 89
Water temperature sensor 96
Checking operation of the fan relay 97
Changing light bulbs 98
6 - Protection and safety devices 99
Checking protection and safety device components 99
Checking the fuses 101
7 - Instruments 103
Instrument panel 103
Instrument panel system (DASHBOARD) 104
Display settings and functions 107
8 - “Hands free” system 174
Hands free system Key-On and Key-Off 175
Key-On/Key-Off using the red key on the handlebar with the active key 177
Key-On/Key-Off using the key on the Hands free lock with the active key 178
Key-On/Key-Off using the red key on the handlebar with the passive key 179
Key-On/Key-Off using the key on the Hands free lock with the passive key 180
Key-On/Key-Off using the pin code (immobilizer release) 180
Entering PIN CODE function for vehicle release 181
9 - Immobilizer and transponder 183
10 - Description of the system 189
Injection and ignition 189
11 - Fuel injection-ignition system 190
12 - System components 191
Positioning of the control system components on the vehicle 191
Control unit support removing 192
Refitting the control unit support 193
Fuel injectors 196
Air pressure sensor 197
Engine temperature sensor 198
Air temperature sensor 199
Removing the coils 199
Throttle valve operation engine 201
Rpm/timing sensor 202
Injection relay 203
CAN Line 203
13 - Diagnostic instruments 204
Using a multimeter to check the electrical systems 204
Description of the diagnosis instrument (DDS) 206
Tester power supply 208
DDS diagnosis instrument 211
Checking and adjusting timing belt tension 212
Check the engine oil pressure 221
Cylinder compression test 225
Fuel pressure test 232
immobilizer override procedure 237
Guided diagnosis 241
Testing the battery charging system 244
Deactivating the “service” indication on the instrument panel 247
Icons table 250
Section 7
7 - Chassis 0
1 - Front wheel 5
Removal of the front wheel 6
Overhauling the front wheel 9
Refitting the front wheel 12
2 - Rear wheel 15
Removing of the rear wheel 16
Overhauling the rear wheel 16
Refitting the rear wheel 18
3 - Front brake control 19
Removal of the front brake master cylinder 20
Refitting the front brake master cylinder 21
Maintenance operations 23
Removal of the front brake system 23
Removal of the brake disks 26
Overhauling the front brake components 26
Refitting the brake disks 26
Refitting the front brake system 27
4 - Rear brake 30
Removing of the rear brake control 32
Disassembly of the rear brake control 34
Refitting the rear brake control 35
Removal of the rear brake calliper 38
Removal of the rear brake disc 39
Refitting the rear brake calliper 40
5 - ABS system information 41
Operating principle 41
ABS system operating information 42
ABS system deactivation 44
6 - System components 45
Replacing the front phonic wheel sensor 46
Replacing the rear phonic wheel sensor 48
Removing of the ABS control unit 49
Refitting the ABS control unit 50
Flexible wiring/hoses positioning 51
Table A 52
Table B 53
Table C 57
7 - ABS components maintenance 61
Adjusting of the AIR-GAP phonic wheel sensor 61
Bleeding of the ABS hydraulic system 63
8.1 - Handlebar assembly - Hand guards -
Rear-view mirrors - Throttle grip 64
Removal of the rear-view mirrors 66
Refitting the rear-view mirrors 67
Removing of the hand guards 68
Refitting the hand guards 68
Removal of the handlebar 69
Refitting the handlebar 70
Adjusting the throttle cable 72
Removal of the throttle twistgrip 72
Refitting the throttle twistgrip 73
8.2 - Handlebar unit: clutch hydraulic control 75
Removal of the clutch master cylinder assembly 76
Refitting the clutch master cylinder assembly 77
Removal of the clutch transmission unit 79
Refitting the clutch transmission unit 81
9 - Gearchange mechanism 85
Removal of the gearchange control 86
Disassembly of the gearchange mechanism 86
Refitting the gearchange mechanism 87
10.1 - Fork - Steering head: front fork (1200 ABS) 88
Refitting the front fork (1200 ABS) 89
Overhauling the front fork (1200 ABS) 90
Refit the front fork (1200 ABS) 98
10.2 - Front fork - Steering head: front fork (1200 S ABS) 99
Removal of the front fork (1200 S ABS) 100
Overhauling the fork 100
Refit the fork (1200 S ABS) 111
10.3 - Fork - Steering head: yoke 112
Adjusting the steering head bearings 113
Steering angle adjustment 114
Removal of the steering head components 115
Refitting the steering head components 118
12 - Rear shock absorber assembly 121
Rear suspension system 122
Removal of the rear shock absorber 123
Overhauling the rear shock absorber 124
Refitting the rear suspension 125
13 - Swingarm 128
Removal of the rear wheel eccentric hub and rear wheel axle 130
Refitting the rear wheel eccentric hub and rear wheel axle 132
Removal of the swingarm 135
Inspecting the swingarm pivot shaft 138
Overhauling the rear swingarm 139
Refitting the swingarm 144
14 - Final drive 147
Inspecting the final drive 148
Removing of the front sprocket 149
Refitting the front sprocket 151
Replacing of the rear sprocket 153
Refitting the rear sprocket 154
Washing the chain 155
Lubricating the chain 155
15 - Footrest brackets 156
Removal of the front footrests 157
Refitting the front footrests 158
Removing of the rear footrests 159
Refitting the rear footrests 159
16 - Stands 160
Removing of the sidestand 161
Refitting the sidestand 163
17 - Frame inspection 164
Disassembly of structural components and the frame 165
Removing of the headlight assembly 167
Refitting the headlight assembly 167
Checking the frame 169
Reassembly of structural components and the frame 170
18 - Licence plate holder 171
Removal of the licence plate holder 172
Refitting the licence plate holder 174
Section 8
8 - Fuel System/Exhaust System 0
2 - Fuel tank 3
Removal of the fuel tank 4
Removing the filler plug unit 7
Refitting the filler plug unit 7
Renewal of the fuel tank flange 8
Refitting the fuel tank flange 9
Refitting the fuel tank 10
6 - Airbox – Throttle Body 15
Removal the airbox and throttle body 16
Refitting the airbox and throttle body 23
7 - Air intake 27
Removal of the air filters 28
Refitting the air filters 29
8 - Exhaust system 31
Removal of the exhaust system 33
Refitting the exhaust system 37
10 - Evaporative emissions canister 42
Evaporative emissions canister system (USA versions only) 43
Removal of the evaporative emissions canister 44
Refitting the evaporative emissions canister 44
Section 9
9 - Engine 0
1 - Removal–refitting of the engine assembly 5
Removal of the engine 6
Refitting the engine 8
2.1 - Lubrication system: oil pump 10
Removal of the oil pump 11
Disassembly of the oil pump 12
Reassembly of the oil pump 13
Refitting the oil pump 13
2.2 - Lubrication system: oil cooler 15
Removal of the lubrication system 16
Oil cooler inspection 17
Refitting the lubrication system 18
2.3 - Lubrication system: oil breather tank 21
Refitting the oil breather tank 22
Refitting the oil breather tank 23
3.1 - Cooling system: coolant expansion tank 26
Removal of the expansion tank 27
Refitting the expansion tank 28
3.2 - Cooling system: radiator 30
Removal of the radiator 31
Renewal of the cooling fan 33
Refitting the radiator 33
Removal of the cooling system hoses and unions 36
Refitting the cooling system hoses and unions 39
3.3 - Cooling system: water pump 45
Removal of the water pump 46
Refitting the water pump 48
4.1 - Cylinder head assemblies: checks and adjustments 53
Checking and adjusting the valve clearances 54
Checking valve lift 57
Checking the engine timing 58
4.2 - Cylinder head assemblies: timing system 61
Removal of the timing belt covers 62
Removal of the movable tensioner/timing belt 63
Removing of the cylinder head pulley/fixed tensioner 63
Removal of the tensioner and idler pulley mounting studs 64
Disassembly of the camshaft pulleys 64
Removing the timing belt driveshaft pulleys 65
Refitting the timing belt driveshaft pulleys 66
Refitting the idler and tensioner pulley mounting studs 68
Reassembly of the timing pulleys 69
Refitting the cylinder heads pulleys/fixed tensioners 70
Refitting the timing belts 72
Refitting the timing covers 78
4.4 - Cylinder head assemblies: camshafts 79
Removal of the camshafts 81
Checking the camshafts and supports 83
Refitting the camshafts 84
Removal of the intake manifold and coolant union 91
Refitting the intake manifold and coolant union 92
2003-2010 Workshop Repair & Service Manual (COMPLETE & INFORMATIVE for DIY REPAIR) ☆ ☆ ☆ ☆ ☆
4.5 - Cylinder head assemblies: valves - rocker arms 94
Removal of the cylinder heads 95
Removing the valves 96
Removing the valve rocker arms 97
Overhaul of cylinder head components 100
Reassembly of the cylinder head 107
Refitting the cylinder head assemblies 115
5 - Cylinder/piston assemblies 116
Removal of the cylinder/piston assembly 117
Overhaul of the cylinder barrel/piston components 120
Refitting the cylinder/piston assembly 125
6.1 - Clutch assembly: clutch 130
Description of the clutch assembly 131
Removal of the clutch 132
Checking and overhauling the components 135
Reassembling the clutch 137
6.2 - Clutch assembly: clutch-side crankcase cover 141
Removal of the clutch-side crankcase cover 142
Disassembly of the clutch-side crankcase cover 143
Reassembly of the clutch-side crankcase cover 144
Refitting the clutch-side crankcase cover 145
6.3 - Clutch assembly: primary drive gears 146
Removal of the primary drive gear 147
Refitting the primary drive gears and checking backlash 149
7.1 - Gearbox assembly: gearchange mechanism 153
Removal of the gear selector lever 154
Disassembly of gear interlock plunger and pawl assembly 156
Refitting the gear interlock plunger and pawl assembly 157
Refitting the gear selector lever 159
7.2 - Gearbox assembly: gearbox shafts 162
Removal of the gearbox assembly 164
Disassembly of the gearbox shafts 167
Overhaul of the gearbox 176
Inspection of the gear selector forks 177
Inspection of the gear selector drum 178
Reassembly of the gearbox shafts 179
Reassembly of the gearbox 183
8 - Flywheel - alternator 184
Removal of the alternator-side crankcase cover 186
Disassembly of the alternator-side crankcase cover 188
Removing the flywheel - generator assembly 189
Overhaul of the flywheel-alternator assembly 191
Refitting the flywheel-alternator assembly 197
Refitting the alternator-side crankcase cover 199
9.1 - Crankcase assembly: external components 203
Removing outer components 205
Refitting the external components 208
Removal of the timing gears 213
Refitting the timing gears 215
Removal of the starter motor idler gear 217
Refitting the starter motor gear 218
9.2 - Crankcase assembly: crankcase halves 219
Separation of the crankcase halves 221
Overhaul of the crankcase halves 224
Main bearings 227
Reassembly of the crankcase halves 230
Shimming the shafts 233
Reassembly of the crankcase halves 236
9.3 - Crankcase assembly: crankshaft/connecting rods assembly 244
Removal of the crankshaft/connecting rods assembly 245
Disassembly of the crankshaft/connecting rods assembly 246
Overhaul of the connecting rods 247
Reassembly of the connecting rods 251
Refitting the crankshaft/connecting rod assembly 255
03-06 Multistrada, Multistrada 1000DS (EN-IT)............2
10 Multistrada 1200_S ABS............594
DUCATI MULTISTRADA 1200 MY2010 ............594
GENERAL INDEX............595
1 - GENERAL............607
1 - How to use this manual............608
How to use this manual............608
Layout of the manual............609
2 - Symbols - Abbreviations - References............610
Product specifications............611
3 - Hazardous Products - Warnings............613
General safety rules............613
General maintenance indications............615
2 - MODEL-SPECIFIC INFORMATION............617
1 - Identification data............618
Multistrada 1200 ABS identification data............618
3 - TECHNICAL DATA............623
1.1 - Technical specifications............624
General............624
Colours............625
Transmission............625
Timing system/valves............626
Crankshaft............626
Cylinder/Piston............627
Gearbox............627
Cooling system............627
Front wheel............628
Front suspension (1200 ASB)............628
Front suspension (1200 S ASB)............628
Rear wheel............628
Rear suspension (1200 ASB)............629
Rear suspension (1200 S ASB)............629
Hydraulic brakes............629
Charging system/alternator............630
Injection-ignition system............630
Fuel system............630
Injection system............630
Lights/instrument panel............631
1.2 - Dimensions............632
2 - Fuel, lubricants and other fluids............633
3 - Torque settings............634
Frame torque settings............634
Engine torque settings............641
4 - Service tools............644
Specific tools for the engine............644
Specific tools for the frame............650
4 - MAINTENANCE OPERATIONS............657
1 - Vehicle pre-delivery............658
2 - Scheduled maintenance chart............659
Operations to be carried out by the dealer............659
List of operations to be performed at 1000 km............659
Operations to be carried out by the dealer............660
List of operations to be performed every 12000 km / year (first limit reached)............660
Operations to be carried out by the customer............660
List of operations to be performed every 1000 km............660
3 - Maintenance operations............661
Reading of the error memory with DDS on the engine control units, vehicle and ABS............661
Checking the engine oil level............661
Changing the engine oil and filter cartridge............662
Checking valve clearances............669
Renew the timing belts............672
Spark plugs replacement............673
Changing and cleaning the air filters............678
Checking the coolant level............681
Change the coolant............682
Changing the brake fluid............690
Draining the brake circuit............695
Filling the brake system with fluid............697
Changing the clutch fluid............701
Draining the clutch hydraulic circuit............702
Filling the clutch circuit............704
Adjusting the steering head bearings............706
Adjusting the chain tension............707
Checking brake pad wear and changing brake pads............709
Adjusting the throttle cable............716
Adjusting the clutch lever and front brake lever............719
Adjusting the position of the gear change and rear brake pedals............720
Front fork adjustment (MTS 1200 ABS)............721
Rear shock absorber adjustment (MTS 1200 ABS)............722
Adjusting the rear ride set-up............723
5 - FAIRINGS............725
1 - Rear-view mirrors............726
Removing the panel............727
Refitting the panel............730
Removing the headlight fairing............733
Refit the headlight fairing............740
2 - Fairings............743
Removing the front half-fairing............744
Refitting the front half-fairing............750
Removal of the fuel tank fairings............753
Refitting the fuel tank fairings............755
3 - Seat - seat cowling and side panels............757
Removal of the seat............758
Removal of the side panels and seat cowling............759
Refitting the side panels and seat cowling............761
Refitting the seat............762
4 - Front mudguard............763
Removal of the front mudguard............764
Refitting the front mudguard............765
Fitting the front semi mudguard............766
Removing the oil sump guard............768
5 - Rear mudguard - Splash guard............770
Removing the rear mudguard............771
Refitting the rear mudguard............771
Fitting the long rear mudguard............772
Removing the splash guard............773
Refitting the splash guard............774
6 - ELECTRIC SYSTEM AND ENGINE CONTROL SYSTEM............777
1 - Wiring diagram............779
Wiring diagram 1200 S ABS - Key............781
Wiring diagram 1200 S ABS - Key............782
Wiring diagram colour codes............783
Key of front fuse box............783
Key of rear fuse box............784
Routing of wiring on frame............785
Table A............788
Table B............788
Table C............789
Table D............791
Table E -1............795
Table E-2............800
Table F............803
Table G............805
Table H............807
Table I............809
Table J............812
Table K............816
Table L............818
Table M............819
Table N............822
Table O............824
Table P............827
Table Q............829
Table R............830
Table S............833
Table T............835
2 - Battery charging system............838
Checking the battery charging system............838
Recharging the battery............839
Topping up the electrolyte............840
Battery............844
Alternator............846
Rectifier-regulator............849
3 - Electric starting system............852
Electric starting system............852
Starter motor............853
Solenoid starter............858
4 - Lights and indicating devices............861
Replacing bulbs............861
Headlight aim............863
5 - Indicating devices............864
Checking the indicating system components............864
Water temperature sensor............871
Checking operation of the fan relay............872
Changing light bulbs............873
6 - Protection and safety devices............874
Checking protection and safety device components............874
Checking the fuses............876
7 - Instruments............878
Instrument panel............878
Instrument panel system (DASHBOARD)............879
Display settings and functions............882
8 - Hands free system............949
Hands free system Key-On and Key-Off............950
Key-On/Key-Off using the red key on the handlebar with the active key............952
Key-On/Key-Off using the key on the Hands free lock with the active key............953
Key-On/Key-Off using the red key on the handlebar with the passive key............954
Key-On/Key-Off using the key on the Hands free lock with the passive key............955
Key-On/Key-Off using the pin code (immobilizer release)............955
Entering PIN CODE function for vehicle release............956
9 - immobilizer and transponder............958
10 - Description of the system............964
Injection and ignition............964
11 - Fuel injection-ignition system............965
12 - System components............966
Positioning of the control system components on the vehicle............966
Control unit support removing............967
Refitting the control unit support............968
Fuel injectors............971
Air pressure sensor............972
Engine temperature sensor............973
Air temperature sensor............974
Removing the coils............974
Throttle valve operation engine............976
Rpm/timing sensor............977
Injection relay............978
CAN Line............978
13 - Diagnostic instruments............979
Using a multimeter to check the electrical systems............979
Description of the diagnosis instrument (DDS)............981
Tester power supply............983
DDS diagnosis instrument............986
Checking and adjusting timing belt tension............987
Check the engine oil pressure............996
Cylinder compression test............1000
Fuel pressure test............1007
immobilizer override procedure............1012
Guided diagnosis............1016
Testing the battery charging system............1019
Deactivating the service indication on the instrument panel............1022
Icons table............1025
7 - CHASSIS............1028
1 - Front wheel............1031
Removal of the front wheel............1032
Overhauling the front wheel............1035
Refitting the front wheel............1038
2 - Rear wheel............1041
Removing of the rear wheel............1042
Overhauling the rear wheel............1042
Refitting the rear wheel............1044
3 - Front brake control............1045
Removal of the front brake master cylinder............1046
Refitting the front brake master cylinder............1047
Maintenance operations............1049
Removal of the front brake system............1049
Removal of the brake disks............1052
Overhauling the front brake components............1052
Refitting the brake disks............1052
Refitting the front brake system............1053
4 - Rear brake............1056
Removing of the rear brake control............1058
Disassembly of the rear brake control............1060
Refitting the rear brake control............1061
Removal of the rear brake calliper............1064
Removal of the rear brake disc............1065
Refitting the rear brake calliper............1066
5 - ABS system information............1067
Operating principle............1067
ABS system operating information............1068
ABS system deactivation............1070
6 - System components............1071
Replacing the front phonic wheel sensor............1072
Replacing the rear phonic wheel sensor............1074
Removing of the ABS control unit............1075
Refitting the ABS control unit............1076
Flexible wiring/hoses positioning............1077
Table A............1078
Table B............1079
Table C............1083
7 - ABS components maintenance............1087
Adjusting of the AIR-GAP phonic wheel sensor............1087
Bleeding of the ABS hydraulic system............1089
8.1 - Handlebar assembly - Hand guards - Rear-view mirrors - Throttle grip............1090
Removal of the rear-view mirrors............1092
Refitting the rear-view mirrors............1093
Removing of the hand guards............1094
Refitting the hand guards............1094
Removal of the handlebar............1095
Refitting the handlebar............1096
Adjusting the throttle cable............1098
Removal of the throttle twistgrip............1098
Refitting the throttle twistgrip............1099
8.2 - Handlebar unit: clutch hydraulic control............1101
Removal of the clutch master cylinder assembly............1102
Refitting the clutch master cylinder assembly............1103
Removal of the clutch transmission unit............1105
Refitting the clutch transmission unit............1107
9 - Gearchange mechanism............1111
Removal of the gearchange control............1112
Disassembly of the gearchange mechanism............1112
Refitting the gearchange mechanism............1113
10.1 - Fork - Steering head: front fork (1200 ABS)............1114
Refitting the front fork (1200 ABS)............1115
Overhauling the front fork (1200 ABS)............1116
Refit the front fork (1200 ABS)............1124
10.2 - Front fork - Steering head: front fork (1200 S ABS)............1125
Removal of the front fork (1200 S ABS)............1126
Overhauling the fork............1126
Refit the fork (1200 S ABS)............1137
10.3 - Fork - Steering head: yoke............1138
Adjusting the steering head bearings............1139
Steering angle adjustment............1140
Removal of the steering head components............1141
Refitting the steering head components............1144
12 - Rear shock absorber assembly............1147
Rear suspension system............1148
Removal of the rear shock absorber............1149
Overhauling the rear shock absorber............1150
Refitting the rear suspension............1151
13 - Swingarm............1154
Removal of the rear wheel eccentric hub and rear wheel axle............1156
Refitting the rear wheel eccentric hub and rear wheel axle............1158
Removal of the swingarm............1161
Inspecting the swingarm pivot shaft............1164
Overhauling the rear swingarm............1165
Refitting the swingarm............1170
14 - Final drive............1173
Inspecting the final drive............1174
Removing of the front sprocket............1175
Refitting the front sprocket............1177
Replacing of the rear sprocket............1179
Refitting the rear sprocket............1180
Washing the chain............1181
Lubricating the chain............1181
15 - Footrest brackets............1182
Removal of the front footrests............1183
Refitting the front footrests............1184
Removing of the rear footrests............1185
Refitting the rear footrests............1185
16 - Stands............1186
Removing of the sidestand............1187
Refitting the sidestand............1189
17 - Frame inspection............1190
Disassembly of structural components and the frame............1191
Removing of the headlight assembly............1193
Refitting the headlight assembly............1193
Checking the frame............1195
Reassembly of structural components and the frame............1196
18 - Licence plate holder............1197
Removal of the licence plate holder............1198
Refitting the licence plate holder............1200
8 - FUEL SYSTEM/EXHAUST SYSTEM............1203
2 - Fuel tank............1204
Removal of the fuel tank............1205
Removing the filler plug unit............1208
Refitting the filler plug unit............1208
Renewal of the fuel tank flange............1209
Refitting the fuel tank flange............1210
Refitting the fuel tank............1211
6 - Airbox - Throttle Body............1216
Removal the airbox and throttle body............1217
Refitting the airbox and throttle body............1224
7 - Air intake............1228
Removal of the air filters............1229
Refitting the air filters............1230
8 - Exhaust system............1232
Removal of the exhaust system............1234
Refitting the exhaust system............1238
10 - Evaporative emissions canister............1243
Evaporative emissions canister system (USA versions only)............1244
Removal of the evaporative emissions canister............1245
Refitting the evaporative emissions canister............1245
9 - ENGINE............1251
1 - Removal-refitting of the engine assembly............1254
Removal of the engine............1255
Refitting the engine............1257
2.1 - Lubrication system: oil pump............1259
Removal of the oil pump............1260
Disassembly of the oil pump............1261
Reassembly of the oil pump............1262
Refitting the oil pump............1262
2.2 - Lubrication system: oil cooler............1264
Removal of the lubrication system............1265
Oil cooler inspection............1266
Refitting the lubrication system............1267
2.3 - Lubrication system: oil breather tank............1270
Refitting the oil breather tank............1271
Refitting the oil breather tank............1272
3.1 - Cooling system: coolant expansion tank............1275
Removal of the expansion tank............1276
Refitting the expansion tank............1277
3.2 - Cooling system: radiator............1279
Removal of the radiator............1280
Renewal of the cooling fan............1282
Refitting the radiator............1282
Removal of the cooling system hoses and unions............1285
Refitting the cooling system hoses and unions............1288
3.3 - Cooling system: water pump............1294
Removal of the water pump............1295
Refitting the water pump............1297
4.1 - Cylinder head assemblies: checks and adjustments............1302
Checking and adjusting the valve clearances............1303
Checking valve lift............1306
Checking the engine timing............1307
4.2 - Cylinder head assemblies: timing system............1310
Removal of the timing belt covers............1311
Removal of the movable tensioner/timing belt............1312
Removing of the cylinder head pulley/fixed tensioner............1312
Removal of the tensioner and idler pulley mounting studs............1313
Disassembly of the camshaft pulleys............1313
Removing the timing belt driveshaft pulleys............1314
Refitting the timing belt driveshaft pulleys............1315
Refitting the idler and tensioner pulley mounting studs............1317
Reassembly of the timing pulleys............1318
Refitting the cylinder heads pulleys/fixed tensioners............1319
Refitting the timing belts............1321
Refitting the timing covers............1327
4.4 - Cylinder head assemblies: camshafts............1328
Removal of the camshafts............1330
Checking the camshafts and supports............1332
Refitting the camshafts............1333
Removal of the intake manifold and coolant union............1340
Refitting the intake manifold and coolant union............1341
4.5 - Cylinder head assemblies: valves - rocker arms............1343
Removal of the cylinder heads............1344
Removing the valves............1345
Removing the valve rocker arms............1346
Overhaul of cylinder head components............1349
Reassembly of the cylinder head............1356
Refitting the cylinder head assemblies............1364
5 - Cylinder/piston assemblies............1365
Removal of the cylinder/piston assembly............1366
Overhaul of the cylinder barrel/piston components............1369
Refitting the cylinder/piston assembly............1374
6.1 - Clutch assembly: clutch............1379
Description of the clutch assembly............1380
Removal of the clutch............1381
Checking and overhauling the components............1384
Reassembling the clutch............1386
6.2 - Clutch assembly: clutch-side crankcase cover............1390
Removal of the clutch-side crankcase cover............1391
Disassembly of the clutch-side crankcase cover............1392
Reassembly of the clutch-side crankcase cover............1393
Refitting the clutch-side crankcase cover............1394
6.3 - Clutch assembly: primary drive gears............1395
Removal of the primary drive gear............1396
Refitting the primary drive gears and checking backlash............1398
7.1 - Gearbox assembly: gearchange mechanism............1402
Removal of the gear selector lever............1403
Disassembly of gear interlock plunger and pawl assembly............1405
Refitting the gear interlock plunger and pawl assembly............1406
Refitting the gear selector lever............1408
7.2 - Gearbox assembly: gearbox shafts............1411
Removal of the gearbox assembly............1413
Disassembly of the gearbox shafts............1416
Overhaul of the gearbox............1425
Inspection of the gear selector forks............1426
Inspection of the gear selector drum............1427
Reassembly of the gearbox shafts............1428
Reassembly of the gearbox............1432
8 - Flywheel - alternator............1433
Removal of the alternator-side crankcase cover............1435
Disassembly of the alternator-side crankcase cover............1437
Removing the flywheel - generator assembly............1438
Overhaul of the flywheel-alternator assembly............1440
Refitting the flywheel-alternator assembly............1446
Refitting the alternator-side crankcase cover............1448
9.1 - Crankcase assembly: external components............1452
Removing outer components............1454
Refitting the external components............1457
Removal of the timing gears............1462
Refitting the timing gears............1464
Removal of the starter motor idler gear............1466
Refitting the starter motor gear............1467
9.2 - Crankcase assembly: crankcase halves............1468
Separation of the crankcase halves............1470
Overhaul of the crankcase halves............1473
Main bearings............1476
Reassembly of the crankcase halves............1479
Shimming the shafts............1482
Reassembly of the crankcase halves............1485
9.3 - Crankcase assembly: crankshaft/connecting rods assembly............1493
Removal of the crankshaft/connecting rods assembly............1494
Disassembly of the crankshaft/connecting rods assembly............1495
Overhaul of the connecting rods............1496
Reassembly of the connecting rods............1500
Refitting the crankshaft/connecting rod assembly............1504
