Multistrada 20120tech Manual PDF

GENERAL INDEX 0
1 - General 0
2 - Model-specific information 0
3 - Technical data 0
4 - Maintenance operations 0
5 - Fairings 0
6 - Electric system and engine control system 0
7 - Chassis 0
8 - Fuel System/Exhaust System 0
9 - Engine 0
General index
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
1 - Identification data 3
Multistrada 1200 ABS identification data 3
Section 3
1.1 - Technical specifications 3
General 3
Colours 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
2 Multistrada 1200 ABS / Multistrada 1200 S ABS - M.Y. 2010 - edition DRAFT
General index
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
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
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
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
Multistrada 1200 ABS / Multistrada 1200 S ABS - M.Y. 2010 - edition DRAFT 3
General index
Section 5
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
1 - Wiring diagram 4
Wiring diagram 1200 S ABS - Key 6
Wiring diagram colour codes 8
Key of front fuse box 8
Key of rear fuse box 9
Routing of wiring on frame 10
Table A 13
Table B 13
Table C 14
Table D 16
Table E -1 20
Table E-2 25
Table F 28
Table G 30
Table H 32
General index
Table I 34
Table J 37
Table K 41
Table L 43
Table M 44
Table N 47
Table O 49
Table P 52
Table Q 54
Table R 55
Table S 58
Table T 60
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
General index
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
General index
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
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
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
General index
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

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
General index
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
General index
2.3 - Lubrication system: oil breather tank 21
Refitting the oil breather tank 22
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
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
General index
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
General index
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
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
1 - General 0
section
1 General
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
1-1 General
1 - How to use this manual
How to use this manual
How to use this manual

This manual has been prepared for technical personnel at Ducati Authorized Service Centres with the aim of providing fundamen-
tal information on how to work in accordance with the modern concepts of “best practice” and “safety in the workplace” during
the maintenance, repair or replacement of original components of the cycle parts and engine of this motorcycle.
All operations described in this manual must be carried out by experienced, skilled technicians, who are required to follow the
Manufacturer's instructions in full.
Some information has been intentionally omitted, as we believe that all specialized technicians should have a basic technical back-
ground. Additional information on how to install various components is provided in the spare parts catalogue.
Important
This manual also describes the essential checks to be carried out prior to delivery of the motorcycle.
Ducati Motor Holding S.p.A. declines all liability for any technical errors or omissions in this manual and reserves the right to make
changes made necessary by the technical evolution of its products without prior notice.
The information contained herein was correct at the time of going to press.
Important
Reproduction or disclosure of all or part of the contents of this manual is strictly forbidden. All rights on this manual are reserved
for Ducati Motor Holding S.p.A. Applications for authorization for reproduction must be submitted in writing and must specify the
reasons for such reproduction.
Ducati Motor Holding S.p.A.
section
1-1 General
Layout of the manual
This manual is divided into sections (1), each identified by a letter.
1 - General
2 - Model -specific information
3 - Technical data
4 - Maintenance operations
5 - Fairings
6 - Electric system and
engine control system
Each section (1) is made up of several chapters (2), which are numbered consecutively.
The chapters (2) may be further subdivided into paragraphs (3).
1 - General
1 - How to use this
manual 2
3 - Layout of the manual
2 - Symbols -
Abbreviations -
References
- Product specifications
The manual describes all repair operations starting from the fully assembled motorcycle.
The full procedure is described up to the point in which the motorcycle is restored to its fully assembled starting condition.
Important
Some of the sections of this manual are not included, since the motorcycle in question is not equipped with the relevant parts.
Important
The structure of the manual has been designed so that all the models types of the DUCATI MOTOR HOLDING products can be
included.
To facilitate consultation of the manual, the table of contents is identical for all motorcycle models.
section
1-2 General
2 - 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 tech-
nical concepts or safety warnings throughout the text. The symbols should therefore be seen as an aid to memory. 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 compo-
nents.
Note
This symbol indicates additional useful information for the current operation.
Text references
(X)
References in bold type indicate a part that is not illustrated in the figures next to the text, but which can be found in the exploded
views at the beginning of each chapter.
(X)
References in non-bold type indicate a part that is illustrated in the figures alongside the text.
section
1-2 General
Product specifications
Symbols in the diagram show the type of thread locker, 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

Engine oil (for characteristics see Sec. 3 - 2, Fuel, lubricants SHELL
and other fluids). Advance Ultra 4
DOT 4 special hydraulic brake fluid. SHELL

Advance Brake DOT 4
SAE 80-90 gear oil or special products for chains with O-rings. SHELL
Advance Chain or Advance Teflon Chain
Anti-freeze (nitride, amine and phosphate free) 30 to 40% SHELL

solution in water. Advance coolant or Glycoshell
GREASE A Multipurpose, medium fibre, lithium grease. SHELL Alvania R3

A
GREASE B Molybdenum disulphide grease, high mechanical stress and SHELL
B high temperature resistant. Retinax HDX2
GREASE C Bearing/joint grease for parts subject to prolonged SHELL

C mechanical stress. Temperature range: -10 to 110 °C. Retinax LX2
GREASE D Protective grease, with anti-corrosive and waterproofing SHELL

D properties. Retinax HD2
GREASE E PANKL grease - PLB 05.

E
GREASE F OPTIMOL grease - PASTE WHITE T.
F
LOCK 1 Low-strength thread locker. Loctite 222
1
LOCK
LOCK 2 Medium-strength thread locker, compatible with oil. Loctite 243

2
LOCK
LOCK 3 High-strength thread locker for threaded parts. Loctite 270

3
LOCK
LOCK 4 Flange sealant resistant to high mechanical stress and Loctite 510
4
LOCK
solvents. Resists high temperatures (up to 200 °C) and
pressures up to 350 bar; fills gaps up to 0.4 mm.
LOCK 5 Permanent adhesive for smooth or threaded cylindrical Loctite 128455
5
LOCK
fasteners on mechanical parts. High resistance to mechanical
stress and solvents. Temperature range: -55 to 175 °C.
LOCK 6 Pipe sealant for pipes and medium to large fasteners. Loctite 577
6
LOCK
For water and gases (except oxygen). Maximum
filling capacity: 0.40 mm diameter clearance.
LOCK 7 Speed bonder for rubber and plastics with elastomer charged Loctite 480
7
LOCK
ethylic base.
section
1-2 General
Symbol Specifications Recommended product
LOCK 8 High-strength retaining compound for threaded parts, Loctite 601
8
LOCK
bearings, bushes, splines and keys.
Temperature range: -55 to 150 °C.
LOCK 9 Medium-strength thread locker. Loctite 406
9
LOCK
LOCK 10 Product for metal parts to seal and lock cylindrical freely Loctite 128443
10
LOCK
sliding or threaded couplings. Resistant to high mechanical
stress and high temperature, excellent resistance to solvents
and chemical attack.
LOCK 11 Medium-strength thread locker Loctite 401
11
LOCK
LOCK 12 Instant adhesive gel offering tensile/shear strength. Loctite 454 gel
12
LOCK
DUCATI liquid gasket. 942470014
Exhaust pipe paste. Self-sealing paste, hardens when heated; Holts Firegum
resists temperatures exceeding 1000 °C.
Spray used to protect electrical systems. Eliminates moisture SHELL

and condensation and provides excellent corrosion Advance Contact Cleaner
resistance. Water repellent.
Dry lubricant, polymerizing on contact with air. Molykote D321R
Molycote M55 Plus
Emulsion for lubrication of rubber. P 80
section
1-3 General
3 - Hazardous Products - Warnings
General safety rules
Carbon monoxide
When a maintenance operation must be performed with the engine running, maker sure that the working area is well-ventilated.
Never run the engine in an enclosed space.
Warning
Exhaust fumes 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 fume 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
Petrol 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
part of your body and do not park the motorcycle next to inflammable material (wood, leaves, etc.).
Used engine oil
Warning
Prolonged or repeated contact with used engine oil may cause skin cancer. If working with engine oil on a daily basis, make it a
rule to wash your hands thoroughly with soap immediately afterwards. Keep away from children.
Brake pad dust

Never clean the brake assemblies using compressed air or a dry brush.
Warning
Inhalation of asbestos fibres is a proven cause of respiratory illness and cancer.
Brake fluid
Warning
Avoid spilling brake fluid onto plastic, rubber or painted parts of the motorcycle to avoid the risk of damage. Protect these parts
with a clean shop cloth before proceeding to service the motorcycle. Keep away from children.
section
1-3 General
Coolant level
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 an irritant and is 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 if it comes into
contact with the skin.
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.
section
1-3 General
General maintenance indications
Useful tips
Ducati recommends that you follow the instructions below in order to prevent problems and obtain the best end result:
- when diagnosing faults, primary consideration should always be given to what the customer reports about motorcycle operation
since this information can highlight anomalies; 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. Note that the disassembly procedures in this manual
describe the most efficient way to reach the part to be repaired.
General advice on repair work

- Always use top quality tools. When lifting the motorcycle, only use devices that comply fully with the relevant European direc-
tives.
- 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 crosswise sequence.
- Always mark any parts and positions which might easily be confused at the time of reassembly.
- Use exclusively Ducati original replacement parts and the recommended brands of lubricants.
- Use special service tools where specified.
- Ducati Technical Bulletins often contain updated versions of the service procedures described in this manual. Check the latest
Bulletins for details.
section
2 Model-specific information
1 - Identification data 3
Multistrada 1200 ABS identification data 3
section
2-1 Model-specific information
1 - Identification data
Multistrada 1200 ABS identification data
Each Ducati motorcycle has two identification numbers -the frame number and the engine number- and an EC nameplate (A)
(NOT PRESENT ON THE US VERSION).
Note
Please quote these numbers, which identify the motorcycle model, when ordering spare parts.
e ?*?? / ?? * ???? *
*ZDM ??????????????* -1
??dB(A) - ???? min
??? ? ??? ??
section
Data stamped on the frame
Europe version
1 Manufacturer: Ducati Motor Holding
2 Type - identical for all the models MTS 1200
3 Variant
4 Version:
AA = MTS 1200
BA = MTS 1200 ABS
CA = MTS 1200 S Touring
AB = MTS 1200 S ABS
5 Year of construction (A=2010)
6 Manufacturing facility
7 Progressive serial No.

Europe version
1 2 3 4 5 6 7
ZDM A2 00 ** A B 0000 01

France version
1 2 3 4 5 6 7
ZDM A2 01 ** A B 0000 01

US version
2 Motorcycle type
3 Variant – Numeric or X (Check digit)
4 Model year (A=2010)
5 Manufacturing facility
6 Progressive serial No.

US version
1 2 3 4 5 6
ZDM 1 2 B L W X B 0000 01
★ Numeric variant from 0 to 9

or x (Check digit)
section
Data stamped on engine
Europe version
2 Engine type
3 Progressive production No.

Europe/France version
ZDM 1198WC*000 001*
1 2 3

US version
1 Engine type
2 Model year
3 Progressive production No.

US version
2BL X 00 0001
1 2 3
section
3 Technical data
1.1 - Technical specifications 3
General 3
Colours 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
3 - 1.1 Technical Data
1.1 - Technical specifications
General
Reference Technical specifications
Motorcycle Total length 2200 mm
dimensions
Total width 985 mm a 1465 mm (fully lifted plexiglas)
Total height 1405 mm
Seat height 850 mm
Minimum ground clearance 170 mm
Wheelbase 1530 mm
Frame Type ALS 420 steel tube trellis frame
Subframe Type ALS 450 steel tube trellis frame, die-cast light alloy connecting
side plates, pivoted on the engine.
Steering head angle 25°
Steering angle 76° rh/lh
Trail 110 mm
Front suspension (1200 ABS) MARZOCCHI:

upside-down hydraulic fork with adjustable compression,
rebound and spring preload.
Fork legs Ø 50 mm.
Front wheel travel (1200 ABS) 170 mm (6.7 in)
Front suspension (1200 S ABS) ÖHLINS:

upside-down fork, fully adjustable, hydraulic rebound damping
and compression electronically managed.
Ø 48 mm fork legs, TIN-coated.
Front wheel travel (1200 S ABS) 170 mm (6.7 in)
Rear suspension (1200 ABS) SACHS:

The rear suspension system uses a hydraulic single shock
absorber adjustable for rebound and compression.
Remote spring preloading adjustment.
Rear wheel travel: 170 mm.
Shock absorber stroke: 59.5 mm.
Rear suspension (1200 S ABS) ÖHLINS:
The rear suspension system uses a hydraulic single shock
absorber fully adjustable for rebound and compression
electronically managed.
Rear wheel travel: 170 mm.
Shock absorber stroke: 59.5 mm.
Front wheel Light alloy with ten spokes
Front wheel size MT 3.50x17”
Front tyre size 120/70 - ZR 17
Rear wheel Light alloy with ten spokes
Rear wheel size MT 6.00x17”
Rear tyre size 190/55 - ZR 17
Type of tyre Radial tubeless tyres
Front brake Hydraulic, 2 callipers with ABS model
Rear brake Hydraulic, 1 calliper with ABS model
section
Engine Type Longitudinal 90º “L” twin cylinder, four-stroke.
Bore 106 mm
Stroke 67.9 mm
Displacement 1198.4 cm³
Compression ratio 11.5±0.5:1
Timing system A toothed belt with two overhead camshafts, 4 valves

per cylinder
Lubrication system Forced lubrication by pump, with oil cooler
Oil pump type Gear pump with bypass valve
Cooling system With liquid with thermostat
Air filter Filtering element in the airbox
Crankshaft type One-piece
Colours
Description Code no
1200 ABS Ducati Anniversary Red 473.101 (PPG)
Clear lacquer 228.880 (PPG)
Racing Grey frame and black wheel rims
Pearl white L2909004 (LECHLHER)
Enamel L2920057 (LECHLHER)
1200 S ABS Ducati Anniversary Red 473.101 (PPG)
Pearl white L2909004 (LECHLER)
Enamel L2920057 (LECHLER)
Black diamond 57E22714 (AKZO)
Enamel 54M22705 (AKZO)
Transmission
Clutch Wet clutch with multiple discs
Clutch control Hydraulic
Gearbox 6 speed
Primary drive 33/61
Transmission ratio 1.84
Final drive 15/40
Gearbox type With constant mesh spur gears, operated by a lever on

the left side of the motorcycle
section
Transmission Gear ratios
1st 15/37
2nd 17/30
3rd 20/27
4th 22/24
5th 24/23
6th 25/22
Timing system/valves
Reference Adjusting clearance Control value every
24000 Kg
Timing diagram With 1 mm valve clearance
Intake Opening 4° B.T.D.C.

Closing 58° A.B.D.C.
Exhaust system Opening 58° B.B.D.C.
Closing 7° A.T.D.C.
Intake valve diameter 43.5 mm
Exhaust valve diameter 34.5 mm
Valve lift With 0 mm valve clearance Intake 12.2 mm

Exhaust 11.2 mm
Opening rocker arm - intake 0.13 to 0.18 mm 0.10 to 0.25 mm
Opening rocker arm - exhaust 0.13 to 0.18 mm 0.10 to 0.25 mm
Closing rocker arm - intake 0.05 to 0.10 mm 0.05 to 0.15 mm
Closing rocker arm - exhaust 0.05 to 0.10 mm 0.05 to 0.15 mm
Reference Adjusting clearance Reset value

(new belt) (used belt)
Belt tensioning when DDS 110±5 Hz (horizontal) 80±5 Hz (horizontal)
cold 110±5 Hz (vertical) 80±5 Hz (vertical)
Limit minimum value with cold machine 70 Hz
Voltage value accepted at the moment of HORIZONTAL VERTICAL

the engine service Voltage (Hz) ±5 Voltage (Hz) ±5
Min. 80 Min. 88
Max. 100 Max. 100
Crankshaft
Reference Standard value Service limit
Crankshaft Ovality 0.005 mm
Taper 0.005 mm
Main bearing journal alignment 0.01 mm on diameter
section
Cylinder/Piston
Cylinder nominal diameter 106 mm
Max. bore ovality 0.010 mm
Max. bore taper 0.015 mm
Diameter
Section A 106.000 mm to 106.010 mm
Section B 106.010 mm to 106.020 mm
Section C 106.020 mm to 106.030 mm
Piston-to-bore clearance 0.085 to 0.105 mm
Piston Nominal diameter 106 mm
Diameter
Class A 105.905 mm to 105.915 mm
Class B 105.915 mm to 105.925 mm
Class C 105.925 mm to 105.935 mm
Connecting rod Connecting-rod big-end 45 mm
diameter
Crankshaft class Connecting rod class Bearings colour
Big-end bearing pairings A A Blue + Yellow
B A Yellow + Yellow
A B Blue + Blue
B B Blue + Yellow
Big-end bearing-to-crankpin Pin selection Ø 42.014 mm/
clearance 0 to 0.016 mm
Gudgeon pin–to-piston clear- 0.015 to 0.024 mm

ance
Nominal diameters Ø 19 mm
Piston Ø 19 mm/0.020 to 0.015
Gudgeon pin Ø 19 mm/0 to 0.004
Gudgeon pin-to-connecting 0.035 to 0.049 mm
rod clearance
Engine cylinder compression 11 to 12 bar 10 bar (MIN.), difference
measured with DDS instru- between the two cylinders:
ment 2 bar (MAX.)
Gearbox
Gearbox shafts Endfloat 0.05 to 0.20 mm
Selector drum Endfloat 0.10 to 0.40 mm
Gear selector fork Selector fork end thickness 3.90 to 4.00 mm
Selector fork-to-gear clearance 0.070 to 0.285 mm 0.4 mm
Cooling system
Type Liquid with two radiators with closed circuit, with double
curved radiator with double fan and mixing thermostat
Coolant capacity 2.3±0.5 litres
Thermostat Opening start 65 °C ±2 °C
Electric fan insertion 103 °C
Electric fan deactivation 102 °C
section
Front wheel
Minimum tread depth In the most worn part 2 mm
Tyre pressure Cold 2.5 bar (rider only)

2.9 bar (with passenger
and/or bags)
Axle runout On 100 mm 0.2 mm
Wheel rim runout Radial 0.8 mm 2 mm
Axial 0.5 mm 2 mm
Front suspension (1200 ASB)

Type MARZOCCHI:
Upside-down hydraulic fork with adjustable
compression, rebound and spring preload.
Fork leg Ø 50 mm
Travel along leg axis 170 mm
Fork Hydraulic damping standard setting. Compression: 1 turn and a half

Undo adjusters from the fully closed Rebound: 2 turns
position (turn counter clockwise).
Spring preload Fully open
Oil charge per leg 720 cm2 (per fork leg) (*)
(*) The value refers to the air column between the free surface of the oil and the end of the sleeve, with the latter fully lowered
and without the preload pipe and spring inside the fork leg.
Front suspension (1200 S ASB)

Type ÖHLINS:
upside-down fork, fully adjustable, hydraulic
rebound damping and compression electronically
managed.
Fork legs Ø 48 mm
Travel along leg axis 170 mm
Fork Oil level per fork leg 170 mm (per fork leg) (*)
Rear wheel
Minimum tread depth In the most worn part 2 mm
Tyre pressure Cold 2.5 bar (rider only)

2.9 bar (with passenger
and/or bags)
Swingarm pivot shaft runout On 100 mm 0.2 mm
Wheel rim runout Radial 0.8 mm 2 mm
Axial 0.5 mm 2 mm
Chain Make REGINA

Type 136 ZRPB
section
Dimensions 5/8" x 1/16"
No. of links 108
Rear suspension (1200 ASB)

Type SACHS:
progressive single shock absorber with adjustable
rebound and compression.
Remote spring preloading adjustment.
Shock absorber Stroke 59.5 mm
Hydraulic damping standard setting. Compression: 1.5 clicks

Undo adjusters from the fully closed Rebound: 9 clicks
position (turn clockwise).
Spring preload 18 mm (Max. 18 mm - Min. 25 mm)
Wheel travel 170 mm
Rear suspension (1200 S ASB)

Type ÖHLINS:
progressive with single shock absorber with adjust-
able rebound, compression and spring preloading.
Shock absorber Stroke 59.5 mm
Wheel travel 170 mm
Hydraulic brakes
FRONT
Brake disc Type Semi-floating drilled dual disc
Minimum thickness 4 mm
Disc thickness 4.5 mm
Braking surface material Steel
Flange material Aluminium
Disc diameter 320 mm
Brake calliper Make Brembo
Type P4.32 K
Calliper cylinder diameter 32 mm
Pad friction material TT2172
Brake master cylinder Type PR 18/19
Master cylinder diameter 18 mm
REAR
Brake disc Type Fixed drilled disc
Shim 5 mm 4.5 mm (min.)
Flange material Steel
Diameter 245 mm
section
Brake calliper Make Brembo
Type P 34c
Calliper cylinder diameter 34 mm
Pad friction material FERIT I/D 450
Brake master cylinder Type PS11
Master cylinder diameter 11 mm
Charging system/alternator
Battery Voltage 12 V
Capacity 10 Ah
Type Sealed, maintenance free
Alternator Capacity 12 V - 500 W
Injection-ignition system
Ignition Type Inductive electric discharge type I.A.W.
Starting Type Electric starter motor, 12 V - 0.7 kW.
Spark plugs Make and type NGK MAR9A-J / MARC9C-J
Electrode gap 0.8±0.1 mm
Fuel system
Make Type
Unleaded fuel 95-98 RON
Throttle body Ø 56 mm
Injectors per cylinder 1
Holes per injector 12
Injection system
Make Type
Electronic Control Unit MITSUBISHI F8TJ
section
Lights/instrument panel
Headlight low beam bulb type 2 x H11 (12V-55W)
high beam bulb type 2xH11 (12V-55W)
Parking light Bulb type LED (13.5 V - 4 W)
Tail light Bulb type LED (13.5 V- 4.2 W/1.5 W)
Front turn signal Bulb type LED (9.8 V - 2.2 W)
Rear turn signal Bulb type RY10W amber (halogen) (12V-10W)
Number plate light Bulb type C5W (12 V - 5 W)
Fuses Regulator 30 A
Front fuse box legend Lights 20 A

Instrument panel 10 A
ECU 5A
Key-sense 15 A
Injection solenoid 20 A
Throttle opening starter motor solenoid (ETV) 10 A
Rear fuse box legend Black Box System (BBS) 7.5 A
Power outlets/navigator/alarms 10 A
ABS 2 25 A
ABS 1 30 A
Fans 10 A
Diagnosis 7.5 A
section
3 - 1.2 Technical data
1.2 - Dimensions
850
170
1530
2200
950
1405
1465
section
3-2 Technical data
2 - Fuel, lubricants and other fluids
Fluids and lubricants Type Quantity
Fuel tank, including a reserve of 4 dm3 (litres) Unleaded fuel with 95 fuel octane rating (at least) 20 dm3 (litres)
Lubrication circuit SHELL - Advance Ultra 4 4.10 dm3 (litres)
Front/rear brake and clutch circuits SHELL - Advance Brake Dot 4 –
Protection for electrical contacts SHELL - Advance Contact Cleaner –
Front fork SHELL - Advance Fork 7.5 or Donax TA 170 mm (per fork leg)
(*) (MTS1200 S ABS)
720 cc (per fork leg)
(*) (MTS1200 S ABS)
Cooling system SHELL Advance Coolant or Glyco SHELL 35-40% 2.3 dm3 (litres)
+ water
Important
Do not use additives in fuel or lubricants.
10W
20W
Uni
20
grade
30
40
20W–40 20W–50
Multi 15W–40 15W–50
grade 10W–40
10W–30
–10 0 10 20 30 40 C
14 32 50 68 86 104 F
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.
Viscosity
SAE 15W-50
The other viscosity grades specified in the table can be used where the average ambient temperatures are within the limits
shown.
section
3-3 Technical data
3 - Torque settings
Frame torque settings
Part Thread (mm) Nm ±10% Notes
Tolerance
Sidestand
Stand sensor bolt 5 Pre-applied threadlocker
Stand plate fixing screw M10x25 43 Pre-applied threadlocker
Side stand fastening pin
Side stand fastening nut M8 20
Front sprocket
Front sprocket retaining nut M25x1.5 186*
Sprocket guard retaining bolt M6x16 6 LOCK 2
Lights and reflectors
Headlight support to chassis fixing screw M8x20 25
Wiring protection on headlamp support fixing screw M5x10 1.5 LOCK 2
Headlight fixing screw M5x22 6
Rear headlamp fixing screw M5x14 3
Front turn signals on hand guard fixing screw M3.5x13 0.5 /0.40
Rear turn signals fixing screw M5x12 3
Left mirror fixing screw M10x1.25 40
Right mirror fixing screw M10x1.25 40
Instruments
Fixing screw on instrument panel M5 By hand
Instrument panel on panel retaining nut M5 3
Front fork
Steering head terminals M6x30 10* GREASE B
Central tightening screw on steering head M8x30 22* GREASE B
Handlebar on head stud bolt (Daniel) M10x1.25 45* LOCK 2
Steering bearing ring nut 3* "GREASE B:
sequence 1-2-1"
Steering limit switch register counter nut M8 18 LOCK 2 on thread nut only
Steering base clamps (Daniel) M8x30 16 ± 5% "GREASE B:
sequence 1-2-1"
Handlebar U-bolt fixing screw (Daniel) M8X25 25*
Front pipe grommet to bottom yoke fixing screw 10
Ohlins fork end terminal fixing screw 19* Sequence 1-2-1
Marzocchi fork end terminal fixing screw 10* Sequence 1-2-1
Splash guard to bottom yoke fixing screw 3 LOCK 2
Electrical/electronic system
Electrical components support to subframe bracket front fixing M6x25 10
screw
Battery bracket fixing screw M5x9 5
Black box bracket fixing screw AF5x16 3.5
section
3-3 Technical data
Tolerance
Vibration damper to black box and bracket retaining nut M5 2 Fit toothed washer
between support and
vibration damper
Solenoid bracket to tank front fixing screw AF5x16 3
Solenoid bracket to tank lower fixing screw M5x12 4
Voltage regulator bracket to electric components housing fixing M6x20 5
screw
Voltage regulator to bracket fixing screw M6x20 10
Electrical components support to frame fixing screw M6x25 6
Mitsubishi control unit bracket fixing screw AF5x16 2
Map Sensor to electrical components support fixing screw M6x18 4
Wiring support to left frame plate fixing screw M5x8 6
Electrical components support to tank fixing screw M5x8.5 5
Left/right light switch fixing screw (Daniel) 1.3
Hands free fixing screw (key lock) 20 LOCK 2
Battery leads and starter motor on solenoid fixing screw 4
Ground cable to crankcase fixing screw 10
Cable to starter motor retaining nut 5
Bolt securing horn to frame 22
Electrical component housing to storage compartment rear 8
fixing screw
Sensor TPRT to front rh half-fairing fixing screw M5x14 5
Power outlet retaining nut 3.5
Rear brake to support STOP switch 5
Cover on wiring support to left plate fixing screw 1.5
Left heated handgrip fixing screw 1.5
Front brake
ABS control unit bracket fixing screw AF5x16 3
Front callipers fixing screw M10x1.25 45* GREASE B
Front brake pump terminal M6x25 10 Sequence 1-2-1 starting
from upper screw
Front brake oil reservoir to hand guard fixing screw 3/2
Front brake hose (pipe grommet) bracket on base fixing screw M6x10 10
ABS tube cover on electrical components housing fixing screw AF5x16 3.5
Front brake calliper pre-tightening M10x1.25 2
Front ABS sensor fixing screw M6x16 10
Rear ABS sensor fixing screw M6x16 10
Rear swingarm
Upper slider and chain guard fixing screw M5x8.5 5 LOCK 2
Lower chain slider fixing screw M5x8.5 5 LOCK 2
Eccentric hub tightening screw M12x1.25 35* "GREASE B:
sequence 1-2-1"
Swingarm pivot tightening screw 72*
section
3-3 Technical data
Tolerance
Rear brake calliper support bracket locking pin 33* LOCK 8
Rear brake
Brake pump and sensor bracket stop to crankcase fixing screw M6x20 10
Rear oil reservoir fixing screw M6x16 2
Rear calliper fixing screw M8x20 25*
Pipe grommet clamps to swingarm fixing screw M6x16 8
Rear brake pipe grommet to swingarm fixing screw M6x15 5
Handlebars - Clutch control
Clutch pump fixing screw (Daniel) M6x25 10 Sequence 1-2-1 starting
from upper screw
Hand guard to right/left pump fixing screw M6x18 10
Hand guard to right/left terminal fixing screw M5x20 5
Piston clutch to crankcase fixing screw M6x20 10 Sequence 1-2-3-1
Oil clutch reservoir to hand guard fixing screw 2
Throttle twistgrip fixing screw 10
Handlebar counterweight fixing screw 2
Rear suspension
Shock absorber upper fixing screw 42* GREASE B
Shock absorber lower fixing screw 42* GREASE B
Ohlins preloading actuator fixing screw M6x15 10
Spring preloading hydraulic press to support (sachs rear shock M5x22 10
absorber) fixing screw
Spring preloading support to left side frame fixing screw 10
Front mudguard
Mudguard to fork fixing screw M6x16 5
Pipe grommet to plastic mudguard plus splash guard fixing M5x9 3.5
screw
Pipe grommet to carbon mudguard fixing screw M5x16
Pipe grommet to carbon mudguard fixing screw
Liquid cooling
Right/left radiator upper fixing screw M6x22 10
Wing on radiator bracket fixing screw M6x10 6
Internal threaded head pin fixing screw 10
Lower radiator fixing screw M5x14 5
Expansion tank fixing screw M6x10 8
Water hose guide clamp (thermostatic valve unit) 2.5
Clamp on water pump tube (piston clutch) 2.5
Expansion tank pipe to radiator fixing clamp 1
Expansion tank pipe fixing clamp 1
Water clamp on radiator 3
Bleed pipe clamp to Horizontal cylinder 1
Water bleed plug on left crankcase 19
section
3-3 Technical data
Tolerance
Footrest and linkage
Brake lever and gearshift on frame plate fixing screw 23 LOCK 2
Spacer on brake lever fixing screw M6x28
Gearshift lever on crankshaft fixing screw M6x18 10 LOCK 1
Gearchange lever tie-rod junction fixing screw M6x20 10
Right/left passenger footrest fixing screw M8X25 24 LOCK 2 on thread
Rear brake linkage to brake lever pivot bolt 5 LOCK 2
Counter nut for rear brake pedal adjuster screw 2.5
Master cylinder pushrod retaining nut 7.5
Handgrip on rear left footrest fixing screw 20
Pannier support rod on rear right/left footrest fixing screw 10
Rear mudguard
Licence plate holder to cover fixing screw M5x12 3
License plate holder unit to storage compartment fixing screw M6x14 6
License plate holder fixing screw M6x18 6
Reflector retaining nut M4x0.7
Mudguard to right side swingarm fixing screw M5x8.5 5
Mudguard to swingarm plus rear brake pipe grommet fixing M5x8.5 5
screw
Carbon mudguard to swingarm plus rear brake pipe grommet M5x8.5 5
fixing screw
Carbon mudguard to right side swingarm fixing screw M5x8.5 5
Splash guard to plastic swingarm fixing screw M6x15 10 LOCK 2 on thread
Splash guard to carbon swingarm fixing screw 10 LOCK 2 on thread
Front wheel
Disc and phonic wheel to wheel rim fixing screw M8x20
Front wheel axle nut 63* GREASE B on the
undersides of the head
and threaded pin
Rear wheel
Phonic wheel to disc fixing screw M5x8 6
Brake disc to pin fixing screw 27
Left/right rear wheel retaining nut M48 230
Rear wheel cush drive retaining nut M10x1 44.0 LOCK 2
Fuel tank
Fuel plug fixing screw M5x30 4
GAC fixing screw M5 6
Front plugs fixing screw M6x30 10
Rear plugs fixing screw M6x40 10
Fuel probe fixing ring nut 8
Exhaust system
Central cover to silencer (Black) fixing screw M5x8 5
Lower silencer cover (Grey) fixing screws 5
section
3-3 Technical data
Tolerance
Upper silencer cover (Grey) fixing screw 5
Starter motor valve to support fixing screw AF4.5x12 2
Lambda sensor fixing 24.5
Starter motor valve support to right footrest bracket fixing 10
screw
Rubber pad for starter motor valve to right plate fixing screw M6x20 10
Exhaust link rod to right/left plate link rod M6x18 10
Left link rod to silencer fixing screw M6x22 10
Right link rod to silencer fixing screw M6x22 10
Drainage to vertical big end retaining nut 10
Drainage to vertical big end retaining nut 10
Drainage to horizontal big end retaining nut 10
Silencer clamp fixing screw 22
C.O. cover screw 25
Bowden cable on the exhaust adjuster nut 2.5
Seat
Saddle lock fixing screw M6 8
Seat lock nut 3
Fixing the retaining pin of the rider saddle 6
Frame
Front frame-plates fixing screw 50* GREASE B
Plate-frame connection rear screw 50* GREASE B
Recovery locking ring nut 100* GREASE B
Frame-engine retaining nut 60* GREASE B
Plates connection brackets fixing screw M8x28 25* GREASE B
Lower plate to right/left crankcase fixing screw M10x28 42* LOCK 8
Rear subframe retaining bolt M8 25*
Clearance adjuster 0.6
Storage compartment to frame fixing screw M8 14*
Carrier side panel to tub lower fixing screw 10
Tub to carrier side panel lateral fixing screw 5
Rear plate to crankcase fixing screw 50*
Oil cooler
Fixing union to radiator (nipple) 23 LOCK 1
Fixing tube to radiator coupling 18 * Lubricate with engine oil
Radiator (to headlight support) upper fixing screw M6x25 6
Tubes plate to crankcase fixing screw M6x14 10
Pressure switch adjustment 19
Air intake oil breather
Funnels to air box fixing screw M5x8.5 5 Solid threadlocker
Duct to air box fixing screw 3.5
Map sensor support to air box fixing screw M6x18 5
section
3-3 Technical data
Tolerance
Map sensor to support retaining nut 5
Blow by to air box fixing screw M5x8.5 5
Clamp on tube valve blow by Clamp Clip 1.5
Injectors to vertical/horizontal funnels fixing screw M5x14 5
Fuel system
Intake funnels to throttle body fixing screw M5x16 2.5 Solid threadlocker
Canister bracket to threaded pin rod fixing screw 5
Nut securing EVAP canister support to bracket M6x20 10
Vertical/horizontal intake manifold throttle body fixing clamp 2.5
GAS cable to throttle body retaining nut 2.5
Fairings
Bracket to crankcase for left gravel guard fixing screw 5
Left oil sump guard plus pipe grommet to plate fixing screw 5
Left gravel guard to bracket on the crankcase fixing screw 5
Left gravel guard support to crankcase stud bolt fixing screw 5
Gravel guard to right frame plate fixing screw 5
Right gravel guard to bracket fixing screw 5
Left/right gravel guard to oil sump guard fixing screw 5
Left oil sump guard to stand bracket fixing screw 24
Right oil sump guard to plate fixing screw 24
Oil sump guard to vibration damper fixing screw 24
Oil sump guard support plate to crankcase fixing screw 24
Cover to central tank fixing screw 4
Right/left panels to lower tank fixing screw 4
Right/left cover (saddle joint) fixing banjo bolt 4
Right/left panel to carrier panel fixing screw 2
Right/left panel to frame and to plate fixing screw 4
Top fairing to headlight support fixing screw 10
Fixing the windshield adjustment slide 5
Slide adjustment knobs stop nut 1.5 LOCK 2
Aerial (HANDSFREE) to top fairing fixing screw Self-tapping 0.7
Windshield to slide fixing screw 3
Right/left panel to top fairing and reservoir fixing screw M5x12 2 Threadlocker
Right/left panel to top fairing fixing screw M5x8.5 2
WING to bracket on right/left radiator fixing screw 5
Front Rh and Lh half-fairing upper joint fixing screw 2
Front Rh and Lh half-fairing lower joint fixing screw 2
Front Rh/Lh half-fairing to reservoir panel fixing screw 2
Right/left deflector to reservoir panel fixing screw 2
WING to front half-fairing fixing screw M3.5X16 1
section
3-3 Technical data
Tolerance
Balk berry holder (right) /relay cover (left) fixing screw 2
Balk berry holder (right) /relay cover (left) fixing screw 4
*dynamic safety-critical point; tightening torque must be within Nm ±5%.
Note
For product specifications and symbols, refer to “Product specifications” (Sec. 1 - 2).
section
3-3 Technical data
Engine torque settings
Part Thread (mm) Nm Min. Max. Notes
Idler and tensioner pulley bolts M20x1 50 45 55 LOCK 2 or TB1324
Camshaft pulley retaining nut M17x1 71 64 78 GREASE A
Rocker arm shaft covers M12x1.25 15 14 16 LOCK 2 or TB1324
Coolant temperature sensor on coolant outlet union M12x1.5 23 20 26 LOCK 4 – Restrain the
insert when tightening
Cylinder head nut: M10x1.5 Apply GREASE C to the
Snug torque 20 underside of the nut and
Preload torque 40 38 42 the thread of the stud
Tightening torque 60 57 63
Cam cap bolt: M8x1.25 Engine oil
Preload torque 10 9 11
Tightening torque 22.5 21 25
Coil retaining bolt M6x1 10 9 11
Pulley flange retaining bolts M6x1 10 9 11
Cylinder head cover bolt M6x1 10 9 11
Exhaust manifold stud M6x1 10 9 11 LOCK 5
Vacuum gauge connection screw on cylinder head M6x1 5 4 6 LOCK 2 or TB1324
(EU only)
Evaporative emissions canister fitting on cylinder M6x1 5 4 6 LOCK 2 or TB1324
head (California only)
Air breather fitting on horizontal cylinder head M6x1 2.5 2 3 LOCK 2
Air breather blanking screw on vertical cylinder head M6x1 10 9 11 LOCK 6
Intake manifold bolt M6x1 10 9 11
Water temperature sensor M6x1 6 5 7
Bolts securing coolant unions to cylinder head M5x1 6 5 7 Pre-applied Tecnologic 150
threadlocker
Oil cartridge M16x1.5 11 10 12 Engine oil on gasket
Oil cartridge nipple M16x1.5 42 38 46 LOCK 2 or TB1324
Oil pick-up pipe plug M14x1.5 24 21 27 LOCK 5
Oil cooler nipple M14x1.5 32 29 35 LOCK 5
Oil drain plug with magnet M12x1.5 20 18 22 THREEBOND TB1215
0603 Gear position sensor M12x1.25 12 11 13
Clutch cover oilway blanking plug M10x1.5 15 13 17 LOCK 5
Neutral sensor M10x1.25 10 9 11
Oil pump adapter bolt M10x1 LOCK 5
Clutch cover inner oilway screw M10x1.5 15 13 17 LOCK 5
Cylinder head/barrel stud M10x1.5 30 28 32 LOCK 2 or TB1324
Vertical cylinder zone crankcase bolt: M8x1.25 GREASE B or Agip GR SM
Preload torque 19 17 21 on thread
Central crankcase bolt + swingarm pivot bolt: M8x1.25 GREASE B or Agip GR SM
Preload torque 19 17 21 on thread
Gear stop lever bolt M8x1.25 18 16 20 LOCK 2 or TB1324
Blow-by valve fixing screw M6x1 10 9 11
Chain side secondary bearing retaining bolt M6x1 10 9 11 LOCK 2 or TB1324
section
3-3 Technical data
Clutch side primary bearing retaining bolt M6x1 10 9 11 LOCK 2 or TB1324
Crankcase bolt – idler area M6x1 10 9 11
Outer crankcase bolt M6x1 10 9 11
Oil pick-up gauze filter bolt M6x1 10 9 11 TB1215
Chain cover oil circuit blanking screw M6x1 8 7 9 LOCK 2 or TB1324
Under-piston oil jet retaining screw M5x0.8 8 7 9 LOCK 2 or TB1324
Starter motor mounting bolt M6x1 10 9 11 Loctite 516 pre-applied to
thread
Starter motor rear bolt M6x1 10 9 11 Loctite 516 pre-applied to
thread
Idler gear shaft retaining bolt M6x1 10 9 11 LOCK 2 or TB1324
Primary sprocket nut retainer M24x1 190 171 209 GREASE B
Ring nut fastening wet clutch primary pinion M24x1 190 171 209 GREASE B
Flywheel retaining nut M24x1 330 313 346 LOCK 5
Balancing cap M12x1.25 28 26 30 LOCK 5
Con-rod bolts: M10x1 Apply GREASE B to thread
Tightening of 45°±1° 30
Torque check 65 to 95
Crankshaft grub screw M8x1.25 13 11 15 LOCK 5
Drilled crankshaft grub screw M8x1.25 13 11 15 LOCK 5
Selector drum locating screw M16x1.5 30 27 33
Selector claw bolt M8x1.25 36 34 38 LOCK 2 or TB1324
Selector claw locator nut M6x1 10 9 11
Selector claw bolt M6x1 16 15 17 LOCK 2 or TB1324
Idler and tensioner pulley bolts M20x1 50 45 55 LOCK 2 or TB1324
Timing belt driveshaft pulley retaining nut M15x1 71 64 78 GREASE A
Timing belt driveshaft gear nut M14x1 55 50 60 GREASE A
Fixed tensioner bearing locking screw M14X2 50 45 50 GREASE A
Idler and tensioner pulley nut M8x1.25 25 22 28 GREASE A
Carbon fibre cover bolts M6x1 6 5.5 6.5 Loctite 516 pre-applied to
thread
Plastic cover bolt M6x1 10 9 11 Loctite 516 pre-applied to
thread
Carbon filter cover support fixing screw M4x0.7 1.75 1.5 2
Self-tapping screw for timing belt cover filter M3.5
Coolant inlet union M30x1.5 25 23 27 LOCK 5
Coolant outlet union M22x1.5 25 23 27 LOCK 5
Oil filler plug M20x2.5 Tighten as far as it will go
Alternator cover inspection plug M15x1 20 18 22 TB1215
Pick-up sensor inspection bolt M12x1 15 13 17 LOCK 2 or TB1324
Water pump cover plug M10x1 20 18 22
Oil pressure sensor M10x1 19 17 21
Clutch oil pan cap M10x1 15 13.5 16.5
Oil way blanking plug M10x1 20 18 22 LOCK 5
Coolant pump bearing stop screw M6x1 10 9 11 LOCK 2 or TB1324
section
3-3 Technical data
Stator wiring clamp bracket bolt M6x1 10 9 11 LOCK 2 or TB1324
Water pump cover screw M6x1 10 9 11
Alternator-side crankcase cover bolt M6x1 10 9 11
Alternator cover screw - idle gear M6x1 10 9 11
Alternator-side crankcase cover + water pump bolt M6x1 10 9 11
Inspection cover bolt M6x1 5 4.5 5.5
Alternator-side crankcase cover bolt M6x1 10 9 11
Alternator stator retaining bolt M6x1 10 9 1 LOCK 2 or TB1324
Clutch cover bolt M6x1 10 9 11
Clutch cover bolt M6x1 10 9 11
Wet clutch cover closing screw M6x1 10 9 11
Wet clutch drum nut M25x1.5 190 180 200 GREASE B
Wet clutch spring screw M6x1 10 9 11
Spark plug M10x1 12 11 13
Alternator rotor/flywheel bolt M6x1 13 11 15 LOCK 5
By-pass pump cap M15x1 25 22 28 LOCK 5
Oil pump retaining bolt M6x1 10 9 11
Oil pump assembly bolt M6x1 10 9 11
Oil pump retaining bolt M8x1.25 26 23 29
Coolant outlet union M22x1.5 25 23 27 LOCK 5
Coolant circuit hose clamps 2.5 2 3
*dynamic safety-critical point; tightening torque must be within Nm ±5%.
Note
For product specifications and symbols, refer to paragraph “Product specifications” (Sec. 1 - 2).
section
3-4 Technical data
4 - Service tools
Spare parts catalogue
MTS 1200 ABS WORKSHOP SERVICE TOOLS
MTS 1200 S ABS WORKSHOP SERVICE TOOLS
Specific tools for the engine

Code no. Description
88713.2011 Tool to lock crankshaft at Top Dead Centre
88713.2676 Wrench for tightening cylinder head nuts
88713.2103 Stand for cylinder head assembly
88713.0123 Timing check tool
Wrench for tightening timing belt tensioner

88713.1821
pulley shafts
88713.2861 Camshaft oil seal installer
section
3-4 Technical data
88713.2060 Gearbox output shaft oil seal installer
88713.1806 Holding tool for pulley tightening
DDS (Ducati Diagnosis System) +

97900.0215
cylinder vacuum meter kit
88765.1518 Valve lift gauge
88713.2878 Fork-type feeler gauge 0.2 mm, 0.3 mm
88713.2874 Alternator holding tool for tightening nut
88713.1920 Tool for installing O-rings on crankcase studs
section
3-4 Technical data
88713.3334 Plate for gear selector fork positioning
Tool for installation of sealing ring on

88713.2442
valve-guide
88713.1749 Puller for drive pulley and cover
88713.1832 Engine repair bench
88713.2651 Wet FCC clutch drum holding tool
88765.1609 Distribution pulley timing tool
88713.1886 Engine cover sheet
section
3-4 Technical data
88713.1010 Exhaust gases pick-up connector
88713.1805 Tool for tightening timing belt driveshaft pulley
88765.1188 Top Dead Centre test gauge
88713.3219 Holding tool for pulley tightening
88713.0869 Water pump front seal installer
Installation tool for counter plate for water

88713.0870
pump front seal
88700.5749 Crankcase assembly cap
section
3-4 Technical data
88713.2877 Sparkplug wrench
88713.1980 Punch for installing caps on shafts
88713.2832 Timing belt tensioner pulley wrench
88765.1298 Spacer lower register control valve
88713.2870 Connecting rod guide tool
88713.2834 Punch and sleeve for installing camshaft circlip
88713.2422 Wrench for tightening primary sprocket nut
section
3-4 Technical data
88713.2906 Oil filter cartridge wrench
88713.2423 Torque wrench for tightening front sprocket nut
section
3-4 Technical data
Specific tools for the frame

88713.1072 Drift to install half bearing in bottom yoke
88713.2562 Chain assembly tool
88713.1058 Wrench for steering stem nut
88713.1062 Tool for installing steering head bearings
Drift for installing the rocker arm needle roller

88713.1071
bearings
88713.2951 Rear wheel balancing tool
section
3-4 Technical data
88713.3211 Wrench for adjustment of the eccentric hub
MARZOCCHI fork service tool - Sealing ring

88713.3204
fitting
88713.3203 Pull bar for MARZOCCHI fork service
88713.1074 Swingarm pivot bolt removal tool
88713.0957 Retainer for SHOWA fork spacer
Drift for installing the swingarm needle roller

88713.1068
bearings
88713.2409 Swingarm ball bearing installation tool
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3-4 Technical data
88713.2856 Bar guide tool
88713.2857 Tool for removing the sliding bushes
88713.2858 Tool for installing the sliding bushes
88713.2855 Bush support rod
88713.2854 Bush to install/remove the fork plug
88713.3220 Engine repair bench
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3-4 Technical data
MTS 1200 ABS DDS TESTER
MTS 1200 S ABS DDS TESTER
Appropriate diagnosis tools

DDS (Ducati Diagnosis System)

97900.0211
without cables
97900.0227 Power cable and diagnosis
Power cable and diagnosis 1060838

97900.0222
(Measurement Module)
97900.0218 Vacuum sensor
552.1.039.1A Pressure sensor
97900.0220 Pressure/vacuum tube
section
3-4 Technical data
97900.0221 Union
97900.0228 Battery socket adapter
814.1.114.1A Oil pressure coupling
514.1.032.1A Auxiliary test cable
552.1.038.1A Cylinder compression cable M10 fitting
875.1.065.1A Oil pressure tube
97900.0230 Feeder
section
3-4 Technical data
97900.0224 Feeder
88765.1371 Belt tensioning sensor
88765.1374 Belt tensioning sensor bracket
590.1.189.1A Fuel pressure tube
88765.1126V Ammeter clamp
section
4 Maintenance operations
1 - Vehicle pre-delivery 3
2 - Scheduled maintenance chart 4

List of operations to be performed at 1000 km 4
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
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 chain tension 52
Checking brake pad wear and changing brake pads 54
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
section
4-1 Maintenance operations
1 - Vehicle pre-delivery
1
section
4-2 Use and Maintenance
2 - Scheduled maintenance chart
Operations to be carried out by the dealer
List of operations to be performed at 1000 km

Reading of the error memory with DDS on the engine control units, vehicle and ABS
Change the engine oil
Change the engine oil filter
Check the indicators and lighting
Check the safety devices (side stand switch, clutch lever switch, right switch engine stop switch and gear position sensor)
Check the battery charge level
Clean the engine oil intake filter
Checking the coolant level
Check the brake and clutch fluid levels
Check brake discs and pad wear.
Check tyre pressure and wear
Check the drive chain tension and lubrication
Check freedom of movements of the side and central stand
Check the tightening of the safety components (ex. wheel disc nuts, brake callipers, sprocket tightening)
Check rubbing points, clearance and freedom of movement of the flexible cables and electric wiring in view
Road test of the motorcycle, testing the safety devices (ex. ABS)
Fill out that the service was performed in the Warranty Certificate
section
Operations to be carried out by the dealer
List of operations to be performed every 12000 km / year (first limit reached)

Change the engine oil
Change the engine oil filter
Check and/or adjust valve clearance (only every 24000 km)
Replace the timing belts (only every 24000 km/60 months)
Replace the spark plugs (only every 24000 km)
Replace the air filter (only every 24000 km)
Replace the front fork oil (only every 24000 km)
Replace the coolant (only every 24000 km)
Check the indicators and lighting
Check the safety devices (side stand switch, clutch lever switch, right switch engine stop switch and gear position sensor)
Check the battery charge level
Check the brake and clutch fluid levels
Check brake discs and pad wear.
Check tyre pressure and wear
Check the drive chain tension and lubrication
Check final drive wear
Check and lubricate the rear wheel shaft (only every 24000 km)
Check freedom of movements of the side and central stand
Check the tightening of the safety components (ex. wheel disc nuts, brake callipers, sprocket tightening)
Check rubbing points, clearance and freedom of movement of the flexible cables and electric wiring in view
Road test of the motorcycle, testing the safety devices (ex. ABS)
Fill out that the service was performed in the Warranty Certificate
Operations to be carried out by the customer
List of operations to be performed every 1000 km

Check the level of the engine oil
Adjust chain tension
1
section
3 - Maintenance operations
Check if there are errors according to the procedure described in the paragraph “Guided diagnosis” (Sec. 6 - 13).
Checking the engine oil level

Check the engine oil level through the sight glass (1) on the right-hand side of the oil sump.
Stop the engine and allow a few minutes for the oil to settle to a steady level.
Check the level with the motorcycle perfectly vertical and with the engine warm (but not running).
The oil must be between the MIN and MAX marks. If the level is low, top it up.
Remove the filler cap (2) and top up with the recommended oil.
Refit the filler plug (2).
1 MAX
MIN
section
Changing the engine oil and filter cartridge
Note
This operation has to be carried out with hot engine (but turned off) because the oil in these conditions is more fluid and its
evacuation is faster and complete.
Remove the under-sump assembly (3) loosening the fixing side screws (4) and the lower fixing nut (5).
3
4
3 4
3 5
section
Remove the drain plug (6) with seal (A) from the oil sump and allow the oil to drain off.
Warning
Dispose of oil and/or filter cartridges in compliance with environmental protection regulations.
Remove any metallic deposits from the end of the magnetic drain plug (6). Clean the threads of the drain plug and apply
THREE BOND TB1215. Refit the drain plug complete with gasket (A) to the sump.
Tighten the exhaust plug (6) to the torque of 20 Nm (Sec. 3 - 3, Frame torque settings).
Remove the oil sump filter cartridge (7) using the tool code 88713.2906.
Important
Dispose of the used cartridge, do not attempt to reutilise it.
Fit a new cartridge (7), using the tool code 88713.2906 making sure to lubricate the gasket with engine oil.
88713.2906
section
Note
As an alternative, it is advisable to refill the filter cartridge with engine oil (7) before fitting it: this enables the recommended oil
level to be maintained without topping up.
Screw it in its seat and tighten it to the torque of 11 Nm (Sec. 3 - 3, Frame torque settings).
Every two oil changes, clean the oil pickup gauze filter.
Unscrew the four screws (8) of the external cap (9) and remove it.
Remove the filtering element (10) and check the O-rings (11) and (12), replace them if necessary.
Clean the filter with petrol and compressed air. Take care not to damage the gauze.
10
11
10
section
12
Place the O-ring (12) on the crankcase and the (11) on the mesh filter (10).
12
11
10
Refit the mesh filter (10).
10
section
Apply a bead of liquid gasket to the cap (9) as shown in the figure.
Remove the filler plug (2) and carry out refilling with the specified oil type (Sec. 3 2, Fuel, lubricants and other fluids)
up to reaching the notch that identifies the MAX level in the sight glass (1).
Refit the filler cap (2). Run the engine at idle speed for a few minutes.
1 MAX
MIN
section
Check that there are no oil leaks and that the engine oil pressure warning light on the instrument panel switches off some
seconds after starting up the engine. If not, switch off the engine and trace the fault.
After a few minutes, check that the oil level is the specified one; if necessary, restore the MAX level.
Tighten the fixing screws (8) of the external cap (9) to the torque of 10 Nm (Sec. 3 - 3, Frame torque settings).
section
Refit the oil sump guard (3) with the lower fixing screw (5) and the side fixing screws (4).
3
4
3 4
3 5
Note
The short screw (4) fixes the oil sump guard to the brake mounting plate.
Tighten the screws (4) and (5) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
Checking valve clearances
To check the valves clearance, it is necessary to have access to the cylinder head covers and then remove the components listed
below.
Operation Section reference

Remove both saddles 5 - 3, Removal of the seat
Remove the tank covers 5 - 2, Removal of the fuel tank fairings
Remove the fuel tank 8 - 1, Removal of the fuel tank
Remove the filter box without 8 - 6, Disassembly of the airbox – throttle
disconnecting the throttle cables and body
support it adequately
Remove the coils 6 - 13, Removing the coils
Undo the upper fixing screws of the timing 9 - 4.2, Removal of the timing belt covers
system belt plate covers
Remove the cylinder head covers 9 - 4.4, Removal of the camshafts
Unscrew the two fixing screws (1) of the cover (2) according to the crankshaft.
Fit the tool handgrip 88713.0123 in the holes of the generator cover to be able to turn the crankshaft so that the valve on which
the control is carried out is in rest position.
88713.0123
section
With the valve in the rest position, slide a feeler gauge between rocker arm (A) and the lowest side of the cam (B) to measure
the clearance.
The clearances must be within the specified limits:
Opening rocker arm

INTAKE:
Operation 0.13 to 0.18 mm
Checking clearance 0.10 to 0.25 mm
EXHAUST:
section
With the valve in the rest position, slide a feeler gauge between closing rocker arm (C) and the highest side of the cam (D)
to measure the clearance.
Closing rocker arm

INTAKE:
EXHAUST:
C D
C D
C D
If detected values exceed the specified limits, replace opening and/or closing shims, as described in paragraph “Removing the
valves” (Sec. 9 - 4.5), with an adequate height to obtain the specified clearance.
Note
Opening rocker arm shims measuring from 1.8 to 3.45 mm and closing rocker arm shims measuring from 2.2 to 4.5 are available
as spare parts. the size is punched on the shim.
section
Remove the handgrip tool 88713.0123 from the hole of the generator cover.
Make sure that the O-ring (3) is fitted on the cover (2).
Refit the cap (2) by tightening the two fixing screws (1) to the torque of 10 Nm.

Refit the cylinder head covers 9 - 4.4, Refitting the camshafts
Tighten the upper fixing screws of the 9 - 4.2, Refitting the timing covers
timing system belt plate covers
Refit the coils 6 - 13, Ignition coils
Refit the air filter box 8 - 6, Reassembly of the airbox – throttle
body
Refit the fuel tank 8 - 1, Refitting the fuel tank
Refit the fuel tank fairings 5 - 2, Refitting the fuel tank fairings
Refit both saddles 5 - 3, Refitting the seat
Renew the timing belts

To replace the timing system belts follow the procedures described in paragraph “Removal of the movable tensioner/timing belt”
and “Refitting the timing belts” (Sec. 9 - 4.2).
section
Spark plugs replacement
Remove both saddles 5 - 3, Removal of the seat
Remove the front half-fairing 5 - 2, Removing the front half-fairing
Remove the fuel tank fairing 5 - 2, Removal of the fuel tank fairings
In order to reach the vertical cylinder head spark plugs remove the tank by loosening the screws (19) and (20) and by installing a
pad under it.
section
Disconnect the fuel sensor connector (3), the fuel pump connector (4) and the snap fittings (5) of the flange.
In order to access the horizontal spark plugs big end unscrew the water radiator fixing screws (6) slightly moving it upwards.
section
Remove the HT leads (7), unscrewing the nuts (8) of both spark plugs.
Using the appropriate tool cod. 88713.2877 replace the spark plugs.
8
7
8
7
Place the HT leads (7) inside the respective seats and screw the nuts (8) by tightening them to the specified torque (Sec. 3 - 3,
Frame torque settings).
8
7
8
7
section
Fix the water radiator to the mounting by fitting and tightening the screws (6) to the specified torque (Sec. 3 - 3, Frame torque
settings).
Connect the fuel sensor connector (3), the fuel pump connector (4) and the snap fittings (5) of the flange.
section
Refit the fuel tank by tightening the screws (1) and (2) to the specified torque (Sec. 3 - 3, Frame torque settings).

Refit the tank fairings 5 - 2, Refitting the fuel tank fairings
Refit the front half-fairing 5 - 2, Refitting the front half-fairing
Refit both saddles 5 - 3, Refitting the seat
section
Changing and cleaning the air filters
The air filter must be replaced at the intervals described in the “Scheduled maintenance chart” (Sec. 4 - 2).

Remove the tank covers 5 - 2, Removal of the fuel tank fairings
Working on the right side of the vehicle, unscrew the fixing screws (1) of the intake duct (2).
Remove the intake duct (2).
Pull out the filter cartridge (3) from the seat in the filter box.
The filter cartridge can be cleaned with a jet of compressed air or renewed as necessary.
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.
section
Reinstall correctly the cartridge into the seat of the filter box, place the intake duct (2) with the rubber (4).
Fit and tighten the screws (1) to the specified torque (Sec. 3 - 3, Frame torque settings).
2 4
Important
If the motorcycle is used in very damp or dusty conditions, the air filter cartridge must be changed more frequently.
Check the air filter (4) in the horizontal timing belt cover (5).
Unscrew the screws (6) fixing the horizontal belt timing cover (5) and remove it from the horizontal cylinder assembly.
5
6
section
Unscrew the screws (7) and remove the filter (4).
Once the check is over, refit the filter (4), tighten the screws (7) and refit the horizontal timing belt cover (5) at the horizontal
cylinder assembly by tightening the screws (6) to the specified torque (Sec. 3 - 3, Frame torque settings).
5
4

Refit the fuel tank covers 5 - 2, Refitting the fuel tank fairings
section
To the specified intervals in the “Scheduled maintenance chart” (Sec. 4 - 2) check the coolant level contained in the expansion
tank, on the right side of the vehicle.
The coolant level must be between the MAX and MIN marks on the tank.
If the level is low, top up with the recommended coolant.
Remove the filler cap (1) and top up with new coolant to the specified level.
Refit the plug (1).
MAX
MIN
For optimal operating conditions (coolant mixture starting to freeze at -20 °C), the recommended liquid antifreeze should be
mixed with water in the following percentages:
ANTIFREEZE: 35 to 40% of the volume;
WATER: 65 to 60% of the volume.
Important
Very hard water with a high mineral salt content can damage the engine.
Increase the amount of coolant to up to 55% volume in the case of very cold climates.
Important
Solutions with less than 30% of coolant will not provide sufficient protection against corrosion.
section
Change the coolant
Warning
This operation must only be carried out when the engine is cold. Attempting to change the coolant with the engine hot could lead
to burns from hot coolant or scalding steam.
Place a container under the engine and place the motorcycle on its side stand.
Remove the complete oil sump guard (1) unscrewing the side fixing screws (2) and the lower fixing screws (3).
1
2
1 2
1 3
Remove the expansion tank filler cap (4).
section
Remove the right wing (5) unscrewing the screws (6) and unhooking the tongue (A) from the slot on the front half-fairing.
Unscrew the screws (7) and the inner fixing screws (8) to the front right half-fairing (9).
section
Disconnect the casing (10) from the air-box resonator, the air temperature sensor connector (11) and remove the right front
half-fairing (9).
10
11
section
Loosen the clamp (12) by unscrewing the screw (13), disconnect the pipe (14) and allow the coolant to flow in a container.
14
13
12
Loosen the cap (15) of the liquid exhaust hole placed on the pump cover.
Allow the coolant to drain off completely.
Screw the cap (15) with a new gasket in the liquid drain hole.
15
Refill the circuit by pouring the new coolant from the remote cap.
section
Connect the pipe (14) tightening the screw (13) to the clamp (12).
14
13
12
Allow several minutes for the coolant to fill all the internal passages.
Start up the engine and allow the coolant to reach 110 °C; run the engine for about 10 minutes.
Stop the engine and allow it to cool down so that all the air is expelled from the cooling circuit.
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 cooling circuit for possible leaks.
Top up the coolant through the expansion tank filler to bring the level up to the MAX mark.
Tighten the cap (1) of the expansion tank.
MAX
MIN
section
Refit the right front half-fairing (9) by connecting the casing (10) to the air box resonator and the air temperature sensor connector
(11).
11
10
Fit the screws (7) and the inner fixing screws (8) to the front right half-fairing (9).
section
Refit the right wing (5) by fitting the screws (6) and the tongue (A) of the slot on the right front half-fairing.
Tighten the screws (6), (7) and (8) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
Refit the complete oil sump guard (1) by fitting the bottom fixing screw (3) and the side fixing screws (2).
1
2
1 2
1 3
Note
The short screw (2) fixes the oil sump guard to the brake mounting plate.
section
Changing the brake fluid
Warning
Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In the case of accidental contact, wash the
affected area thoroughly with plenty of running water.
Changing the fluid in the front brake circuit

Remove the cover (1) with the membrane from the front brake fluid tank (2) by undoing the screws (3).
Siphon off the fluid from the reservoir (2).
Replace the membrane (without the plug) on the tank to avoid brake fluid splashes during the following operations.
Move the brake callipers pistons back: to carry out this operation unscrew the fixing screws (4) of the callipers on the fork plates
and push, by removing them from each other, both pads from every calliper; during this operation be careful with the fluid level,
that must always be aspirated each time that it flows back in the tank.
section
Once that all pistons of both callipers are fully moved back and that all the liquid in the tank has been aspirated, connect to the
bleed valve (5) a transparent canula by immersing the end in a container placed on the floor.
Fill the reservoir (2) with new brake fluid up to the MAX mark.
MAX
MIN
2
Operate the lever to reach the 20-30 mm end of stroke and keep the lever in this position by using a non-elastic clamp.
20-30 mm
Loosen the bleed valve of the left calliper (from the rider view) (5) and then take the lever through the whole stroke to allow fluid
to escape.
The lever is supported to the grip.
section
Tighten the bleed valve (5) to the specified torque (Sec. 3 - 3, Frame torque settings) then release the lever.
Repeat the operation described above until the old liquid flows completely.
Then, with the bleed valve definitely closed to the specified torque actuate repeatedly the lever until a pressure is detected in
the brake system.
Warning
After the elimination of the old fluid from the tank, during the refill operation always keep the oil level above the MIN mark to
prevent the formation of air bubbles inside the circuit.
section
Changing the rear brake circuit fluid
Unscrew the cap (6) of the rear brake fluid reservoir (7).
Attach a length of transparent plastic tubing to the bleed valve (8) and insert the other end of the tubing in a container placed on
the floor.

Fill the reservoir (7) with new brake fluid up to the MAX mark.
MAX
7 MIN
Press the pedal to allow the circuit to go under pressure.

Keep the pedal pressed to the bottom.
section
Loosen the bleed valve (8) to allow fluid to escape.
The pedal is at the end of the stroke in lower position.
At this point, tighten the bleed valve (8) to the specific torque (Sec. 3 - 3, Frame torque settings) and release the pedal; press the
pedal.
Repeat the operation described above until the old liquid flows completely.
Warning
After eliminating the old fluid from the tank, during the refilling operation always keep the oil level above the MIN mark to prevent
the formation of air bubbles inside the circuit.
section
Draining the brake circuit
Warning
Remove the cover (1) with the membrane from the front brake liquid tank (2) by unscrewing the screws (3) or unscrewing the
cap (6) of the rear brake liquid tank (7).
Connect to the bleed valve (5) of the left front calliper or to the bleed valve (8) of the rear calliper one bleeder for brakes, usually
available in stores.
Note
Follow the manufacturer's instructions when using a commercial brake bleeding tool.
section
Tighten the bleed valve (5) or (8) and suck with the bleeder until there is no more fluid in the system.
In case the bleeder is not available, connect to the bleed valve (5) of the left front calliper or to the bleed valve (8) of the rear
calliper, a transparent plastic canula and dip the end into a container placed on the floor and with used brake fluid.
Loosen the bleed valve.

Operate the brake lever (or pedal) until all the fluid has drained out.
Repeat this operation for each brake calliper.
Note (front system)

With this procedure in the front system the front callipers fluid-filled remain; in case the callipers also need to be emptied, it is
necessary to carry out a retreat piston operation described in the chapter “Changing the brake fluid” keeping the bleeder (if avail-
able) still running and connected to the bleed valve.
Note (rear system)

If there is no bleeder, carry out piston retreat operation described in the chapter “Changing the brake fluid”.
section
Filling the brake system with fluid
Warning
Refill the tanks (2) or (7) with specific oil (Sec. 3 - 2, Fuel, lubricants and other fluids) taken from an intact container.
MAX
MIN
2
MAX
7 MIN
Important
During the following operation, the fluid level in the tank must remain topped over the MIN mark all times. The end of the trans-
parent plastic pipe must remain immersed in the discharged fluid at all times.
section
Operate the lever or the brake pedal and keep it actuated during the refilling.
Connect to the bleed valve (5) of the left front calliper or to the bleed valve (8) of the rear brake the bleeder.
Note
Follow the manufacturer's instructions when using a commercial brake bleeding tool.
section
Aspirate with bleeder and loosen the bleed valve (5) or (7) always checking that the level of the corresponding tank does not fall
below the MIN.
Continue this procedure until all the air is expelled from the system.
Close the bleed valve to the specified torque (Sec. 3 - 3, Frame torque settings).
If you do not have a brake bleeding tool available, connect a transparent plastic canula to the bleed valve (5) or (8) as described
in the exhaust procedure.
Press the lever or the pedal half way or until the pressure in the system is detected, open the bleed valve and take the lever or
pedal through the whole stroke; Tighten the bleed valve to the specified torque and release the lever or the pedal.
Important
Do not release the brake lever (or pedal) until the bleed valve has been fully tightened.
section
Repeat the operation until the liquid inside the system is air-bubble free; For this purpose, when refilling is over, carry out bleeding
operation by acting on all the valves of the system, one at a time.
In particular, to completely eliminate the air that can remain on the highest point of the front brake pump, act the same way on
the bleed valve (9).
Finally check that with the bleed valves closed the activation of the pressure with the lever or pedal is correctly.
Tighten all the bleed valves to the specified torque (Sec. 3 - 3, Frame torque settings) and install the protection cover.
Level the liquid and refit the cover (1) by tightening the screws (3) on the tank (2) or the cap (6) on the tank (7).
1
3
MAX
MIN
2
MAX
7 MIN
section
Changing the clutch fluid
Warning
Clutch fluid will damage painted surfaces if spilled on them. It is also very harmful if it comes into contact with the skin or with
the eyes; in the event of accidental contact wash the affected area with abundant running water.
Remove the cover (1) with membrane of the clutch fluid tank system (2).
Fill the tank (2) with new oil up to the MAX mark.
MAX
MIN
2
Operate the clutch lever two or three times until the circuit is pressurised.
Hold the lever pulled in towards the grip.
Attach a length of transparent plastic tubing to the bleed valve (3) and insert the other end of the tubing in a container placed on
the floor.
Open the bleed valve (3) to allow fluid to escape.
Warning
During the filling operation, always keep the oil level above the MIN mark to prevent the formation of air bubbles in the circuit.
Allow the fluid to flow from the bleed valve (3) until it changes colour. Retighten the bleed valve (3) and tighten to the specified
torque (Sec. 3 - 3, Frame torque settings) and restore the correct level of oil in the tank.
section
Draining the clutch hydraulic circuit
Warning
the eyes; In the case of accidental contact, wash the affected area thoroughly with plenty of running water.
Remove the dust cap to expose the bleed valve (3).

Connect a clutch circuit bleeding tool to the clutch slave cylinder bleed valve (3).
Note
Follow the manufacturer's instructions when using a commercial clutch bleeding tool.
Remove the cover (1) with membrane of the clutch fluid tank system (2).
Open the bleed valve and pump with the bleeding tool until no more fluid emerges.
If you do not have a bleeding tool available, attach a length of transparent plastic tubing to the bleed valve (3) and insert the other
end of the tubing in a container of old clutch fluid placed on the floor.
Unscrew the bleed valve by a 1/4 turn.

Operate the clutch lever until all the fluid has been expelled.
section
To completely empty the circuit it is advisable to remove the cap of clutch recover.
Remove the clamps (A) and release the clutch tube (4) from the side stand wire (B).
Loosen the screws (5) and slide off the clutch recover unit (6) paying attention to the O-ring (7) positioned on its inside.
A 5
4
B 6
5
Push in the internal piston to force out all the fluid from inside the cap.
Proceed with the refitting of the cap by tightening the fixing screws (5) to the specified torque (Sec. 3 - 3, Frame torque settings).
Tighten the bleed valve to the specified torque (Sec. 3 - 3, Frame torque settings).
Strip the clutch pipe (4) to the side stand wire (B) and insert this last one into the breaker (C).
B
C
section
Filling the clutch circuit
Warning
the eyes; In the case of accidental contact, wash the affected area thoroughly with plenty of running water.
Fill the tank with specified oil (Sec. 3 - 2, Fuel, lubricants and other fluids) taken from an intact container.
Important
During the following operation, the fluid level must remain topped up at all times. The end of the transparent plastic tubing must
remain immersed in the discharged fluid at all times.
MAX
MIN
Operate the clutch lever and keep it pulled to fill the circuit and expel any air.
Connect the bleed tool to the bleed valve (3).
Note
Follow the manufacturer's instructions when using a commercial clutch bleeding tool.
Pump with the bleeder and open the bleed valve (3) making sure that the level does not fall below the MIN mark.
Repeat the bleeding operation until the fluid flowing from the tube is completely free of air bubbles.
If you do not have a bleeding tool available, connect a length of transparent plastic tubing to the bleed valve (3) as outlined in the
draining procedure.
section
Open the bleed valve by a 1/4 turn and operate the clutch lever several times until the fluid flows out of the bleed valve (3).
Pull the lever fully in and then loosen the bleed valve by at least a 1/4 turn.
Wait for a few seconds; then release the lever gradually while simultaneously closing the bleed valve (3).
Important
Do not release the clutch lever until the bleed valve has been fully tightened.
Repeat the bleeding operation until the fluid emerging from the plastic tube is free of air bubbles.
Close to the specified torque (Sec. 3 - 3, Frame torque settings) the bleed valve (3) and install the protection cover.
Top up the fluid level to approximately 3 mm above the MIN mark of the tank.
Refit the cover with membrane (1).
MAX
MIN
section
Adjusting the steering head bearings
Excessive handlebar play or shaking forks in the steering head indicate that the play in the steering head bearings requires ad-
justment. Proceed as follows:
Loosen the clamp screw (1) that holds the steering tube to the top yoke.
Slacken the clamp screws (2) securing the top yoke to both fork legs.
With specific wrench 88713.1058 tighten the ring nut (3) of registration to the specified torque (Sec. 3 - 3, Frame torque settings).
Push the steering head against the ring (3) and tighten the screws loosened previously to the specified torque (Sec. 3 - 3, Frame
torque settings).
88713.1058
3
section
Adjusting the chain tension
Move the motorcycle slowly until you find the point at which the upper section of the chain is most taut.
Place the motorcycle on the side stand.
Measure chain tension at the centre of the lower section, with the motorcycle on the side stand: lower the chain by pressing
down on it only with your finger, release it and measure the distance (A) between the centre of the chain pins and the aluminium
section of the swingarm.
It must be: A = 35 ÷ 37 mm.
.
35 ÷ 37 mm
To adjust the tension remove the rear splash guards (Sec. 5 - 5, Removing the splash guard).
Slacken off the two clamp screws (1) that secure the rear wheel hub to the swingarm.
Fit the hook spanner code 88713.1038 inserting its tooth in the eccentric hub (2).
Rotate the eccentric hub (2) to obtain the correct chain tension.
Turn anticlockwise to tighten the chain; clockwise to loosen (from chain side).
Important
An incorrectly tensioned chain will lead to accelerated wear of the transmission components.
section
If the screws (1) are removed, lubricate with specified grease underhead and thread, then tighten the screws (1) to the torque of
35 Nm ± 5% (Sec. 3 - 3, Frame torque settings) proceeding with sequence 1-2-1.
Warning
The correct tightening of the fixing screws of the eccentric hub is essential for the safety of the rider and the passenger (Sec. 3
- 3, Frame torque settings).
Refit the rear splash guard (Sec. 5 - 5, Refitting the splash guard).
section
Checking brake pad wear and changing brake pads
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.
Checking front brake pad wear

Check through the slot of the calliper that the groove on the pads friction surface (1) is visible.
Important
If either of the pads is worn, both pads must be renewed as a set.
MIN
Turn the pins (2) sealing the pads clockwise.
Remove the safety cotter pin (3).
section
Withdraw the pad retaining pins (2) from the outside.
Remove the clip (4) from between the two calliper halves.
2
4
Force the calliper pistons back into their bores by forcing the old brake pads apart.
Remove the worn pads (1).
Note
Change pads that have a shiny or “vitrified” appearance.
Fit the new pads and corresponding spring (4) placing it with the arrow pointing up.
4 2
Fit the pins (2) of sealing pad and fix it with safety cotter pins (3).
section
Turn the pins (2) sealing the pads anticlockwise.
Operate the brake lever repeatedly so that the pads are firmly bedded in against the disc by the force of the brake fluid.
Check that the level in the pump tank is not below the MIN mark.
If necessary, top up as follows.
Turn the handlebar so that the reservoir is level.
Remove the cover (5) with membrane of the front brake liquid tank (6) by unscrewing the screws (7).
Top-up with specified liquid (Sec. 3 - 2, Fuel, lubricants and other fluids) until reaching the mark MAX.
1
3
MAX
MIN
2
section
Checking rear brake pad wear
Check through the slot between the two half callipers that there is at least 1 mm of friction material on the pads.
Important
If either of the pads is worn, both pads must be renewed as a set.
1 mm
Change the brake pads as follows.

Remove the security ring (1) from the pad sealing pin (2).
2 1
The split pin is on calliper inner side. Withdraw the brake pad retaining pin (2) and pull it out.
Remove the clip (3) from between the two calliper halves.
section
Remove the rear brake calliper by unscrewing the screws (4).
Force the brake pads apart to push the calliper pistons into their housings.
Remove the worn pads (5).
Fit the new pads.

Refit the rear brake calliper by fitting and tightening the screws (4) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
Fit the spring (3) of the sealing pad, the centring pin (2) fixing it with the ring (1).
2 1
Operate the brake pedal repeatedly so that the pads are bedded in against the disc by the force of the brake fluid.
section
Check that the brake fluid level in the tank is between the MIN and MAX marks. If this is not the case, act on to the top-up after
unscrewing the tank cap (6).
MAX
MIN
Warning
Being the brake callipers a security component of the engine, follow instructions indicated in Sec. 7 - 3, Removal of the front
brake system, Sec. 7 - 4, Removing of the rear brake control and pay attention, during the refitting, to the torque (Sec. 3 - 3, Frame
torque settings) of the fixing screws of the calliper.
section
Adjusting the throttle cable
The throttle grip in all steering positions must have free play, measured on the periphery of the flange of the grip, of 1.5 ÷ 2.0 mm.
1,5÷2 mm ➤ ➤
If necessary, adjust using the adjusters (1) and (2) located on the steering tube on the left side of the motorcycle.
Adjuster (1) adjusts the throttle opening control, while adjuster (2) adjusts the throttle closing control.
B
Slip the rubber gaiters (3) off the adjusters and loosen the counter nuts (4).
Adjust both adjusters by the same amount: turn clockwise to increase free play and anticlockwise to reduce free play.
When finished, tighten the counter nuts and refit the protection casings (3) to the adjusters.
Periodically check the condition of the outer cables of the throttle opening (1) and closing cables (2). The plastic covering should
show no signs of pinching or cracking.
Lubricate the ends of the inner cables with the specified grease periodically to ensure they run freely.
1 3
4
2
-
B
section
Operate the control to check that the inner cable slides smoothly inside the outer cable: if you feel excessive resistance or
stiffness, renew the cable.
To lubricate the throttle grip, it is necessary to slide off the protection cover (A), unscrew the screws (7) and remove the covers
(5) and (6) of the throttle grip.
2 A
1
5
Lubricate the ends of the cable and the race (B) with the recommended grease.
When refitting the cover, make sure that the cables are correctly positioned in the race (B).
section
Place the covers (5) and (6) in the reference hole of the handlebar.
Fix the covers (5) and (6) by tightening the screws (7) to the specified torque (Sec. 3 - 3, Frame torque settings).
2 A
1
5
section
Adjusting the clutch lever and front brake lever
The clutch lever (1) is fitted with a span adjuster (2) which serves to alter the distance of the lever from the handlebar.
The lever distance can be adjusted through 10 clicks of the dial (2). Turn clockwise to increase lever distance. Turn the adjuster
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. Correct use of the
clutch lever is very important in all riding situations, especially when moving off.
The position of the front brake lever (3) can be adjusted in the same way.
Warning
Any adjustment of clutch and brake levers must only be carried out when motorcycle is stationary.
1 2
3 2
section
Adjusting the position of the gear change and rear brake pedals
The position of the gear change and rear brake pedals in relation to the footrests can be adjusted to suit the preferred riding
position.
To modify the gear change pedal position act in the following mode:
Use an open ended spanner to hold the rod (1) on flat (A) and slacken off the counter nut (2).
Turn the screw (4) to detach the rod (3) from the gear change lever.
Turn the rod (3) to move the gear change pedal to the position.
Tighten the screw (4) to secure the gear change lever to the rod (3).
Tighten the counter nut (2) against the rod (1).
1 A 2
3
4
To adjust the position of the rear brake pedal, proceed as follows.

Loosen the counter nut (5).
Turn the pedal travel adjustment screw (6) until the pedal is in the desired position.
Tighten the counter nut (5) to the specified torque (Sec. 3 - 3, Frame torque settings).
Verify, by acting manually on the pedal, that there is a clearance of about 1.5÷2 mm before starting the braking operation.
If not, check to modify the length of the cylinder push-rod in the following mode.
Slacken off the counter nut (7) on the pushrod.
Screw the rod into the clevis (8) to increase play, or unscrew it to reduce play.
Tighten the counter nut (7) to the specified torque (Sec. 3 - 3, Frame torque settings) and check again the clearance.
8
7
6 5
section
Front fork adjustment (MTS 1200 ABS)
The front fork used on this motorcycle has rebound, compression and spring preload adjustment.
The settings are adjusted by way of external adjuster screws:
1) rebound damping;
2) inner spring preload;
3) compression damping.
Park the motorcycle in a stable position on its side stand.

Turn the adjuster (1) on fork leg top with a flat screwdriver to adjust rebound damping.
Turn the adjuster (3) on the bottom of each fork leg with a flat-blade screwdriver to adjust the compression damping setting.
As you turn the adjusters (1) and (3), you will hear them click. Each click corresponds to different damping setting.
The stiffest damping setting is obtained with the adjuster turned fully clockwise to the “0” position. Start with this position and
turn anticlockwise. Count the clicks, which correspond to position 1, 2 and so forth.
Turn the hexagonal headed adjuster screw (2) to adjust the preload of the internal spring in each stanchion. Each full clockwise
turn corresponds to 1 mm of preload. Maximum adjustment possible is 15 mm.
A 2
3 3
STANDARD factory setting is as follows:

Compression: 1 turn and a half;
Rebound: 2 turns.
Preload spring (A): 15 mm
Important
Adjust both fork legs to same settings.
section
Rear shock absorber adjustment (MTS 1200 ABS)
The shock absorber has external adjusters that enable you to adjust the suspension to suit the load on the motorcycle.
The adjuster (1) on the shock absorber expansion reservoir controls compression damping.
To access the register (1) remove the cover (4) by unscrewing the screws (5).
4
5 5
The adjuster (2), located on the left-hand side at the point at which the shock absorber is fixed to the swingarm, controls rebound
damping.
Turn the adjusters (1) and (2) clockwise to stiffen the damping or anticlockwise to soften it.
The adjusting knob (3) on the left side of vehicle lets you set shock absorber spring preload; see indications printed on knob.
The STANDARD setting is obtained when the knob is in the minimum position (LOW).
STANDARD length of preloaded spring on shock absorber: 162±1.5 mm.
section
STANDARD setting:
from the fully closed position (turned fully clockwise), unscrew:
register (1) of 1.5 clicks;
register (2) of 9 clicks.
Spring preload: 18 mm (Max.18 mm - Min.25 mm)
Warning
The shock absorber is filled with high-pressure gas and can cause injuries if inexpertly dismantled.
Important
If the motorcycle is to be ridden with a pillion rider and luggage, we recommend setting the rear shock absorber spring preload
to the maximum to ensure the best handling and proper ground clearance at all times. It may also be necessary to adjust the
rebound damping accordingly.
Adjusting the rear ride set-up

Motorcycle track alignment as set at the factory is the result of tests carried out under different riding conditions by DUCATI test
riders. Modifying factory setting is a very delicate operation, which may lead to serious damages if carried out by unskilled people.
Since this motorcycle is often used in competitions, DUCATI saw it fit to equip it with special mechanisms to modify rear sus-
pension and steering head geometry to suit all kinds of track conditions.
The rider can set four different set-up configurations on the instrument panel:
- Single passenger;
- Single passenger with luggage;
- Two passengers;
- Two passengers with luggage.
For each of these settings, four riding modes (SPORT, TOURING, URBAN and ENDURO) can be selected and within each of
these, the initial settings for traction control (DTC), engine power and suspension dampening control can be modified.
For the setup variation follow what reported in the Sec. 7 - 7 “Riding Mode customisation”.
5 - Fairings 0
section
5 Fairings
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
1
section
5-1 Fairings
1 - Rear-view mirrors
3 4 28
11 10 5
19
9
26
8
6
2 1 24
19
13 12 14
13 16 27
12 15 25 23
17
7 24
22
18
20
19 21
1 Screw 15 Bush
2 Nut 16 Rubber pad
3 Spring washer 17 Special screw
4 Vibration-damping pad 18 Screw
5 Special screw 19 Clip nut
6 Immobiliser antenna 20 Pin
7 Complete top fairing 21 Spring
8 Movable top fairing support 22 Top fairing panel (left)
9 Windshield 23 Top fairing panel (right)
10 Rubber pad 24 Screw
11 Special screw 25 Cover (left)
12 Knob 26 Cover (right)
13 Screw 27 Mat
14 Special screw 28 Instrument panel

1200 ABS HEADLIGHT FAIRING
1200 S ABS HEADLIGHT FAIRING
Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the
exploded view diagram.
section
5-1 Fairings
Removing the panel
Removing the left panel

Remove the fuse panel cover (25).
25
Undo the screws (24) and remove the left panel (22) lifting it from the rear part to unhook the tongues (A) from the slots (B) on
the top fairing.
22
24
25
24
22
22
section
5-1 Fairings
Removing the right panel

Remove the glove-box cover (26).
26
Undo the screws (24) and remove the right panel (23) lifting it from the rear part to unhook the tongues (A) from the slots (B) on
the top fairing.
24
23
24
23 24
section
5-1 Fairings
22
section
5-1 Fairings
Refitting the panel
Refitting the left panel

Refitting the left panel (22) fitting the tongues (A) in the slots (B) on the top fairing.
22
Fit and tighten to the specified torque (Sec. 3 - 3, Frame torque settings) the screws (24).
22
24
25
24
22
section
5-1 Fairings
Refitting the fuse panel cover (25).
25
Refitting the right panel

Refitting the right panel (23) fitting the tongues (A) in the slots (B) on the top fairing.
22
24
23
24
section
5-1 Fairings
23 24
Refitting the glove-box cover (26).
26
section
5-1 Fairings
Removing the headlight fairing
Remove the left and right panel 5 - 1, Removing the panel
Disconnect the Immobilizer antenna connector (A).
Undo the fixing screws (18) of the fuel tank fairings.
18
section
5-1 Fairings
Undo the screws (18) on both sides of the light support frame.
18
18
Slide the top fairing (7) upwards, releasing it from the rubber pad (B) of the front light unit.
Disconnect the instrument panel connector (C) and remove the top fairing (7) from the vehicle.
section
5-1 Fairings
If it is necessary to replace the windscreen (9) undo the screws (11), slide the windscreen (9) and retrieve the rubber pads (10).
11
10
section
5-1 Fairings
Disassembly of the headlight fairing
Completely undo the windscreen adjustment knobs (12), remove it and retrieve the special screws (14).
14
12
Undo the special screw (17) and remove the windscreen support (8) from the top fairing (2): retrieve the screw (8), the spacers
(10) and the rubber pad (11).
7 17
8
Undo the screws (1) and remove the Immobilizer antenna (6) from the windscreen support (8).
section
5-1 Fairings
Remove the instrument panel (28) undoing the nuts (30).
28
30
28
30
section
5-1 Fairings
Reassembly of the headlight fairing
Fit the instrument panel (28) on the top fairing (7) tightening the nuts (30).
Tighten the nuts (2) to the specified torque (Sec. 3 - 3, Frame torque settings).
28
28
Place the Immobilizer antenna (6) on the windscreen support (8) fitting the screws (1).
Tighten the screws (1) to the specified torque (Sec. 3 - 3, Frame torque settings).
Refit the windscreen support (8) on the top fairing (7) fitting a spacer (15) in the front part as shown in figure.
Fit the special screw (17) with the rubber pad (16) and other spacer (15) in the inner part of the windscreen support (8).
Tighten the special screw (17) to the specified torque (Sec. 3 - 3, Frame torque settings).
7 17
8
section
5-1 Fairings
Refit the windscreen adjustment knobs (12) fitting the special screws (14).
Screw the windscreen adjustment knobs (12) completely.
14
12
section
5-1 Fairings
Refit the headlight fairing
Make sure that the quick couplings (19) are fitted on the top fairing (7).
19
19
Fit the windscreen (9) with the rubber pads (10) on the top fairing (7) and hand tighten the screws (11).
11
10
Connect the instrument panel connector (G) and refit the top fairing (7) on the vehicle by introducing the slot (H) in the rubber pad
(I) on the front light unit.
section
5-1 Fairings
Fit and tighten to the specified torque (Sec. 3 - 3, Frame torque settings) the screws (18) on both sides of the light support frame.
18
18
Fit and tighten to the specified torque (Sec. 3 - 3, Frame torque settings) the fixing screws (18) to the tank fairings.
18
section
5-1 Fairings
18
Connect the Immobilizer antenna connector (J).

Refit the left and right panel 5 - 1, Refitting the panel
1
section
5-2 Fairings
2 - Fairings
16 17
18 21
23
10 3 15
13 20 15 22
11 9 19
8
20
6
12 7 17 16
1 5 23
14
15
3
28
29 27
24
26
2 4 25
3
1 Half-fairing (front right) 16 Screw

2 Half-fairing (front left) 17 Washer
3 Special screw 18 Right tank half-fairing
4 Screw 19 Hands Free cover*
5 Screw 20 Clip nut
6 Half-fairing (front lower) 21 Central tank half-fairing
7 Clip nut 22 Special screw
8 Air deflector (right lower) 23 Left tank half-fairing
9 Bush 24 Special screw
10 Bracket 25 Vibration-damping pad
11 Vibration-damping pad 26 Bracket
12 Gasket (right) 27 Bush
13 Air deflector (front right) 28 Screw
14 Air deflector (front left) 29 Air deflector (lower left
15 Nylon washer

1200 ABS FAIRING
1200 S ABS FAIRING
Important
Note
The pieces identified with a * are not present in version USA.
section
5-2 Fairings
Removing the front half-fairing
On the right side, undo and remove the screws (24).
Remove the right wing (13) undoing the screws (4), retrieving the nylon washers (15) and unhooking the tongue (A) from the slot
on the front half-fairing (1).
24
1 A
On the left side, undo and remove the screw (24).

Undo the side fixing screws (4) of the front half-fairing.
24
24
section
5-2 Fairings
Carry out the same procedure and remove the left wing (14).
Disconnect the casing (A) from the air box resonator, the air temperature sensor connector (B).
13
section
5-2 Fairings
Remove the front half-fairing unit (D) paying attention to unhook the pin (B) from the rubber pad on the oil radiator (E).
section
5-2 Fairings
Front half-fairing disassembly
Undo the screws (3) and remove the lower half-fairing (6) from the front half-fairing unit.
Undo the screws (3) and separate the front right half-fairing (1) from the left one (2).
Slide the casing (A) and undo the screw (F) to remove the pressure sensor (6).
A
G
section
5-2 Fairings
Front half-fairing reassembly
Make sure that the quick couplings (7) are fitted on the front half-fairings.
Refit the casing (A) and the pressure sensor (G) on the front right half-fairing fitting and tightening the screw (F) to the specified
torque (Sec. 3 - 3, Frame torque settings).
A
G
Couple the half-fairings by fitting the screws (3).
section
5-2 Fairings
Fit the lower half-fairing (6) on the front half-fairing unit and fit the screws (3).
section
5-2 Fairings
Refitting the front half-fairing
Refit the front half-fairing unit (9) paying attention to insert the pin (D) in the rubber pad on the oil radiator (E).
Connect the air temperature sensor connector (B) and place the casing (A) in the air box resonator.
section
5-2 Fairings
13
Fit and tighten to the specified torque (Sec. 3 - 3, Frame torque settings) the side fixing screws (4) of the front half-fairing (13).
24
24
Refit the right wing (13) fitting the tongue (A) in the slot on the front half-fairing (1).
1 A
section
5-2 Fairings
13
24
Carry out the same procedure and refit the left wing (14).
section
5-2 Fairings
Removal of the fuel tank fairings
Undo the screws (16) fastening the top fairing to the tank fairings retrieving the washers (17).
16
16
Undo the screws (16), (22) and (3) and remove the left (23) and right (18) lateral tank fairings, retrieving the washers (20), (15) and
(17).
16
22
23
3
16
22
18 3
section
5-2 Fairings
Undo the screws (22) and remove the central tank fairing (21), retrieving the washers (15).
21
22
22
section
5-2 Fairings
Refitting the fuel tank fairings
Refit the central tank fairing (21) by fitting and tightening the screws (22), complete with washers, to the specified torque (Sec.
3 - 3, Frame torque settings).
21
22
22
Refit the left (23) and right (18) lateral tank fairings, fitting and tightening the screws (16), (22) and (3), complete with washers,
to the specified torque (Sec. 3 - 3, Frame torque settings).
16
22
23
3
16
22
18 3
section
5-2 Fairings
Fit and tighten to the specified torque (Sec. 3 - 3, Frame torque settings) the screws (1) fastening the top fairing to the tank fair-
ings, complete with washers.
16
16

1
section
5-3 Fairings
3 - Seat – seat cowling and side panels
16 9 11 7 3
12
6
19 22
9
16 26 27
23
5
4
13 10
25 20
21 11
20
24
1 17 9 16
25
2
18 8
15
14 10
13
1 Rider seat 15 Tool bag

2 Rubber mounting 16 Bolt
3 Rubber mounting 17 Seat lock
4 Rubber mounting 18 Plate
5 Rubber 19 Banjo bolt
6 Rubber mounting 20 Seat catch
7 Pillion seat 21 Pin
8 Left side panel 22 Helmet lock cable
9 Washer 23 Tail guard (lower right)
10 Nylon washer 24 Tail guard (lower left)
11 Clip nut 25 Bolt
12 Right side panel 26 Banjo bolt
13 Banjo bolt 27 Bolt
14 Special nut

1200 ABS SEAT
1200 ABS REAR SUBFRAME
1200 S ABS SEAT
1200 S ABS REAR SUBFRAME
Important
section
5-3 Fairings
Removal of the seat
Insert the key into the seat lock (17) and rotate it clockwise until you hear the release click.
0 0
1 1
17
Slide off the passenger saddle (7), from the front retainer element pushing it forward and lift it up to remove it.
Remove the rider seat (1) from the bike by pulling it backwards slightly and lifting.
section
5-3 Fairings
Removal of the side panels and seat cowling
Removal of the side panels

To remove the side panels, it is necessary to remove the rider saddle (1) as described previously.
Unscrew the bolts (13) and (16) securing the right (12) and left (8) side panels to the rear subframe, and recover the washers (10)
and (9).
16
13
16
12
16
13
16
Remove the right (12) and left (8) side panels by sliding them from the rear tail fairing.
Tighten and remove the six screws (25).
25
section
5-3 Fairings
Unscrew and remove the two screws (29) and the four screws (26).
26
29
23
26
24
29
Remove the two tail guards (23) and (24).
section
5-3 Fairings
Refitting the side panels and seat cowling
Refitting the side panels

Place the right (12) and left (8) side panels on the vehicle.
Fasten the right (12) and left (8) side panels inserting the screws (16) and left (13) with the washers (9) and (10).
16
13
12
16
13
Insert the six screws (25).
25
Tighten the bolts (13), (16) and (25) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
5-3 Fairings
Refitting the seat
Place the saddle (1) inserting the tongue (A) in the appropriate pins (B) of the tank, as shown in figure.
Insert the hook (C) of the passenger saddle (7) bottom in the appropriate tail guard opening.
Push the passenger saddle rear end (7) until pin clicks in place inside latch.
1
section
5-4 Fairings
4 - Front mudguard
14
10
17
16
18
12
15
8 9 14
6 20
5 21
4
22
23
1 19 15
2
3 16
16 17
11
15 16
15 17 14 24 25 13 17 14
7
1 Front mudguard 14 Bolt

2 Washer 15 Clip nut
3 Bolt 16 Rubber mounting
4 Clip nut 17 Spacer
5 Cable support 18 Bracket (right)
6 Bolt 19 Oil sump (lower)
7 Nut 20 Rubber mounting
8 Special short screw 21 Bracket (front)
9 Bracket (rear) 22 Clip nut
10 Front mudguard – front section 23 Special long screw
11 Hose clip 24 Damping rubber
12 Oil sump (right) 25 Special screw
13 Oil sump (left)

1200 ABS OIL SUMP
1200 ABS SWINGARM
1200 ABS LICENSE PLATE HOLDER
1200 S ABS OIL SUMP
1200 S ABS SWINGARM
1200 S ABS LICENSE PLATE HOLDER
Important
section
5-4 Fairings
Removal of the front mudguard
Remove the front brake pipe protection (5) undoing the screws (6).
Undo the nut (B) and release the front brake pipes (A) from the pipe grommet (C).
C A
Remove the retaining screws (3) and recover the nylon washers (2).
2
3
3
2
Remove the front mudguard (1).
Note
On USA versions, a reflector is mounted on the front mudguard (1).
section
5-4 Fairings
Refitting the front mudguard
Warning
Do not use the motorcycle without the front mudguard fitted to avoid the risk of the brake pipes fouling the wheel on braking.
If previously removed, place the speed sensor cable (E) in the slot (D).
Place the front mudguard (1) inserting the fixing screws (3) with the spacers (2), turning them as shown in figure.
Important
During fitting of the carbon front mudguard (“S” version), do not use spacers with collar (2).
2
3
3
2
section
5-4 Fairings
Place the pipe grommet (C) on the mudguard and lock it with the nut (B).
C A
Refit the front brake pipe protection (1) inserting the screws (6).
Tighten to the prescribed torque (Sec. 3 - 3, Frame torque settings) the nut (B) and the screws (3) and (6).
Fitting the front semi mudguard

Unscrew the two screws (6) and remove the pipe grommet (5).
section
5-4 Fairings
Place the front brake pipe (A) and the front tone wheel sensor cable (B) on the front semi mudguard (10) and place it on the front
mudguard (1) paying attention to fix the slot (C) as shown in figure.
10
B 1
10
10
Insert the two screws (6) previously removed and tighten to the prescribed torque (Sec. 3 - 3, Frame torque settings).
section
5-4 Fairings
Removing the oil sump guard
Place a container under the engine and place the motorcycle on its sidestand.
Remove the oil sump unit with the screws (25), and the lower fixing screws (14) and collect the nut (7).
14
14
25
14
25
section
5-4 Fairings
Refitting the oil sump guard
Refit the oil sump guard unit inserting the screws (14), the lateral fixing screws (25) and the nut (7).
14
14
25
14
25
Note
The short screw (25) fastens the oil sump guard to the brake support plate.
Tighten the screws (25), (14) and the nut (7) to the specified torque (Sec. 3 - 3, Frame torque settings).
1
section
5-5 Fairings
5 - Rear mudguard - Splash guard
1 5
4
3
6 7
1 Long rear mudguard

2 Rear mudguard
3 Rear splash guard
4 Special screw
5 Special screw
6 Screw
7 Splashguard
8 Special screw

1200 ABS SWINGARM
1200 S ABS SWINGARM
Important
section
5-5 Fairings
Removing the rear mudguard
Undo the screws (5) and (6), remove the rear mudguard (2) from the swingarm.
Refitting the rear mudguard

Place the rear mudguard (2) on the swingarm, fitting the screws (5) and (6).
section
5-5 Fairings
Fitting the long rear mudguard
Place the long rear mudguard (1) on the swingarm, fitting the screws (5) and (6).
6 5
section
5-5 Fairings
Removing the splash guard
Undo and remove the screws (4) and (8).
Remove the splash guard (7) and rear splash guard (3).
section
5-5 Fairings
Refitting the splash guard
If previously disassembled, reassemble the splash guard (7) with the rear splash guard (3) as shown in figure.
Fit and tighten the three fixing screws (4) and (8) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
5-5 Fairings
section
6 Electric system and engine control system
1 - Wiring diagram 4
Wiring diagram colour codes 8
Key of front fuse box 8
Key of rear fuse box 9
Routing of wiring on frame 10
Table A 13
Table B 13
Table C 14
Table D 16
Table E -1 20
Table E-2 25
Table F 28
Table G 30
Table H 32
Table I 34
Table J 37
Table K 41
Table L 43
Table M 44
Table N 47
Table O 49
Table P 52
Table Q 54
Table R 55
Table S 58
Table T 60
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
section
6 Electric system and engine control system
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

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
Electric system and engine control system
Multistrada 1200 ABS / Multistrada 1200 S ABS - M.Y. 2010 - edition DRAFT
13
14
16
17
3
11
22
19
20
6
12
+
23
1
Bk - -
R/Y
15
5
R/W
- - 30A
+
R -
STARTER ENGINE STOP UNLOCK 2 1 Bk Bk
BW Bk RW RBk RW RBk 1 2 3 4
FREE OFF OFF
PUSH RUN RUN
4
1 2
1 2 + -
Ecu Bk
Key
Inj R/G R/G
Dash Y Y Y
Light
R/Y Bn Etv Bk Bk 1-34 35-68
O R R R R R R/Bk B/Bk
R/W R/W R
R/Y R/V Bk
R
18
Bk
1 2 3 4 1 2 3
21
1 2 1 2
10
Bk
46 Signal Map Sensor Horizontal

Gr/G
8
9
R/Y N.C.
1 2 3 4 5 8 B/Bk
R R/Y Gr/G R/Y Gr/Bk
37 Signal Map Sensor Vertical

Gr/Bk Lb
63 Signal O2 Sens ( vertical)

Bk
40 Signal Speed sens Front

R R R R/Bk R R R/Gr R/Y R/Y
R
2 Injector Horizontal main
39 Signal Speed sens rear
61 Communication Line B
62 Communication Line A
P/Bk P/Bk R/B
R/Y R/Y
27 Injector Vertical Main
3 Injector Horizontal top
67 V supply APS ( main)

28 O2 heater Horizontal
38 CranK Angle Sens +
53 Engine Temp. Sens.

54 Signal O2 Sensor H
W/B Lb
47 CranK Angle Sens -

R/Bk
66 Signal APS ( main)

43 V supply APS (Sub)
17 Radiator Fan Relay
29 O2 heater Vertical
48 Sensor Supply 5V
4 Injector Vertical top
65 Gnd APS ( main)

31 Fuel Pump Relay
50 Signal APS (sub)
68 Signal Tps Main

35 Battery Monitor
57 Signal Tps (sub)

36 Air Temp Sens.
60 Self Shut-down
24
58 APS (sub) gnd
41 Oil Press sw
30 Starter Relay
15 SideStandsw
49 V supply TPS
1 coil Horizontal
34 Control Gnd
55 Sensor Gnd
7 ETV Motor +
26 coil Vertical
10 Power Gnd
18 Power Gnd
32 Neutral Sw
23 Quick Shift
8 ETV Motor -
6 ETV Source
25 Starter sw
Bn Bn R/V
16 Cluth Sw
59 Can High
R/V
33 STop Sw
9 ETV Relay
51 Can Low
24 Brakesw
56 TPS Gnd
R/G R/Bk
5 ETV Gnd
44 Battery
Bk
67
11
12
13
14
19
20
21
22
42
45
52
64
Y
A B
65
25
O Bk
Gr/B Bk Lb/R Lb/G W/O Lb/Bk W/B G/Y Lb/Gr Bk Bn/W G/O W/Y R/Bk Bn/Y Gr/G G/Y Bk/Y Bk/W R/Y Y Bk/O Bn/R
R/Gr Lb/Bk Bn/W Bn/Bk R/Bn Lb/G Bn/Bk
G/W
66
n.c
n.c
n.c
n.c
n.c
P/Y R/Bn Lb/Bk Bk W Bk Gr/G Lb/Y B/Bk P/Bk G/B Bn/B Bn/V O/BK G/W Bk/V O/G Gr/Bk W G/V O O/B
Bk 1 2
4
63 64
W/B
Bn/R
H 11 LAMP W
3
Bk
Bk 2
Y/Bk Y/Gr
H 11 LAMP Y/Bk
Bn/W 1
Bk
26
H 11 LAMP
Y/Bk
10 W
Bk O Bk
H 11 LAMP
W
62
27
W Y/W
Bk
Gr/R
Y
61
W/Bk
Bk
1 W/G
Led
2 W/Bk
3
4 Y
60
Bk
W/Bk 10 W
28
W/Bk
W/G
29
Can Low 24 Gr/G Gr/G 11 Can Low
Can HI 23 Gr/Bk Gr/Bk 1 Can Hi
In Left/Right indicator 10 Gr 17 Out Right Rear Indicator
Menu Input 3 B/Y 16 Out Left Rear Indicator
Menu confirm_Off indicator 11 Br Gr 12 In Quick shift
Passing_Start_stop_lap 5 O Gr/R 6 Out Stop Light
HI Beam input 12 B Lb 2 In ABS Lamp
Claxon Out 19 V/Bk Gr/B 5 In ON/OFF ABS
Pilot light out 18 Y Y 7 Position light
T air input 8 n.c 15 5V Sns Vcc
Front left ind out W/Bk In Sign exup
30
26 4
Front right ind out 25 G/Bk 10 Out Sns Gnd
SnS 5V 17 18 M+
W/B
SnS Gnd 22 n.c 19 M-
Front Speed 9 B 3 In Fuel Sensor
59
Hi Beam Relay 2 Y/Gr 13 In Gear Sensor

Low Beam Relay 1 Y/W G/V 14 In speed sensor
Claxon Input 6 B/W R/Bk 8 Key sense
Grip Heather 7 W/V Bk 9 Gnd
Grip Heather 13 W/V R/Y 20 Vbatt
Bk/W
Bn/R
Bk/O
Bk/B
Y/B
Y/G
brake sw 4 Gr/R
Key_sense 15 R/Bk R/W 5 diretto
VBatt1 14 R/Y R/B 6 Key
Vbatt2 20 R/Y Bk 4 Gnd
31
1 IN-pilot light
Gnd1 16 Bk
Gnd2
Y 2 Out-pilot light
21 Bk
7 In Unlock hands free
8 Out unlock hands free
3 Led
Bk
68
Lb
W/V
Bk
W/V
Bk
W/Bk
Led
58
Bk/V
Bk Bk
Gr/Y Bn/W Gr/Bk Bn/W
1 - Wiring diagram
2 1 R/B
B/W 3 2 1 3 2 1
Bk/V Bk/V
Bk B/Y Bk Gr Br B O
Wiring diagram 1200 ABS
Bn/R
G/Y
G
B
8 4 2 1 3 5 6 7 Bn/R
Bk
V/Bk 1 2 3 4 1 2 3 4
Gr/Bn
Bn/R
G/Y
Gr/B
Gr
G/V
Lb
R/Bk
2 1
R/Y
P/Y
B/V
Bk
R/Y
Bn/V
G
G/B G/W Bn/V
Bn/W Bn/W Bk/V Bk/V Bk/V G/W Bn/B Bk/O 1 2
Bn/R
Bk/V G/W Bn/Y O/B Lb/Bk
Bk/W
B
O
Bk/O
Bn/R
Bk/B
Bn/R
Y/B
Bk/B
Y/G
SC Bk/Y O/G Lb/R Bk/W G/BK Bn/R
2 1 2 1 2 1 2 1 1 2 3 1 2 3 3 2 1
Bk Bk Bk Gr/R G H F A B C D E
4 2 1 3 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Bk W/Y
Gr/R W/Bk
C W Gr 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
+ +
HALL R
f f
FREE FREE N PUSH PUSH PUSH HALL f
f f f
PUSH PUSH L OFF OFF OFF f f f f
RB BW B RB O RB
57
RB BY R Bk R Bk Gr RB Br - +
SET DOWN SET UP TURN HORN HI BEAM PASSING
V O
OM VM
55
41
54
49
47
H V
56
45
51
50
1 2 3 1 2 3
37
36
44
43
42
40
39
38
35
34
33
32
section
48
46
6-1
53
52
4
Electric system and engine control system
5
20
13
14
16
17
3
11
6
21
22
19
12
+
1
23
Bk
- -
5
R/Y + -
Bk
15
R R/W 30A
- -
+
+
UNLOCK
- Bk Bk
STARTER ENGINE STOP
68
69
70
BW Bk RW RBk RWRBk 2 1 1 2 3 4
FREE OFF OFF
PUSH RUN RUN
4
1 2
1 2
R/G R/G
Y Y Y
1-34 35-68
24
18
R/Y Bn Bk Bk R/Bk
O R R R R R B/Bk R
R/Y R/W R/W Bk
R/V
R
Bk
25
1 2 1 2 3 4 1 2 3 f
10
Bk
46 Signal Map Sensor Horizontal
Gr/G
8
9
R/Y
1 2 3 4 5 8 B/Bk
R R/Y Gr/G R/Y Gr/Bk
37 Signal Map Sensor Vertical
63 Signal O2 Sens ( vertical)

Gr/Bk
Bk Lb 4
40 Signal Speed sens Front
R R R R/Bk R R R/Gr R/Y R/Y

1 2 3 4 1 2 3 4
39 Signal Speed sens rear
61 Communication Line B
62 Communication Line A
P/Bk R
2 Injector Horizontal main
P/Bk R/Y R/Y R/B
67 V supply APS ( main)

3
27 Injector Vertical Main
3 Injector Horizontal top
38 CranK Angle Sens +

28 O2 heater Horizontal
W/B
53 Engine Temp. Sens.

54 Signal O2 Sensor H
Lb
47 CranK Angle Sens -

R/Bk 1 2 1 2 3 4 5
UBMR
66 Signal APS ( main)
UBVR
43 V supply APS (Sub)
1B
1A
1A
1B
2
48 Sensor Supply 5V
17 Radiator Fan Relay
29 O2 heater Vertical
2B
2A
2A
2B
65 Gnd APS ( main)
4 Injector Vertical top
31 Fuel Pump Relay
s
50 Signal APS (sub)
W/B
-
68 Signal Tps Main
35 Battery Monitor
57 Signal Tps (sub)
B/Bk
36 Air Temp Sens.
60 Self Shut-down
DC A
DC B
R/Y
Bk
1
58 APS (sub) gnd

41 Oil Press sw
Gr
49 V supply TPS
30 Starter Relay
15 SideStandsw
1 coil Horizontal
55 Sensor Gnd
34 Control Gnd
7 ETV Motor +
26 coil Vertical
10 Power Gnd
18 Power Gnd
32 Neutral Sw
23 Quick Shift
8 ETV Motor -
6 ETV Source
25 Starter sw
Bn Bn R/V
59 Can High
R/V
51 Can Low
56 TPS Gnd
16 Cluth Sw
R/G
33 STop Sw
9 ETV Relay
R/Bk
24 Brakesw
44 Battery
5 ETV Gnd
Bn/W
67
O/G
Bk
R/B
Y/W
42
45
52
64
Y
11
12
13
14
19
20
21
22
Y/Lb
A B Bk
1 10
65
R/Bk
O Bk
R/Bk
2 11 19 27
66
Gr/B Bk Lb/R Lb/G W/O Lb/Bk W/B G/Y Lb/Gr Bk Bn/W G/O W/Y R/Bk Bn/Y Gr/G G/Y Bk/Y Bk/W R/Y Y Bk/O Bn/R
R/Gr Lb/Bk Bn/W Bn/Bk R/Bn Lb/G Bn/Bk
3 12 20 28
71
G/W
n.c
n.c
n.c
n.c
n.c
P/Y R/Bn Lb/Bk Bk W Bk Gr/G Lb/Y B/Bk P/Bk G/B Bn/B Bn/V O/BK G/W Bk/V O/G Gr/Bk W G/V O O/B
Bk Y/P
4 13 21 29
H 11 LAMP W O/B 5 14 22 30
63 64
B/Y 6 15 23 31
Bk
Y/Bk Y/Gr R/B 7 16 24 32
H 11 LAMP Y/Bk
R/Y
8 17 25 33
H 11 LAMP Bk
Gr
9 18 26 34
B/Y
Y/Bk R/Y
Bk
Bk
Bk O Bk Y/G
H 11 LAMP
O/Y
W
B/G
Gr/G
V/Y
V/B
V/W
62
V/G
O/V
B/V
26
W Y/W Gr/Bk
27
10 W
61
Multistrada 1200 ABS / Multistrada 1200 S ABS - M.Y. 2010 - edition DRAFT
Bk
Gr/R
Y
Led
Bk
Bk 1 W/G 10 W
W/Bk
60
2 W/Bk
3 Bk
4 Y
28
W/Bk
W/G
29
Can Low 24 Gr/G Gr/G 11 Can Low
Can HI 23 Gr/Bk Gr/Bk 1 Can Hi
In Left/Right indicator 10 Gr 17 Out Right Rear Indicator
Menu Input 3 B/Y 16 Out Left Rear Indicator
Menu confirm_Off indicator 11 Br Gr 12 In Quick shift
Passing_Start_stop_lap 5 O Gr/R 6 Out Stop Light
HI Beam input 12 B Lb 2 In ABS Lamp
Claxon Out 19 V/Bk Gr/B 5 In ON/OFF ABS
Pilot light out 18 Y Y 7 Position light
T air input 8 n.c 15 5V Sns Vcc
Front left ind out 26 W/Bk 4 In Sign exup
Front right ind out G/Bk 10 Out Sns Gnd
30
25
SnS 5V 17 R/B 18 M+
SnS Gnd 22 n.c 19 M-
59
Front Speed 9 B 3 In Fuel Sensor

Hi Beam Relay 2 Y/Gr 13 In Gear Sensor
Low Beam Relay 1 Y/W G/V 14 In speed sensor
Claxon Input 6 B/W R/Bk 8 Key sense
Grip Heather 7 Gr/R Bk 9 Gnd
Grip Heather 13 W/V R/Y 20 Vbatt
Bk/W
Bn/R
Bk/O
Bk/B
Y/B
Y/G
brake sw 4 W/V
Key_sense 15 R/Bk R 5 diretto
VBatt1 14 R/Y R/B 6 Key
Vbatt2 20 R/Y Bk 4 Gnd
In pilot light N.C.
1
Gnd1 16 Bk
Y 2out pilot light
31
Gnd2 21 Bk
7 In hands free Unlock N.C.
Bk
dx 8 Out hands free Unlock N.C.
3 Led
74
W/V
sx Lb
Bk
W/V
Bk
W/Bk
Led
Bk/V
58
Bk/V
Bk Bk
Gr/Y Bn/W Gr/Bk Bn/W
2 1 R/B
B/W 3 2 1 3 2 1
Bk/V Bk/V
Bn/R Bk B/Y Bk Gr Br B O
Wiring diagram 1200 S ABS
G/Y
G
B
2A
2A
2B
2B
1A
1A
1B
1B
8 4 2 1 3 5 6 7 Bn/R
V/Bk 1 2 3 4 1 2 3 4
Gr/Bn
Bn/R
G/Y
Gr/B
Gr
G/V
Lb
2 1
R/Y
P/Y
B/V
4 3 2 1 4 3 2 1
R/Y
Bn/V
G
Bn/V
Bk
G/B G/W
Bk
Bn/W Bn/W Bk/V Bk/V Bk/V G/W Bk/V G/W Lb/Bk Bn/B Bk/O 1 2
Bn/R
Bn/Y O/B
Bk/W
B
O
Bk/O
Bn/R
Bk/B
Bn/R
Y/B
Bk/B
Y/G
SC Bk/Y O/G Lb/R Bk/W G/BK Bn/R
2 1 2 1 1 2 3 1 2 3 3 2 1
Gr/R 2 1 2 1
Bk Bk Bk G H F A B C D E
4 2 1 3 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Bk W/Y
Gr/R W/Bk
C W Gr 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
+ +
HALL R f f
FREE FREE N PUSH PUSH PUSH HALL f
f f f
PUSH PUSH L OFF OFF OFF f f f f
RB BY R Bk R Bk Gr RB Br RB BW B RB O RB
- M +
V O
OM VM
57
73
72
f
H V
41
54
49
47
56
45
51
50
1 2 3 1 2 3
55
37
36
44
43
42
40
39
38
35
34
33
32
48
46
section
6-1
53
52
section
6-1 Electric system and engine control system
Wiring diagram 1200 S ABS - Key
1 Right-hand handlebar switch 67 Parking light
2 immobilizer 68 Heated handgrip connector
3 Hands Free relay
4 Hands free
5 Front fuse box
6 Right fan
7 Left fan
8 Fan relay
9 Fuel pump relay
10 Ride-by-wire relay (ETV)
11 Injection control unit (EMS)
12 Navigator
13 Left 12V power outlet
14 Right 12V power outlet
15 Rear fuse box
16 Data Acquisition/Diagnosis
17 Starter motor
18 ABS diagnosis
19 Fused solenoid
20 Battery
21 Wiring ground
22 Regulator
23 Generator
24 Fuel pump
25 Fuel level
26 Rear right turn signal
27 Rear light
28 Rear left turn signal
29 Rear wiring loom
30 Vehicle control unit (BBS)
31 Antitheft alarm
32 Exhaust valve starter motor
33 Gear sensor
34 Rear speed sensor
35 ABS control unit
36 Throttle twistgrip position sensor (APS)
37 Starter motor - position sensor / ride-by-wire (TPS/ETV)
38 Timing/rpm sensor
39 Vertical MAP sensor
40 Horizontal MAP sensor
41 Engine temperature
42 Air temperature sensor
43 Vertical lambda sensor
44 Horizontal lambda sensor
45 Oil pressure switch
46 Rear stop
47 Side stand switch
48 Clutch switch
49 Front stop
50 Main vertical injector
51 Main horizontal injector
52 Horizontal coil
53 Vertical coil
54 Left-hand handlebar switch
55 Horn
56 Front speed sensor
57 Antitheft alarm led
58 Front left turn signal
59 Instrument panel
60 Front right turn signal
61 Low beam headlight relay
62 Left low beam headlight
63 Left high beam headlight
64 Right high beam headlight
65 Right low beam headlight
66 High beam relay
section
Wiring diagram 1200 S ABS - Key
1 Right-hand handlebar switch 67 Parking light
2 immobilizer 68 Rear suspension - compression - stepper C
3 Hands Free relay 69 Rear suspension - rebound - stepper D
4 Hands free 70 Rear suspension - hydraulic spring preload
5 Front fuse box 71 Active suspension ECU
6 Right fan 72 Front fork - rebound - stepper B
7 Left fan 73 Front fork - compression - stepper A
8 Fan relay 74 Heated handgrip connector
9 Fuel pump relay
10 Ride-by-wire relay (ETV)
11 Injection control unit (EMS)
12 Navigator
13 Left 12V power outlet
14 Right 12V power outlet
15 Rear fuse box
16 Data Acquisition/Diagnosis
17 Starter motor
18 ABS diagnosis
19 Fused solenoid
20 Battery
21 Wiring ground
22 Regulator
23 Generator
24 Fuel pump
25 Fuel level
26 Rear right turn signal
27 Rear light
28 Rear left turn signal
29 Rear wiring loom
30 Vehicle control unit (BBS)
31 Antitheft alarm
32 Exhaust valve starter motor
33 Gear sensor
35 ABS control unit
36 Throttle twistgrip position sensor (APS)
37 Starter motor - position sensor / ride-by-wire (TPS/ETV)
39 Vertical MAP sensor
40 Horizontal MAP sensor
41 Engine temperature
43 Vertical lambda sensor
44 Horizontal lambda sensor
46 Rear stop
47 Side stand switch
48 Clutch switch
49 Front stop
50 Main vertical injector
51 Main horizontal injector
52 Horizontal coil
53 Vertical coil
54 Left-hand handlebar switch
55 Horn
57 Antitheft alarm led
58 Front left turn signal
59 Instrument panel
60 Front right turn signal
61 Low beam headlight relay
62 Left low beam headlight
63 Left high beam headlight
64 Right high beam headlight
65 Right low beam headlight
66 High beam relay
section
Wiring diagram colour codes
B Blue
Bk Black
Bn Brown
G Green
Gr Grey
LbLight blue
O Orange
P Pink
R Red
V Violet
W White
Y Yellow
Key of front fuse box
1 2 3 4 5 6
Pos. Consumer Rating

1 Lights 20 A
2 Instrument panel 10 A
3 ECU 5A
4 Key-sense 15 A
5 Injection solenoid 20 A
6 Throttle opening starter motor solenoid (ETV) 10 A
section
Key of rear fuse box
1 2 3 4 5 6
Pos. Consumer Rating

1 Black Box System (BBS) 7.5 A
2 Power outlets/navigator/alarms 10 A
3 ABS 2 25 A
4 ABS 1 30 A
5 Fans 10 A
6 Diagnosis 7.5 A
section
Routing of wiring on frame
The routing of the 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.
The plates on the following pages show the origins (“0” points) for correct re-routing of wiring and the locations of cable ties.
Each figure includes references to the plates showing the wiring routing or the item to which it must be connected.
Position Description
1 Table A Vertical MAP sensor
2 Table B Connector 1 Injection control unit (EMS)
3 Table B Connector 2 Injection control unit (EMS)
4 Table B Injection relay
5 Table B Ride-by-wire relay (ETV)
6 Table B Fan relay
7 Table B Horizontal MAP sensor
8 Table B Navigator (optional)
9 Table C High beam relay
10 Table C Front fuse box
11 Table C Low beam headlight relay
12 Table C Left low beam headlight
13 Table C Hands Free relay
14 Table D Instrument panel
15 Table D Right high beam headlight
16 Table D Right low beam headlight
17 Table D Front speed sensor (Sec. 7-6)
18 Table D Oil pressure switch
19 Table D Left high beam headlight
20 Table D Parking light connector
21 Table D Antitheft alarm led
22 Table E -1 Front brake light connector
23 Table E -1 Front right turn signal
24 Table E -1 Right-hand handlebar switch
25 Table E -1 Air temperature sensor
26 Table E -1 Hands free connector
27 Table E -1 Right heated handgrip
28 Table E -1/Table F Left heated handgrip
29 Table E -1 Front fork - rebound - stepper B (S VERSION)
30 Table E-2 Handfree connector - tank cap
31 Table E-2 Handfree connector - Immobilizer
32 Table F Left-hand handlebar switch
33 Table F Front left turn signal
34 Table F Clutch switch
35 Table F Front fork - compression - stepper A (S VERSION)
36 Table G Starter motor - position sensor / ride-by-wire (TPS/ETV)
37 Table G Sidestand switch
38 Table H Main horizontal injector
39 Table H Main vertical injector
section
40 Table H Engine temperature
41 Table H/Table I Wiring ground
42 Table I Left fan
43 Table I Horizontal coil
44 Table I/Table T Ground cable - battery negative
45 Table J Timing/rpm sensor
46 Table J Right fan
47 Table J Throttle twistgrip position sensor (APS)
48 Table J Horn
49 Table K Horizontal lambda sensor
50 Table K Rear brake light connector
51 Table L Fuel level
52 Table L Fuel pump
53 Table M Rear speed sensor (Sec. 7-6)
54 Table M Vertical coil wire
55 Table M Vertical coil
56 Table M Gear sensor
57 Table M Gear sensor
58 Table M Left 12V power outlet
59 Table N Rear suspension - compression - stepper C (S VERSION)
60 Table N Rear suspension - rebound - stepper D (S VERSION)
61 Table O ABS control unit
62 Table O Vertical lambda sensor cable
63 Table O Vertical lambda sensor
64 Table O Vehicle control unit (BBS)
65 Table P Data Acquisition/Diagnosis
66 Table P Rear light cable
67 Table P Rear light
68 Table P Rear wiring loom
69 Table P/Table Q Rear wiring unit
70 Table P Active suspension control unit (S VERSION)
71 Table Q Rear right turn signal
72 Table Q Rear left turn signal
73 Table Q Number plate light
74 Table R ABS diagnosis
75 Table R Rear fuse box
76 Table R Fused solenoid
77 Table R ABS Positive
78 Table R Rear suspension - hydraulic spring preload - connector (S VERSION)
79 Table R Rear suspension - hydraulic spring preload - connector (S VERSION)
80 Table R Solenoid - battery positive
81 Table R/Table T Solenoid - starter motor
section
82 Table S Regulator
83 Table S Exhaust valve starter motor
84 Table S Exhaust valve starter motor
85 Table S Antitheft alarm
86 Table S Right 12V power outlet
87 Table S/Table T Regulator - alternator
section
Table A
E-1
B
1
Table B
8
3 A
4
2
5
6
section
Table C
11
10
13
12
section
9 11 13
10
section
Table D
21 14
16
19
17 Sec. 7-6
15
18
20
section
14
20
21
19
section
19
16
15
section
18
section
Table E -1
26
22
25
27
28 24
F 23
29
24
22
23
section
23 29
24
22
22
23
24
section
24
23
26
section
E-2
26
24 27
section
25
section
Table E-2
E-1
26
31
30
30
section
30
24
30
30
22
section
31
31
26
section
Table F
35
33
28
32
34
E-1
32
35
28
33
section
34
32
35
A
33
33
34
35
32
section
Table G
36
37
37
section
37
36
section
Table H
38
39
40
41
section
40
40
section
Table I
44
41
41
44
43
42
section
42
43
43
42
44
41
section
43
section
Table J
45
47
46
48
48
46
47
45
section
48
48
46
45
47
section
45
45
section
45
section
Table K
49
50
49
section
50
49
section
Table L
52
A
51
section
Table M
55
N
56
Sec. 7-6
55
53
54
55
section
57
55
Sec. 7-6
54 53
56
55
56
55
54 53
Sec. 7-6
section
57
57
57
section
Table N
M
58
60
59
60
58
59
section
58
60
59
section
Table O
63
P
61
62
64
62
64
61
section
62
63
section
63
section
Table P
R
70
65
70
section
68
66
67
69
section
Table Q
71
73
69
72
P
section
Table R
78
75
74
81
P
76
79
78
section
79 78
76
77
section
81
76
80
80
77
section
Table S
82
86
85
83
section
84
83
82
87
85
T
86
84
84
section
Table T
44
87
81
44 87
81
44
section
81
81
section
87
1
section
2 - Battery charging system
Checking the battery charging system
To check the current flow of the recharging circuit, use the “DDS” diagnosis instrument, which is equipped with an inductive
clamp-type amperemeter: refer to chapter “Checking the battery charging system”, Sec. D 5.
With the “DDS” diagnosis instrument you can determine the engine rpm required for the alternator to produce sufficient current
to charge the battery, feed the injection/ignition system and all the electrical equipment on the motorcycle. When applied to a
cable, the clamp-type amperemeter detects the magnetic field generated by the current passing through that cable.
The tester performs an automatic calibration routine using its own transducer. If the measured current is a positive quantity, it
means that generator is feeding all electric items and charging battery at the same time. A negative value means that charging
system is not powering the loads and a significant amount of current must be supplied by the battery, which is discharging at the
time of the measurement.
Or it is possible to use a multimeter (Sec. 6 -13, Diagnostic instruments). connect the multimeter probes to the battery terminals,
select the DC scale on the instrument and check for the presence of 14.5 V±0.5 at an engine speed of 3000 rpm.
Important
If polarity is reversed when clamping the ammeter onto the cable, the sign of the readings will also be reversed, giving rise to
incorrect diagnosis.
section
Recharging the battery
Examine the label on the battery showing the check intervals in order to determine when to test the voltage.
Charge the battery if the open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could
damage it. Check the battery charge with a voltmeter.
Always check the condition of the battery before recharging and 1 to 2 hours afterwards.
Important
Pay careful attention to recharging times. Stop charging immediately if the battery becomes too hot to the touch. Leave to cool
before resuming charging.
Use only constant-voltage battery chargers.

Check that battery terminals are properly connected to the battery charger.
To charge the battery, proceed as follows.
Type of charging Volt. Ampere (A) Time (Hours)

Normal 12 1.8 5-10
Fast 12 9 1
Use fast charging in emergencies only.
Storing the battery

If the battery voltage is less than or equal to 11.5 V, it must be recharged.
Connect the battery charger to the battery.
Use a voltage of 16-17 V.
If the ammeter shows no change, increase the voltage to the maximum of 25 V.
Charge for 5 minutes.
If the ammeter shows a change, return the voltage to 16-17 V; otherwise replace the battery.
section
Topping up the electrolyte

Removing the rider seat Sec. 5 - 3, Removal of the seat
Remove the battery Sec. 6 - 2, Removal of the battery
Warning
Before carrying out any operations on the battery, keep in mind the safety standards (Sec.1 - 3, General safety rules). The electro-
lyte in the battery is toxic and can cause burns if it comes into contact with the skin because it contains sulphuric acid. Wear pro-
tective clothing, a face-mask and goggles when adding electrolyte. If the liquid comes into contact with the skin, wash thoroughly
with cold water. If it comes into contact with the eyes, wash thoroughly with water for 15 minutes and consult an ophthalmologist.
In the event of accidental ingestion, drink large quantities of water or milk, and continue with milk of magnesia, beaten egg or
vegetable oil. Do not allow sparks, flames, cigarettes or any other heat source to come near the battery, as it produces explosive
gases. When recharging or using the battery indoors, make sure that the room is adequately ventilated. Do not inhale the gases
produced during recharging. KEEP OUT OF REACH OF CHILDREN.
Place the battery on a flat surface. Remove the protective film (1).
Warning
Make certain that the electrolyte is of the specific type for your battery.
Remove the container with the electrolyte from the plastic bag. Remove the cap strip (3) from the container (2).
section
Important
Keep the cap strip (3) to hand because it will be used later as plugs for the battery cells.
Warning
Do not peel or perforate the sealed areas.
Place the electrolyte container (2) upside down. Align the six sealed elements with the six filler holes on the battery.
Push the container (2) downwards with sufficient force to break the seals and allow the liquid to flow out.
Note
Do not tilt the electrolyte container as this could interrupt the flow temporarily or even permanently.
Make certain that air bubbles emerge from all six filler holes. Leave the container in this position for at least twenty minutes.
If no bubbles emerge from one of the holes, tap gently on the bottom of the respective container.
Important
Never move the container away from the battery. Do not cut or puncture the liquid container.
section
Make sure that all the electrolyte has flowed out. Carefully extract the container (2) from the battery.
Fit the cap bar (3) -previously removed from the electrolyte container (2)- to the battery, ensure the caps plug off all filler holes.
3 -12 Ah batteries: leave to stand for at least 30 min.

12 Ah batteries: leave to stand for at least 1 hour.
Rest the cap strip on the filler holes without fixing it. Recharge the battery as described in the paragraph “Recharging the bat-
tery”.
Note
When using an automatic reduction battery charger, check that the charger current (ampere) is equal or higher than the value of
standard charging system (STD) indicated on the battery itself.
30 A YYY
+ -
R
R
R
Bk R BkBk
section
Press firmly downwards with both hands until the caps are firmly in place (do not use a hammer).
section
Battery
Battery safety rules
Warning
Before carrying out any operations on the battery, keep in mind the safety standards (Sec. 1 - 3, General safety rules). When
under charge, batteries produce explosive gases. Keep batteries away from heat sources, sparks or open flames.
Instructions for use

The battery is a sealed, maintenance-free type and therefore requires no servicing installation.
Note
Always keep the battery clean. Apply grease around the battery terminal clamps to prevent corrosion.
Warning
Never remove the valve cover located on top of the cover. If the block, cover or terminals are broken or if the valve cover has
been tampered with IT IS ABSOLUTELY NECESSARY TO REPLACE THE BATTERY.
Important
If the motorcycle is left unused for more than 30 days, remove the battery and store it in a safe, cool place.
Always charge the battery before the first operation and after long storage periods – such as before selling the vehicle.
Removal of the battery

Removing the rider seat Sec. 5 - 3, Removal of the seat
Undo the screw (1) and remove the battery retaining bracket (2).
Undo the screws (3), remove the terminals (4) always starting from the negative (-) one and remove the battery (5) sliding it up-
wards.
4 3 4
5
1
section
Refitting the battery
Fit the battery (5) on its support, fix the battery terminals (4), always starting from the positive (+) and insert the screws (3).
Check that the contacts are not oxidised and tighten the screws (3) of the terminals at the torque of XX Nm, applying waterproof
spray.
Position the battery on the retaining bracket (2) and tighten the screw (1).
4 3 4
5
1

Refitting the rider seat Sec. 5 - 3, Refitting the seat
section
Alternator
It is equipped with a 12 V, 360 W alternator, consisting of a fixed element (stator, A) located on the alternator cover and of a
movable element (rotor, B) fixed to the crankshaft.
B A
Note
To check the battery charging system for faults, use the DDS diagnosis instrument and follow the instructions given in the para-
graph, “Testing the battery charging system“ (Sec. 6 - 13).
The absolute value of voltage measured across the terminals of two of the three yellow cables (the measured value will be the
same whichever combination of cable is used) must be within the range indicated in the table below.
(Ambient temperature: 20 °C)
Important
Before testing, disconnect the alternator wiring from the electrical system when the ignition key is set to OFF.
Engine rpm 2000 6000

V effective 27±10 78±10
Values significantly lower than those indicated above can be due to:
- partially demagnetised rotor;
- short-circuited windings.
In the above cases the whole alternator assembly (rotor and stator) should be renewed.
If checks have a favourable outcome, reconnect the alternator to the regulator with ignition key on OFF. Make sure that no cables
are damaged or disconnected.
section
Removal of the alternator
Draining the cooling system 4 - 3, Change the coolant
Remove the front sprocket cover 7 - 14, Removing of the front sprocket
Drain the engine oil 4 - 3, Changing the engine oil and filter car-
tridge
Remove the clutch pushrod 7 - 8.2, Removal of the clutch transmission
unit
Remove the pump-cylinder hoses 9 - 5, Removal of the cylinder/piston as-
sembly
Remove the water pump-radiator hose 9 - 3.3, Removal of the water pump
Disconnect the cables of the alternator-side electric system (Sec. 6 -1, Routing of wiring on frame).
Remove the alternator cover, the stator (A) and the rotor (B) (Sec. 9 - 8, Removal of the alternator-side crankcase cover).
section
Refitting the alternator
Fit the rotor (B), the stator (A) and the alternator-side crankcase cover.
Connect the cables of the alternator-side electric system (refer to the table in chapter “Routing of wiring on frame”, Sec. 6-1).

Refit the water pump-radiator hose 9 - 3.3, Refitting the water pump
Refit the pump-cylinder hoses 9 - 5, Refitting the cylinder/piston assem-
bly
Fill the cooling system 4 - 3, Change the coolant
Refit the clutch control piston 7 - 8.2, Refitting the clutch transmission
unit
Refit the sprocket cover 7 - 14, Refitting the front sprocket
Fill the system with engine oil 4 - 3, Changing the engine oil and filter car-
tridge
section
Rectifier-regulator
The regulator (1) is placed on the rear right side of the vehicle under the semi-cowling.
The rectifier/regulator consists of an aluminium casing containing the diodes that rectify the current produced by the alternator.
It also contains an electronic device that regulates the current supplied by the alternator in accordance with battery voltage.
If the battery is drained, the current has the value necessary to restore optimum operating conditions of the battery. In contrast,
if the battery is fully charged, the current value will be lower.
Note
Control the charger current by using the “DDS” tester (Sec. 6 - 13, Diagnostic instruments).
Removal of the regulator

Remove both seats 5 - 3, Removal of the seat
Remove the right-hand semi-cowling 5 - 3, Removal of the side panels and seat
cowling
Disconnect the voltage regulator connector (2) and the alternator connector (3) from the main wiring.
Undo the two fixing screws (4) of the regulator (1) and remove it together with them.
Important
Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator.
2 A
4 3
section
Refitting the regulator
Position the regulator (1) on the support.
2 A
4 3
Important
Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator.
Connect the voltage regulator connector (2) and the alternator connector (3) to the main wiring.

Refit the right-hand semi-cowling Sec. 5 - 3, Refitting the side panels and seat
cowling
Refit both seats Sec. 5 - 3, Refitting the seat
section
Regulator fuse
The 30 A fuse placed on right side of the rear frame, protects the electronic regulator.

Remove the rider seat Sec. 5 - 3, Removal of the seat
Remove the fuse cap (A) to reach it.
A blown fuse can be identified by breakage of the inner filament (B)
In good condition Blown
Important
To avoid possible short circuits, replace the fuse with ignition key set to OFF.
Warning
Never use a fuse with a rating other than the specified value. Failure to observe this rule may damage the electric system or even
cause fire.
1
section
3 - Electric starting system
Note
The references of the elements listed below are those of the “Wiring diagram”, Sec. 6 -1.
Electric starting system

The key components of the electric starting system are a solenoid (6) and a starter motor (5) fed by the battery (7).
The engine starting strategy is managed entirely by the engine ECU (34), which monitors the following inputs:
- Engine Stop switch on right-hand handlebar switch (1)
- Engine starter switch on right-hand handlebar switch (1)
- Neutral sensor (31)
- Sidestand sensor (29)
- Clutch microswitch (36).
When these inputs are combined in the required manner, the engine control unit (34) enables engine starting.
The table lists possible engine starting combinations.

In accordance with the status of specific engine control unit inputs and the indications given in the table, the control unit enables
operation of the starter motor (ON status) when the START button is pressed.
X = generic status of neutral sensor, clutch, and sidestand.
Safety device functions table
CONTROL UNIT INPUTS CONTROL UNIT OUTPUTS
NEUTRAL CLUTCH STAND ENGINE STOP STARTER MOTOR
ENGINE 14 BODY 33 BODY 38 BODY 27 BODY 1

ECU PIN ECU PIN ECU PIN ECU PIN ECU PIN
X X X OFF OFF
NEUTRAL PULLED EXTENDED ON ON
NEUTRAL RELEASED EXTENDED ON ON
GEAR RELEASED EXTENDED ON OFF
GEAR PULLED EXTENDED ON OFF
NEUTRAL PULLED RETRACTED ON ON
NEUTRAL RELEASED RETRACTED ON ON
GEAR RELEASED RETRACTED ON OFF
GEAR PULLED RETRACTED ON ON
section
6- 3 Electric system and engine control system
Starter motor
Power:
0.7 kW/12 V
Direction of rotation:
counterclockwise viewed from power take-off side.
The starter motor is highly compact and reliable and therefore rarely gives any type of problem. In case of troubles, ensure that
the starter motor cable terminal is properly tightened under the nut and shows no oxidation. If the terminal is properly tightened
and free from corrosion, remove the starter motor and test it under no-load conditions (no load applied to the shaft). Secure the
starter motor to a test bench, making sure you do not damage the casing. Use a fully charged 12 V battery for the test. Use bat-
tery-motor connection cables which are no longer than 70 cm and with the same cross-section as the cable on the motorcycle
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 high speed. Take care not to short-circuit the two
cables connected to the battery.
section
Removing the starter motor

Remove the complete oil sump guard 5 - 4, Removing the oil sump guard
Drain the engine oil 4 - 3, Changing the engine oil and filter car-
tridge
Remove the front sprocket cover 7 - 14, Removing of the front sprocket
Remove the clutch pushrod 7 - 8, Removal of the clutch transmission
unit
Drain the cooling system 4 - 3, Change the coolant
Remove the pump-cylinder hoses 9 - 5, Removal of the cylinder/piston as-
sembly
Remove the water pump-radiator hose 9 - 3.2, Removal of the radiator
Remove the alternator cover and the fly- 9 - 8, Removal of the alternator-side crank-
wheel/alternator assembly case cover
Remove the timing gears 9 - 9.1, Removal of the timing gears
Remove the starter motor cam chain idler 9 - 9.1, Removal of the starter motor idler
gear gear
Disconnect the starter motor/solenoid cable (4).

Remove the fixing screw (1) and, if necessary, the insert (2).
2 4
section
Unscrew the fixing screws (3): the lower screw (3) fixes also the ground cable (6). Collect the toothed washer (7) and the washer
(8).
8 3
Note
The starter motor retaining screws are assembled with threadlocker.
Slide out the starter motor and gasket (5).
section
Refitting the starter motor
Inspect the condition of the gasket (5) and renew if necessary.
Position the gasket (5) and the starter motor on the crankcase. Fit the fixing screws (3), the lower one (3) with the ground cable
(6) and the toothed washer (7). Tighten the screws (3) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
Locate the insert (2) (if removed) in the crankcase half, hand tighten the fixing screw (1) and tighten it to the specified torque
(Sec. 3 - 3, Frame torque settings).
Connect the starter motor/solenoid cable (4).
Important
Fill the cap with protective grease before fitting it on the starter motor.
2 4

Refit the timing cam chain idler gears 9 - 9.1, Refitting the timing gears
Refit the starter motor idler gear 9 - 9.1, Refitting the starter motor gear
Refit the flywheel/alternator assembly and 9 - 8, Refitting the flywheel-alternator as-
the alternator cover sembly
Refit the water pump-radiator hose 9 - 3.2, Refitting the radiator
Refit the pump-cylinder hoses 9 - 5, Refitting the cylinder/piston assem-
bly
Fill the cooling system 4 - 3, Change the coolant
Refit the clutch control piston 7 - 8, Refitting the clutch transmission unit
Refit the sprocket cover 7 - 14, Refitting the front sprocket
Fill the system with engine oil 4 - 3, Changing the engine oil and filter car-
tridge
Refit the complete oil sump guard 5 - 4, Refitting the oil sump guard
section
Solenoid starter

Remove the rider seat 5 - 3, Removal of the seat
The solenoid (1) is elastically mounted to the battery mount.

Disconnect the battery (Sec. 6 -2, Battery).
Remove the protection cover (A).
Undo the nuts (2), taking care to collect the spring washers (3).
Remove the starter motor-solenoid cable (4) and the solenoid-battery cable (5).
Disconnect the wiring connector (6) of the starter solenoid from the wiring harness.
5 2
3
4 6
3
2
Remove the starter solenoid (1) sliding it upwards.
section
Checking operation of the starter solenoid
Apply 12V (battery voltage) to the positive (A) and negative (B) terminals of the connector.
B A
12V
With a multimeter connected between the two poles (threaded pins (C) and (D)) of the solenoid, check for electric continuity
(Sec. 6 -13, Diagnostic instruments). If there is no electrical continuity, renew the solenoid.
ECU
control
Live positive Positive

lead for system
Wiring side
- +
ECU Live positive
control lead
+ Positive + Positive
for system for system
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Ensure that the terminals are not oxidised and apply water repellent spray.
Position the solenoid-starter motor cable (4) and the solenoid-battery cable (5) on the solenoid terminals.
Insert the nuts (2) fitting the spring washers (3).
Fasten the nuts (2) to the specified torque (Sec. 3 - 3, Frame torque settings).
Refit the protection cover (A).
Connect the connector (6) between the starter solenoid and the battery wiring harness (Sec. 6 -2, Battery).
Fix the starter solenoid (1) to the battery support inserting it in the tongues (B).
5 2
3
4 6
3
2
B
1

Refit the rider seat 5 - 3, Refitting the seat
1
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4 - Lights and indicating devices
Replacing bulbs
Changing the headlight bulbs

Before replacing a burnt out light bulb, ensure that the replacement bulb has the same voltage and power rating as specified for
the lighting device in question (Sec. 3 - 1.1, Lights/instrument panel).
Warning
The halogen light bulbs in the headlight become hot when switched on and remain hot for some time after they are switched
off. Allow bulbs to cool before replacing them.
Bulb position in the headlight (1) is the following: low beam (LO), high beam (HI) and parking lights (A).
HI
LO LO
Remove the panel as described in the Sec. 5 - 1 “Removing the panel”.
Low beam (LO), high beam (HI)

To access the low beam (2) or the high beam (3) bulbs take the handlebar to full lock, introduce the hand into the light support
and disconnect the connectors (4).
3
2
2
3
section
Turn the low beam (2) or high beam (3) bulbs anticlockwise, remove them from their seats and replace the blown bulbs.
Note
Do not touch the transparent part of the bulb with your fingers, this will darken it and cause a loss of brightness.
Refit the low beam (2) or high beam (3) bulbs, lock them by turning them clockwise and reconnect the connectors (4).
3
2
2
3
Refit the panel as described in the Sec. 5 - 1, “Refitting the panel“.
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Changing the number plate light bulb
To access the bulb in the license plate light (4), open the license plate light glass (5), slide the bulb out of the holder and replace it.
Headlight aim
The motorcycle must be perfectly upright with the tires inflated to the correct pressure and with a rider seated, perfectly perpen-
dicular to the longitudinal axis.
Position the motorcycle 10 metres 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 conditions of low ambient 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 nine tenths
of the height of the centre of the headlight from the ground.
Note
This is the procedure specified by Italian regulations for checking the maximum height of the light beam.
9 x
x
10
10 m
The vertical alignment of the headlamp can be adjusted manually by turning screw (1).
The horizontal alignment of the headlight can be adjusted manually by turning screw (2).
1
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5 - Indicating devices
Checking the indicating system components
In the event of a fault, the internal connections of the device must be checked in all operating conditions. To do this, it is neces-
sary to disconnect the switch connector from the main wiring (Sec. 6 - 1, Routing of wiring on frame).
Then analyse the switch using an analogue or digital multimeter (Sec. 6 - 13, Diagnostic instruments).
Note
The same test may be done using the “DDS” tester (Sec. 6 - 13, DDS diagnosis instrument).
Checking the left-hand handlebar switch

To remove the left-hand handlebar switch, undo the fixing screws (1) and disconnect it from the electrical system.
The colours mentioned in the following descriptions refer to the colours of the wires from the switch and not to the colours of
the wires of the main electrical system.
HORN button
Connect the terminals of a multimeter to the Red/Blue and Blue/White cables to check for electric continuity, which must be
available when HORN is pressed (see Sec. 6 - 13, Diagnostic instruments, related to multimeter operation). When HORN button
is pressed, resistance value taken by the multimeter should be close to zero and, if available, a continuity beep should be heard.
When the horn button is not pressed, the resistance value should be infinity (there is no continuity as the electrical contacts inside
the pushbutton are open) and no continuity beep should be heard. If these conditions are not met, the device must be replaced.
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Turn indicator switch (TURN)
Connect the multimeter to the Grey and Red/Blue wires arriving from the turn signal switch and check for electrical continuity
when operating the right turn signal (see Sec. 6 - 13, Diagnostic instruments, related to operation of the multimeter).
Repeat the above procedure for the left turn signal, but connect the multimeter to Black and Grey cables. Colours mentioned in
the descriptions refer to the colour of wires from the switch and not to the colour of wires of the main electric system.
Low and high beam lights (HI BEAM)

Test using the same procedure, applying the probes of the meter to the Blue and Red/Blue cables.
Control switch (SET UP / SET DOWN)

Connect the multimeter to the Black and Red wires arriving from the function selector switch and check that when operating the
pushbutton (2) in the (▲) position there is electric continuity (Sec. 6 - 13, “Diagnostic instruments“, related to operation of the
multimeter). Repeat the same procedure, operating the push button (3) in the (▼) position, connecting the multimeter to the Blue/
Red/Blue and Blue/Yellow cables.
Flasher (PASSING)
Check for continuity between the Orange and Red/Blue cables.
- - - - - - - -
C
R
FREE FREE N PUSH PUSH PUSH
PUSH PUSH L OFF OFF OFF
RB BY R Bk R Bk Gr RB Br RB BW B RB O RB
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Refit the left-hand switch tightening the screws (1) to the specified tightening torque (Sec. 3 - 3, Frame torque settings).
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Checking the right-hand handlebar switch
To remove the right-hand handlebar switch, undo the retaining screws (1) and disconnect the wiring connector from the electrical
system.
The colours mentioned in the following descriptions refer to the colours of the wires from the switch and not to the colours of
the wires of the main electrical system.
ENGINE STOP button

With the multimeter check the conditions of the electric continuity between the Red/White and Red/Black cables (Sec. 6 -13, Diag-
nostic instruments related to operation of the multimeter). When the button is in RUN position, there should be electrical continuity
between the two wires. When the button is in the OFF position, there should be no electrical continuity between the two wires. If
these conditions are not met, the engine stop switch is not working correctly and must be renewed.
STARTER button
Proceed as described for the engine stop button and check for electric continuity between the Blue/White and Black cables when
the starter switch is pressed (Sec. 6 -13, Diagnostic instruments related to operation of the multimeter). If there is no continuity,
the starter button is faulty and must be renewed. Colours mentioned in the descriptions refer to the colour of wires from the switch
and not to the colour of wires of the main electric system.
STARTER ENGINE STOP UNLOCK
BW Bk RW RBk RW RBk
FREE OFF OFF
PUSH RUN RUN
- - - - - -
Refit the right-hand switch tightening the screws (1) to the specified tightening torque (Sec. 3 - 3, Frame torque settings).
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Checking the front and rear brake light switches, neutral light switch, oil pressure switch and clutch switch
Brake light switches
To check operation of the front (1) and rear (2) brake light switches use a multimeter to check that when the front or rear brake
is pressed, there is electric continuity (Pos. A) between the terminals of the corresponding switch (Sec. 6 - 13, Diagnostic instru-
ments, related to operation of the multimeter). No electric continuity should be available when brakes are not enabled (Pos.B). If
these tests fail to produce positive results, the part in question must be renewed.
Pos. B Pos. A
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Neutral indicator light
To check the neutral light switch (3) proceed as follows:
The neutral light does not illuminate on the instrument panel.

Remove the electric terminal connected to the neutral switch. Switch on the ignition switch (ignition key to ON position)
and ensure that the light illuminates when the terminal is earthed. If the light switches on, the neutral light switch should
be changed. If the light stays off, switch off the ignition (ignition key set to OFF) to switch off the instrument panel and
check for electrical continuity between the neutral switch and engine ECU with a multimeter.
The neutral light on the instrument panel is permanently illuminated.
Switch on the ignition (ignition key set to ON) and remove the electrical terminal from the neutral switch. If the light turns off,
the neutral switch should be changed. If the light stays off, switch off the ignition (ignition key set to OFF) and use a multimeter
to check whether the section of circuit between neutral switch and engine ECU is earthed.
Oil pressure sensor

To test the operation of the engine oil pressure sensor (4), proceed as follows:
Use the tester to check that oil pressure into the engine oil circuit complies with the specified values (Sec. 6 - 13, Check the
engine oil pressure).
If the engine oil pressure value is outside the specified range, check the oil circuit components and service as necessary.
If engine oil pressure value is within the specified range and the oil pressure warning light on the instrument panel stays off, switch
on the instrument panel (ignition key set to ON) without starting the engine, and disconnect the electrical terminal from the pres-
sure sensor and connect it to earth. If the warning light now illuminates, this means the sensor is defective and must be replaced.
If the warning light does not illuminate, use a multimeter and check for electrical continuity in the section of the circuit between
sensor and warning light on the instrument panel (this check must be performed with the ignition key set to OFF, i.e. with instru-
ment panel off).
If the engine oil pressure complies with the stated values and the engine oil pressure warning light on the instrument panel
is continuously illuminated, switch on the instrument panel (ignition key set to ON) and start the engine, then disconnect the elec-
trical terminal normally inserted on the pressure sensor. If the warning light now switches off, this means the sensor is defective.
If the warning light does not switch off, use a multimeter to check that the section of the circuit between sensor and warning light
on the instrument panel is not connected to earth (this check must be performed with the ignition key set to OFF, i.e. instrument
panel off).
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Clutch switch
For the clutch switch (5) proceed in the same manner as for the brake light switches (see beginning of this paragraph).
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Water temperature sensor
The coolant temperature sensor (6) sends an electrical signal to the ECU, which shares it with the instrument panel over the CAN
line. To check that the sensor (6) is functioning correctly, connect the DDS diagnosis instrument to the diagnostics socket of the
control unit and follow the instructions given in the paragraph “Guided diagnosis“ (Sec. 6 - 13). After making the correct selec-
tions from the menu, read the value of the coolant temperature from the parameters shown on the tester display. With the engine
completely cold, the air temperature (also read using the DDS diagnosis instrument) should be similar to that of the coolant. With
the engine hot and the cooler fan only just activated, the coolant temperature should be more or less equal to the fan activation
temperature. If these tests do not give a positive result, renew the coolant temperature sensor. If the DDS reads an error in the
control unit memory of the type “coolant temperature sensor short circuit or broken circuit“, check the circuit connecting the
sensor to the control unit. If this circuit is not faulty (not broken, not shorted and not grounded), replace the sensor.
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Checking operation of the fan relay

Remove the left front half-fairing 5 - 2, Removing the front half-fairing
Disconnect the relay from the electrical system and apply 12 V (battery voltage) between the small contacts: you should hear a
click that confirms that the internal electromagnet has switched.
Connect a multimeter to the big contacts to check for electric continuity (Sec. 6 - 13, Diagnostic instruments). The resistance
reading should be near zero and, if present, the continuity sound signal should be emitted. If this does not occur, the part must be
renewed.
12V
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Changing light bulbs
Changing the turn signal light bulbs

It is possible to replace only the rear turn indicator bulbs.
Undo the screw (1) and detach the lens (2) from the turn signal support (3).
The bulb has a bayonet-type end fitting: to remove it, push it in and turn it counter-clockwise.
To remove the support (3), refer to Sec. 7 - 18, Removal of the licence plate holder.
Push in the new bulb and turn it clockwise until it clicks into place.
Refit the lens by inserting the tab (A) in the corresponding slot in the turn signal support.
Tighten the screw (1).
1
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6 - Protection and safety devices
Checking protection and safety device components
Checking the key switch

Disconnect the ignition key (A) from the electric system by opening its connection (Sec. 6 - 1, Table I) and use a multimeter to
check continuity of its internal connections as follows:
turn the ignition key to OFF ( ) and connect a multimeter to contacts (1) and (4) to check for electric continuity (Sec. 6 - 13,
Diagnostic instruments, concerning operation of the multimeter). The resistance reading should be near zero and, if present, the
audible continuity signal should be emitted;
turn the key to ON ( ) and connect the multimeter to contacts (1) and (2) and then to (3) and (4) to check for electric continuity.
The resistance reading should be near zero and, if present, the audible continuity signal should be emitted;
turn the key to PARK ( ) and connect the multimeter to contacts (1) and (4) to check for electric continuity. The resistance
reading should be near zero and, if present, the audible continuity signal should be emitted;
turn the key to LOCK ( ) and connect the multimeter to contacts (1) and (4) to check for electric continuity. The resistance
reading should be near zero and, if present, the continuity sound signal should be emitted.
Note
W/R G/Bk Y Y/Gr

LOCK
PARK
OFF
ON
1 2 3 4
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Checking the sidestand switch
Remove the switch (1) from the side stand and disconnect the main wiring connector from the switch (Sec. 6 - 1, Table T).
Use an analogue or digital multimeter (Sec. 6 - 13, Diagnostic instruments) to check switch operation (see table).
Note
Pos. pin (A) Consumers Rating.

●-▲ 0 X
▲-■ X 0
Multimeter pos. Green/ Green/
Green Yellow
White Black
0 = Open contact
X = Closed contact
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Checking the fuses
The front (1) and rear (2) fuse boxes are respectively positioned under the rider seat and under the left panel.
To access the rear fuse box (2) remove the left panel as described in Sec. 5 - 1, “Removing the panel“.
To access the front fuse box (1) remove rider seat as described in Sec. 5 - 3, “Removal of the seat“.
To expose the fuses, take off the box protective cover. Mounting position and ampere capacity are marked on box cover.
For ampere ratings, refer to the chapter “Wiring diagram”, Sec. 6 - 1.
Important
Before replacing a damaged fuse with a new one of the same rating, identify the cause of the problem.
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A blown fuse can be identified by the breakage of inner filament (A).
In good condition Blown
Important
To avoid possible short circuits, replace a fuse with ignition key set to OFF.
Warning
Never use a fuse with a rating other than the specified value. Failure to observe this rule may damage the electric system or even
cause fire.
As well as the fuses in the fuse box, the vehicle has a 30 A fuse (3), located under the rider seat, that protects the electronic
regulator (Sec. 6 - 2, Rectifier-regulator).
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7 - Instruments
Instrument panel
Note
The instrument panel is supplied as a single component; its internal components cannot be renewed separately.
Important
Whenever the instrument panel is renewed, the ignition key programming procedure must be repeated.

Remove the left and right panels 5 - 1, Removing the panel
Remove the top fairing 5 - 1, Removing the headlight fairing
Unscrew the nuts (1) and remove the instrument panel (2) from the top fairing; retrieve the vibration damper mounts (3) and the
washers (4).
2
3
4 4
1
When refitting, tighten the nuts (1) to the specified torque (Sec. 3 - 3, Frame torque settings).

Refit the top fairing 5 - 1, Refit the headlight fairing
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Instrument panel system (DASHBOARD)
The instrument panel (1) consists of a large main LCD (A) and a circular dot matrix LCD (B).
The type of information shown can be selected by two pushbuttons (1) and (2), the turn indicator reset button (3) and the high-
beam flashing button (4) on the left hand switch.
In the instrument panel there are eight indicator lights, and a further auxiliary indicator light indicating when the “Over rev” rev
limit is reached and when the DTC is activated.
The instrument panel is backlighting with a white light with three different brightness settings: MAX, MIDDLE and MIN, set from
the menu described in the paragraph “Instrument panel backlighting adjustment”.
To protect the backlight LEDs in the event of voltage spikes, they are disabled if the power supply voltage exceeds 16 Volts; if
the power supply voltage drops below 6 Volts, the LEDs switch off as general instrument panel functionality is no longer ensured.
DDA
LAP
GEAR
A B
3
2
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Indicator lights
The following indicator lights are mounted on the instrument panel:
5 Neutral light N (GREEN).
Illuminates when the gearbox is in neutral.
6 High beam headlight indicator (BLUE).
It turns on to indicate that the high beam lights are on.
7 Engine oil pressure light (RED).
Illuminates when engine oil pressure is too low. It must turn on at Key-On, but must turn off a few seconds after the engine
has started.
It may come on briefly if the engine is very hot, but should go out again as engine speed increases.
8 Fuel warning indicator (AMBER YELLOW).
Comes on when fuel is low and 4 litres of fuel left in the tank.
9 Indicators repeater lights (GREEN).
Illuminates and flashes when the turn signal is in operation.
10 “Engine/Vehicle diagnosis - EOBD” indicator (AMBER YELLOW).
It turns on in the case of “engine” and/or “vehicle” errors and in some cases will lock the engine.
11 “Over rev” rev limiter/traction control indicator “DTC” (RED):
Over rev light

No limiter Off
1st threshold - no. RPM before the limiter On - STEADY
threshold (*)
Rev limiter (limiter engaged due to over- On - Flashing
revving) (*)
DTC intervention lights

No intervention Off
DTC intervention On - STEADY
(*) depending on the model, each calibration of the Engine Control Unit may have a different “setting“ for the thresholds that
precede the rev limiter and the rev limiter itself.
Note
If the Over rev function light and the DTC intervention light should both come on at the same time, the instrument panel gives
priority to the Over rev function.
12 ABS lights (AMBER YELLOW).

This turns on to indicate that ABS is disabled or not functioning.
Engine off / speed below 5 Km/h

Light off Light flashing Light steady
- ABS disabled with the ABS enabled but not
menu function “DISAB yet functioning
ABS” (**)
Engine on / speed below 5 Km/h
- ABS disabled with the ABS enabled but not
menu function “DISAB yet functioning
ABS”
Engine on / speed above 5 Km/h
ABS enabled and ABS disabled with the ABS disabled and not
functioning menu function “DISAB functioning due to a problem.
ABS”
(**) The ABS should be considered actually disabled only if the light continues to flash after starting the engine.
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7 12
5 10
8
6
DDA
LAP
GEAR
11 9
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Display settings and functions
When the instrument panel is switched on, all the digits of the main LCD activate for 3 seconds, except for the vehicle speed
digit, in which a countdown is displayed from 0 to 300 in 1.5s and from 300 to 0 in another 1.5s, and the rev counter digits, which
increase from 0 to 11000 rpm in 1.5s and decrease again to 0 in another 1.5s; the script “DUCATI“ and the vehicle model
“MTS1200“ are displayed on the circular display; all lights turn on in sequence from the bottom to the top.
OFF
CHECK
DDA
LAP
GEAR
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At the end of the check, the instrument panel always displays the Odometer (TOT) as the “main“ indicator on the main display
(A) and the riding mode in the circular display (B).
Note
The check can be interrupted by pressing the button (1).
A
RUN
LAP
GEAR
Upon Key-On, the instrument panel always displays the following information (deactivating any previously activated functions,
with the exception of Traction Control, if active).
At the end of the initial check, the instrument panel will always show the “main“ display, indicating the following information.
Main LCD (A):
- Vehicle speed indication;
- Engine rpm indication (RPM);
- Gear indication;
- Clock indication;
- Fuel level indication
- Coolant temperature indication;
- TOT - Odometer
Press (1) “s” to switch between the following functions:
- TRIP1 - Trip meter 1

- TRIP2 - Trip meter 2
- P1 and P2 - Front (P1) and rear (P2) tyre pressure (enabled only if the tyre sensor accessory is installed)
Dot matrix LCD (B):

- WARNING (only if active)
- ERRORS (only if active)
- DESMO SERVICE (only if active)
- SET UP - “Riding mode“ setting
Press (2) “t” to switch between the following functions:

- RANGE - Remaining range
- CONS I. - Current fuel consumption
- CONS M. - Average fuel consumption
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- AVG - Average speed
- AIR - Air temperature
- TIME TRIP - Trip time
DDA
LAP
GEAR
A B
Important
This menu is enabled only if the speed of the vehicle is less than 20 km/h. If this menu is on the display and the speed
of the motorcycle exceeds 20 km/h, the instrument panel automatically exits the menu and returns to the initial display. Press and
hold (2) “▼“ for 3 seconds to exit the MENU at any time.
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Vehicle speed indicator
This function displays vehicle speed (Km/h or mph depending on the set measurement system).
The instrument panel receives information about the actual speed (calculated in km/h) and displays the number increased by 8%.
Maximum speed displayed is 299 km/h (186 mph).
Over 299 km/h (186 mph) a series of dashes will be displayed “- - -” (not flashing).
Engine rpm indicator (RPM)

This function displays the rpms.
The instrument panel receives the engine rpm information and displays it.
This information is displayed progressively from the left to the right, identifying the rpms.
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Engaged gear indicator
This function displays the gears.
The instrument panel receives information and indicates the engaged gear or “N” for neutral.
In the case of a gear sensor “error”, a dash “-” (not flashing) will be displayed.
GEAR GEAR GEAR GEAR GEAR GEAR GEAR GEAR
Clock
This function shows the time.
Time is always displayed as follows:
AM from 0:00 to 11:59
PM from 12:00 to 11:59
If battery power is suddenly cut off (Batt-OFF), when battery power is restored and at the next Key-On, the clock is reset and re-
starts from “0:00“.
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Fuel level indicator
This function displays the fuel level.
The low fuel light turns on when the level goes down to 2 marks and there are still 4 litres in the tank; if the level goes down further,
the last mark will be displayed flashing.
Important
If the vehicle enters the reserve status and the light has turned on, when refuelling it is recommended to turn off the vehicle (Key-
Off); adding fuel with the motorcycle on without turning it off (Key-On and engine off) the data update may not be immediate.
Note
In the case of a level sensor “error”, the bargraph without marks is displayed and the rest of the digit will flash.
Steady marks
Steady marks
Series of
flashing
dashes
+
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Coolant temperature
This function indicates coolant indication state.
Select the temperature unit of measurement
(°C or °F).
The reading is indicated as follows:
if the reading is between - 39°C and +39°C “LO” is shown flashing on the instrument panel (steady);
if the reading is between +40°C and +120°C it appears on the instrument panel (steady);
if reading is +121 °C or higher, “HI“ is shown flashing on the information panel.
Note
In the event of a sensor “error“, flashing dashes (“- - -”) are shown and the “Engine/vehicle diagnosis - EOBD“ indicator (11) turns
on.
vs. EU, CND, FRA, JAP Steady reading
Steady reading Steady reading
Flashing reading
Flashing reading
Engine Diagnosis
vs. UK, USA

Steady reading
Steady reading Steady reading
Flashing reading
Flashing reading
Engine Diagnosis
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Total distance covered indicator: “Odometer“
This function shows the total distance covered by the vehicle.
At Key-On the system automatically enters this function.
The odometer reading is stored permanently and cannot be reset.
If it exceeds 99999 km (or 99999 miles), the reading “99999” remains displayed permanently.
vs. EU, CND, FRA, JAP vs. UK, USA
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“Trip 1“ meter
This function shows the distance travelled since the trip meter was last reset.
Press and hold (1) “▲“ for 3 seconds while in this function to reset the trip odometer.
When the reading exceeds 999.9, distance travelled is reset and the meter automatically starts counting from 0 again.
If the system measurement units are changed at any moment, or if there is an interruption in the power supply (Battery Off), the
distance travelled is reset and the count starts from zero (considering the newly set unit of measurement).
Note
When this value is reset, also the “Average fuel consumption”, “Average speed” and “Trip time” functions are reset.
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“Trip 2“ meter
This function shows the distance travelled since the trip meter was last reset.
Press and hold (1) “▲“ for 3 seconds while in this function to reset the trip odometer.
When the reading exceeds 999.9, distance travelled is reset and the meter automatically starts counting from 0 again.
If the system measurement units are changed at any moment, or if there is an interruption in the power supply (Battery Off), the
distance travelled is reset and the count starts from zero (considering the newly set unit of measurement).
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Indication if the DTC function is active/not active
This function indicates if DTC (Ducati Traction Control) is active.
When “DTC” is not lit up in the inside the rim, this means that the function is disabled.
DTC OFF DTC ON
Indication if the LAP function is active/not active

This function indicates if LAP (Lap number) is active.
When “LAP” is not lit up, this means that the function has been switched off.
LAP OFF LAP ON
LAP
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Warning indication (Alarms/Signals)
The instrument panel shows certain indications/malfunctions in real time on the circular dot matrix display (B) that are not dan-
gerous for correct vehicle operation.
At Key-On (at the end of the check) one or more “warnings” are displayed if they are active.
If a “warning” is activated while the vehicle is in use, the current indication on the circular dot matrix display (B) is replaced au-
tomatically by the relative warning indication.
If there are multiple indicators, they will scroll automatically every 3 seconds.
Note
No signal lights turn on if one or more “warnings” are activated.
The following “warnings” could be displayed:

- Battery level;
- Traction control;
- Hands free key;
- Hands free key battery level;
- Coolant temperature;
- Front tyre pressure alarm (if present);
- Rear tyre pressure alarm (if present);
- “Low” front tyre sensor battery level (active only if the tyre sensor accessory is present);
- “Low” rear tyre sensor battery level (if present);
- Steering release error.
With one or more “warnings” active, the user may access other functions by pushing button (2) “▼”.
DDA
LAP
GEAR
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“Low” battery level
The activation of this “warning” indicates that the status of the battery vehicle is low.
It is activated when the battery voltage is ≤ 11.9 Volt.
Note
Charge the battery as soon as possible with the specific charger, as it is very likely that the vehicle will not start.
Traction Control (DTC) deactivated

The activation of this “warning” indicates that DTC (Ducati Traction Control) has been turned off.
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Hands Free key (HF) not recognised
This “warning” indicates that the Hands Free system has not detected an active key (C) near the vehicle.
Check that the active key (C) is near the vehicle (and has not been lost) or that it functions properly.
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“Low“ Hands Free key (HF) battery level
This “warning” indicates that the Hands Free system has detected that the battery allowing the active key (1, fig. 64) to commu-
nicate and turn the vehicle on is almost flat.
Replace the battery as soon as possible as described in paragraph “Replacing the active key battery”.
“High“ engine coolant temperature

The activation of this “warning” indicates that the engine coolant temperature is high.
It is activated when the temperature reaches 121°C (250°F).
Note
In this case, stop the vehicle and switch the engine off immediately; make sure that the fans are working.
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Front tyre pressure alarm (active only if the tyre sensor accessory is present)
This “warning” indicates that the front tyre pressure is too low (£ 1.6 bar).
Note
Check front tyre pressure.
Rear tyre pressure alarm (active only if the tyre sensor accessory is present)
This “warning” indicates that the rear tyre pressure is too low (£ 1.6 bar).
Note
Check rear tyre pressure.
“Low” front tyre sensor battery level (active only if the tyre sensor accessory is present)
The activation of this “warning” indicates that the battery inside the front sensor is almost discharged and therefore the front
tyre pressure reading will soon no longer be available.
Note
Take the vehicle to a Ducati dealer as the sensor must be replaced.
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“Low” rear tyre sensor battery level (active only if the tyre sensor accessory is present)
The activation of this “warning” indicates that the battery inside the rear sensor is almost discharged and therefore the rear tyre
pressure reading will soon no longer be available.
Note
Have the sensor checked as soon as possible as the sensor itself must be replaced.
Steering release error - Steering still locked

The activation of this “warning” indicates that the Hands Free System was not able to extract the steering lock.
Note
In this case, we recommend switching the vehicle off and on (Key-Off / Key-On), while holding the handlebar pushed to full lock.
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Instrument panel diagnosis
This function identifies any abnormal vehicle behaviours.
The instrument panel activates any abnormal vehicle behaviours in real time (ERRORS).
At Key-On (at the end of the check) one or more “ERRORS” are displayed (only if they are active).
If an “error” is activated during operation, the current indication on the circular dot matrix display (B) is automatically replaced by
the error indication.
If there are multiple errors, they will scroll automatically every 3 seconds; the “Engine/vehicle diagnosis - EOBD” indicator (8)
always turns on when one or more errors are activated.
When one or more errors are active, press (2) “▼” to access other functions.
The table below shows the errors that can be displayed.
DDA
LAP
GEAR
section
Warning light Error message Error
BBS/DTC Black Box / Traction Control control unit
GEAR SENSOR Gear sensor
FUEL SENSOR Fuel Level Sensor
SPEED SENSOR Speed sensor
EXVL ERROR Exhaust valve starter motor
UNKNOW DEVICE Unknown control unit
DEVICE ECU ECU control unit not functioning
DEVICE DASHBOARD Instrument panel not functioning
DEVICE HANDS FREE Hands Free control unit not functioning
THROTTLE POSITION Incorrect throttle position
ACCELERATOR Incorrect accelerator position

POSITION
ETV MOTOR Throttle starter motor not functioning
ETV RELAY Relay starter motor not functioning
PRESSURE Atmospheric pressure sensor
ENGINE Engine temperature

TEMPERATURE
INTAKE AIR Air temperature

TEMPERATURE
FUEL INJECTION Injection relay
COIL Coil
INJECTOR Injector
PICK-UP Timing/rpm sensor
LAMBDA Lambda sensor
LAMBDA HEATER Lambda heater
FAN RELAY Fan relay
HIGH BEAM High beam headlight relay
LOW BEAM Low beam headlight relay
HORN Horn
CAN CAN communication line
BATTERY Battery voltage (HIGH or LOW)
DEVICE SUSPENSION Suspension ECU not functioning
SUSPENSION Problem related to suspension ECU operation

GENERIC
STOP LIGHT Rear stop light
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Warning light Error message Error
ECU GENERIC ECU error
KEY ERROR HF communication problem
HANDS FREE Hands Free ECU error

GENERIC
TYRE SENSOR ERROR Tyre sensor error
SUSPENSION FRONT Problem with the stepper that adjusts suspension front compression
COMPRESSION
SUSPENSION FRONT Problem with the stepper that adjusts front suspension rebound
REBOUND
SUSPENSION REAR Problem with the stepper that adjusts suspension rear compression
COMPRESSION
SUSPENSION REAR Problem with the stepper that adjusts suspension rear rebound
REBOUND
SUSPENSION Problem with the DC starter motor that adjusts the rear suspension preload
PRELOADER
ADJUSTER
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Maintenance indicator
This function indicates that the vehicle is about to or has travelled a distance for which an Authorised Ducati Service Centre should
be contacted to have the general maintenance or oil change performed.
Residual range indication when the SERVICE is due

When 1000 Km (621 miles) are left until reaching the mileage programmed by Ducati for having the “SERVICE“ performed, the
instrument panel activates (at the end of the initial check) the indication of which type of service should be performed and the
residual range (countdown).
The indication is activated each time the motorcycle is turned on (Key-On) for 5 seconds (flashing).
The residual range is updated every 100 Km (-1000, -900, -800, -700, etc.…..).
Indication of range reached for SERVICE

If you reach the mileage programmed by Ducati, the information panel will activate (at the end of the initial check) the indication
that you should go to a Ducati Dealer or Authorised Service Centre to have the scheduled maintenance “DESMO SERVICE” or
“OIL SERVICE” performed.
The indication is activated each time the motorcycle is turned on (Key-On) (not flashing); press (2) “▼” to display other functions;
The indication will remain until it is reset and it can be displayed at any moment by scrolling the functions.
Note
The distance travelled thresholds are defined in an “absolute” sense and do not account for when the “reset” request for the
indication is made by the Authorised Ducati Service Centre.
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Maintenance table
Indicator Mileage count down -1000 count down -1000 DESMO OIL SERVICE
travelled distance DESMO SERVICE OIL SERVICE SERVICE
1 1000 •
2 11000 •
12000 •
3 23000 •
24000 •
4 35000 •
36000 •
5 47000 •
48000 •
6 59000 •
60000 •
7 71000 •
72000 •
8 83000 •
84000 •
9 95000 •
96000 •
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SET UP - “Riding Mode set“ indication
This function indicates the “Riding Mode” set for the vehicle.
Four “Riding Modes” are available: SPORT, TOURING, URBAN and ENDURO.
Each Riding Mode can be changed using the “Riding Mode” function.
In the “base” version, only the set Riding Mode is indicated.
“Base” version
On the “S” version, the setup and the riding mode settings are indicated.
“S” version
Single passenger
Single passenger
with luggage
Two passengers
Two passengers
with luggage
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“S” version
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“RANGE” indicator - remaining range
This function indicates the distance that can be travelled with the fuel currently in the tank.
The calculation is made based on the fuel level and an average consumption in reference to the last 90 seconds of driving (not
the average fuel consumption “CONS M.”).
If you refuel adding more than 4 litres of fuel with the vehicle switched off, at the subsequent Key-On, the remaining range read-
ing will be updated instantaneously and will be calculated based on the new fuel level and an average fuel consumption of
18.0 Km/L; otherwise (that is, if you add less than 4 litres) the reading will only be updated after the vehicle is in movement (not
instantaneously).
When the range arrives to “0” the indication will flash together with the symbol (motorcycle + fuel pump).
Warning
It is recommended to turn off the motorcycle (Key-Off) when refuelling; if adding fuel without turning off the motorcycle (Key-
On/engine off), the reading will be updated as soon as the vehicle starts to move (speed greater than zero).
Indicator “CONS I.“ - Instantaneous fuel consumption

This function indicates the “instantaneous” fuel consumption.
The calculation is made considering the quantity of fuel used and the distance travelled during the last second.
The active calculation phase only occurs when the engine is running and the vehicle is moving (moments when the vehicle is not
moving when speed is equal to 0 and/or when the engine is off are not considered). Dashes “- -.-”. are shown on the display
when the calculation is not made.
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Indicator “CONS M.“ - Average fuel consumption
This function indicates the “average” fuel consumption.
The calculation is made considering the quantity of fuel used and the km travelled since the last Trip 1 reset. When Trip 1 is reset,
the value is set to zero and the first available value is shown on the display 10 seconds after the reset. Dashes are displayed for
the first 10 seconds, as the value is not yet available.
“- -.-”.
moving when speed is equal to 0 and/or when the engine is off are not considered).
Indicator “AVG” - Average speed

This function shows the average speed of the motorcycle.
The calculation is made considering the distance and time travelled since the last Trip 1 reset. When Trip 1 is reset, the value is
set to zero and the first available value is shown on the display 10 seconds after the reset. Dashes “- -.-“ are displayed for the
first 10 seconds, as the value is not yet available.
moving when speed is equal to 0 and/or when the engine is off are not considered).
The calculated value is displayed increased by 8% to align it with the vehicle indicated speed.
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Air temperature indicator
This function shows the external temperature.
Display limits: -39°C ÷ +124°C
In the event of a sensor FAULT (-40°C,+125°C or disconnected), a string of dashes “- - -” (not flashing) is displayed, the “Engine/
Vehicle Diagnosis - EOBD” indicator (4) turns on and an error is indicated in the “Errors” Menu.
Note
When the vehicle is stopped, the engine heat could influence the displayed temperature.
DDA
LAP
GEAR
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When the detected temperature drops to 4°C (39°F), the display warns that the formation of ice is possible. The indication turns
off when the temperature rises to 6°C (43°F).
Warning
This warning does not exclude the possibility of icy road sections even at temperatures above 4°C (39°F); when external temper-
atures are “low“ it is always recommended to drive carefully, particularly on sections that are not exposed to the sun and/or on
bridges.
Indicator “TIME TRIP“ - Trip time

This function shows the vehicle trip time.
The calculation is made considering the time travelled since the last Trip 1 reset. When Trip 1 is reset, the value is set to zero.
The active time calculation phase only occurs when the engine is running and the vehicle is moving (when the vehicle is not mov-
ing and the speed is equal to 0 and/or when the engine is off, the time is automatically stopped and automatically restarts when
the active counting phase restarts).
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“Riding Mode” function (Riding Mode change)
This function changes the motorcycle Riding Mode.
Each Riding Mode is associated with a different intervention level of the traction control (DTC - Ducati Traction Control) and dif-
ferent engine power and output.
For the “S” version with electronic suspension, each Riding Mode change is also associated with different motorcycle setup.
To change riding mode, press the reset button (3) once. The “SET UP” menu open in the circular display (B).
Select the desired riding mode by pressing the reset button (3) repeatedly. Press the same button for 3 seconds to confirm the
Riding Mode.
If the twistgrip is closed (vehicle stopped) the Riding Mode change will occur immediately; if the twistgrip grip is open (vehicle
moving) the message “CLOSE THROTTLE TO ACTIVATE” will appear on the display, which means that the throttle must be
closed; this message will appear for 5 seconds, during which the gas must be closed in order to activate the new Riding Mode.
If the twistgrip is not closed after 5 seconds, the procedure is aborted (no change is made).
If the reset button (3) is not pressed for a period of 10 seconds while the “SET UP” menu is open, the instrument panel auto-
matically exits the display mode without applying any changes.
Warning
Ducati recommends changing the Riding Mode when the vehicle is stopped. If the Riding Mode is changed while riding, be very
careful (it is recommended to change the Riding Mode at a low speed).
Press RESET Version “S” only
press RESET for

2 sec.
Press RESET
press RESET for
2 sec.
Press Press RESET

RESET
press RESET for
2 sec.
Press RESET
press RESET for
2 sec.
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“LOAD” FUNCTION (setup change)
This function, which is only available in the “S” version, changes the vehicle setup.
Each individual riding mode is associated with four different setups.
To change the vehicle setup, press and hold the reset button (3) for 3 seconds. The “LOAD“ menu is opened on the circular
display (B).
Select the desired setup by pressing the reset button (3) repeatedly. To confirm the setup, press and hold the reset button (3)
for 3 seconds. At the end of the 3 seconds, the change occurs immediately and the instrument panel exits the display mode
automatically.
Example: if a setup change is made from “individual passenger“ to “passenger with luggage”, the change may vary depending
on the set Riding Mode (the “passenger with luggage” setup may have different adjustments depending on if the Riding Mode
that is set to SPORT, TOURING, URBAN or ENDURO).
If the reset button (3) is not pressed for a period of 10 seconds while the “LOAD” menu is open, the instrument panel automat-
ically exits the display mode without applying any changes.
Warning
The setup change can lead to a different motorcycle Riding Mode; it is recommended to be careful if changing the setup while
riding (it is recommended to change the setup at a low speed).
Version “S” only press RESET for 2 sec.
Press RESET for

2 sec.
single passenger
setup activation
Press RESET
Press RESET for

2 sec.
single passenger
with luggage setup
activation
Press Press RESET
RESET
Press RESET for
2 sec.
two passenger setup
activation
Press RESET
Press RESET for

2 sec. two passenger with
luggage setup
activation
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“Setting” menu
This menu is used to set/enable some motorcycle functions.
To access the “setting menu” press and hold (2) “▼” for 2 seconds.
Note
Once in this menu, it is not possible to scroll through the functions on the main display (A).
Important
For safety reasons, the setting menu can only be accessed when motorcycle speed is lower than or equal to 20 Km/h. If this
menu is open and the speed of the motorcycle exceeds 20 km/h, the instrument panel automatically exits the menu and returns
to the “main“ display.
The setting menu contains the following “items”:

- EXIT
- ABS
- BATTERY
- SETUP
- B.LIGHT
- LAP
- DTC
- RPM
- CLOCK
- PIN CODE
- EXIT
To exit the setting menu, use button (1) “▲” or button (2) “▼” to highlight “EXIT” (listed at the beginning and the end of the
menu option list) and press reset (3).
Press “▼” for 2 sec.
Press “▲” Press “▼”
Press “▲” Press “▼” Press “▲” Press “▼”
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3
2
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ABS disabling function
This function disables the ABS control unit.
To display the function, enter the “Setting” menu page and access the “ABS” page.
After accessing the display, press and hold the reset button (3) for 3 seconds to disable ABS.
The instrument panel will send the disable request (“WAIT....“ is shown on the circular display (B)) for 6 seconds) and then if ABS
is successfully disabled, “DISABLED“ will appear on the circular display (B).
The ABS light (12) indicates disabled status by switching from “off“ to “flashing”.
To re-enable the ABS system, turn the motorcycle off and on (Key-Off/Key-On).
Press
RESET
Press RESET
Press
RESET
for 3 s.
Press
Press
“▼”
“▲”
Press
RESET
12
DDA
LAP
GEAR
Note
If the disabling request was not successful, the instrument panel will display “NOT DISABLED“ in the circular display (B).
In this case, repeat the procedure.
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Battery voltage indicator (BATTERY)
This function describes the battery voltage indicator.
To display the function, enter the “Setting” menu page and access the “BATTERY” page.
The information will be displayed as follows:

- if battery voltage is between 12.0 and 14.9 Volt the reading will be displayed steady;
- if battery voltage is between 11.0 and 11.9 Volt the reading will be displayed flashing;
- if battery voltage is between 15.0 and 16.0 Volt the reading will be displayed flashing;
- if battery voltage is 10.9 Volts or less, the word “LOW“ is shown flashing and the Vehicle/Engine Diagnosis - EOBD“ light (10)
turns on;
- if battery voltage is above 16.1 Volts, the word “HIGH“ is shown flashing and the Vehicle/Engine Diagnosis - EOBD“ light (10)
turns on.
Note
Dashes “- - -“ appear if the reading is not available.
10
DDA
LAP
GEAR
Press RESET
Press RESET Press RESET Press RESET
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“Riding Mode” customisation
This function customises each Riding Mode.
To display the function, enter the “Setting” menu page and access the “SET UP“ page.
When accessing the function, the four riding modes appear on the circular display; to customise the parameters, use buttons (1)
“▲” and (2) “▼” to select the riding mode to be modified and press reset (3) to confirm.
The parameters that can be “customised“ are “DTC” (Ducati Traction Control), ”ENGINE” and, only for “S” versions, the elec-
tronic suspension regulations “des”.
Any parameter change made is saved in the memory also after a Battery-Off.
To change the DTC parameters, see the paragraph “DTC (Ducati Traction Control)“.
To change the Engine parameters, see the paragraph “ENGINE (engine power control)”.
To change the electronic suspension parameters (only for “S” versions) see the “DES (Ducati Electronic Suspension)” paragraph.
The parameters set by Ducati for each individual driving style can be restored with the ”DEFAULT” function.
To restore the “default” parameters, see the paragraph “DEFAULT (Resetting Ducati default parameters)”.
Warning
Changes should only be made to the parameters by people who are experts in motorcycle setup; if the parameters are changed
accidentally, use the “DEFAULT” function to reset the parameters.
“base” “S”
Press “▼”
Press RESET
Press “▼”
Press RESET

Press RESET

Press RESET
3
2
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DTC (Ducati Traction Control) setting function
This function customises the intervention level of the DTC (Ducati Traction Control).
To display the function, enter the “Setting” menu page and access the “SET UP“ page. Use buttons (1) “▲” and (2) “▼” to
select the riding mode to be modified and press reset (3) to access the “DTC“ function.
When the function is accessed, the current DTC level setting “LEVEL N“ will appear at the top of the circular display.
The intervention levels range from “1” to “8”; the higher the number, the greater the intervention of the Traction Control system.
To change the DTC intervention level select the “NEW LEVEL” displayed with buttons (1, fig. 7) “s” and (2, fig. 7) “t” and press
the reset button (14, fig. 4).
The number to be set is shown on the display; press (1) “▲” and (2) “▼” to increase or decrease the value; press the reset button
(3) to confirm the new level.
Store the new setting by pressing the reset button (3) with “MEMORY” highlighted.
The upper indication “LEVEL N.2“ will be updated to confirm that the new setting was “received” and stored.
To exit the function, highlight “EXIT” and press the reset button (3).
The DTC intervention increases, passing from level 1 to level 8.
The following table indicates the most suitable level of DTC intervention for the various riding types as well as the default settings
in the “Riding Modes“ that can be selected by the rider:
DTC level Riding type Use Default?

1 ENDURO Professional Off-road for very expert riders. It permits elevated NO
rear wheel spin. It does not intervene in time on as-
phalt.
2 ENDURO Off-road for less experienced riders. Does not inter- It is the default level for
vene in time on asphalt. the “ENDURO” Riding
Mode
3 TRACK Track for very expert riders. Permits sliding sideways NO
4 SPORT Sporty driving on a road or track It is the default level for
the “SPORT” Riding
Mode
5 TOURING Normal riding It is the default level for
the “TOURING” Riding
Mode
6 URBAN “Very safe” riding together with the use of an 100HP It is the default level for
ENGINE (maximum power 100 HP) the “URBAN” Riding
Mode
7 RAIN Wet road NO
8 HEAVY RAIN Wet road and slippery asphalt NO
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“Base” version
“S” version
Press
Press RESET RESET for
3 sec.

Press RESET
Press “▲” Press “▼” Press RESET

for 4 sec. for 4 sec.
Press RESET
3
2
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Tips on how to select the sensitivity level
Warning
The 8 level settings of the DTC were calibrated using tyres of the same make, model and size as those originally fitted to the
motorcycle.
The use of tyres of different size to the original tyres may alter the operating characteristics of the system.
In the case of minor differences, such as for example, tyres of a different brand and/or model than the original, but with the same
dimensions (rear = 190/55-17; front = 120/70-17), it may be sufficient to simply select the most suitable level setting from those
available to restore optimal system operation.
If tyres of a different size class are used or if the tyre dimensions differ significantly from the original tyres, it may be that the
system operation is affected to the point where none of the 8 available level settings will give satisfactory results.
In this case is it is advisable to deactivate the traction control system.
If level 8 is selected, the DTC control unit will kick in at the slightest hint that the rear wheel is starting to spin.
Between level 8 and level 1 there are a further 6 intermediate levels. The level of DTC intervention decreases in equal steps from
level 8 to level 1.
When levels 1, 2 or 3 is selected the DTC control unit will allow the rear wheel to spin and also slide sideways on exiting a corner;
we recommend that this setting is only used by very experienced riders.
The choice of the correct level depends on 3 main variables:

1 The grip (type of tyre, amount of tyre wear, the road/track surface, weather conditions, etc.)
2 The characteristics of the track/road (curves taken at similar speeds or at very different speeds)
3 The Riding Mode (whether the rider has a “smooth” or an “aggressive” style)
The relation of the DTC intervention level to grip conditions:

The choice of level setting depends greatly on the grip conditions of the track/circuit (see below, tips for use on the track and on
the road).
The relation of the DTC intervention level to the circuit characteristics:

If all the corners on the track/circuit can be taken at a similar speed, it will be easier to find an intervention level that is satisfactory
for every bend; on the other hand, if the track has, for example, one corner that is much slower than all the others, it will necessary
to find a compromise level (on the slow corner the DTC will tend to control more than on the faster corners).
The relation of the DTC intervention level to Riding Mode:

The DTC will tend to kick in more with a “smooth” Riding Mode, where the bike is leaned over further, rather than with a “rough”
style, where the bike is straightened up as quickly as possible when exiting a turn.
Tips for use on the track

We recommend level 8 be used for a couple of full laps (to allow the tyres to warm up) in order to get used to the system. Then
try levels 7, 6, etc., in succession until you identify the DTC intervention level that suits you best (always try each level for at least
two laps to allow the tyres to warm up).
Once you have found a satisfactory setting for all the corners except one or two slow ones, where the system tends to kick in
and control too much, you can try to modify your Riding Mode slightly to a more “rough” approach to cornering i.e. straighten up
more rapidly on exiting the corner, instead of immediately trying a different level setting.
Tips for use on the road

Activate the DTC, select level 8 and ride the motorcycle in your usual style; if the level of DTC intervention seems excessive, try
reducing the setting to levels 7, 6, etc., until you find the level that suits you best.
If changes in the grip conditions and/or circuit characteristics and/or your Riding Mode, and the level setting is no longer suitable,
switch to the next level up or down and proceed as described above to determine the best setting (e.g. if with level 7 the DTC
intervention seems excessive, switch to level 6; alternatively, if on level 7 you cannot perceive any DTC intervention, switch to
level 8).
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ENGINE setting function (Engine Power Control)
This function customises engine power and output.
To display the function, enter the “Setting” menu page and access the “SET UP“ page. Use buttons (1) “s” and (2) “t” to select
the riding mode to be modified and press the reset button (3) to access the “ENGINE“ function.
When the function is accessed, the current engine setting (150 HIGH, 150 LOW or 100 HP) appears at the top of the circular
display.
To change the engine “power“ setting, use buttons (1) “▲” and (2) “▼” to select the “NEW SET“ indicated and press the reset
button (3).
Use the buttons (1) “▲” and (2) “▼” to select one of the 3 selections (150 HIGH, 150 LOW or 100 HP); press the reset button
(3) to confirm the new level.
Store the new setting by pressing the reset button (3) for 3 seconds with “MEMORY” highlighted.
The upper indication will be updated to confirm that the new setting was “received” and stored.
Press
Press RESET RESET for
3 sec.

Press RESET
Press “▲” Press “▼” Press RESET
Press RESET
3
2
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DES setting function (Ducati Electronic suspension)
Available in the “S” version only.
To display the function, enter the “Setting” menu page and access the “SET UP“ page. Use buttons (1) “▲” and (2) “▼” to
select the riding mode to be modified and press reset (3) to access the “DES“ function.
When the function is accessed, the four different setup types are shown on the circular display.
Use buttons (1) “▲” and (2) “▼” to select the setup to customise and press the reset button (3).
Press RESET
Press RESET
3
2
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The three modifiable parameters are shown on the circular display:
FRONT: adjustment of the front shock absorber rebound and compression;
REAR: adjustment of the rear shock absorber rebound and compression;
PRE-LOAD: adjustment of the rear shock absorber spring preload.
Use buttons (1) “▲” and (2) “▼” to select the parameter to change and press the reset button (3).
Press RESET
Press “▼”
Press “▲”
Press RESET
3
2
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“FRONT” adjustment
the current compression [C.] and rebound [R.] settings are shown at the top of the circular display.
Press buttons (1) “▲” and (2) “▼” to select the parameter to change and press the reset button (3).
The number to change appears on the circular display (B);
press buttons (1) “▲” and (2) “▼” to increase or decrease the value (between 1 and 32);
press the reset button (3) to confirm the new level.
Note
Increasing the set value “decreases” the hydraulic “braking”; decreasing the value “increases“ the hydraulic “braking“ of the
shock absorber.
The upper indication [C.] or [R.] will be updated to confirm that the new setting was “received” and stored.
3
2
“S” version
Press RESET
RESET Press “▲” for 12 s Press “▲”

RESET RESET
Press
Press Press “▼” for 12 s RESET Press “▼”
Press “▼” Press “▲” for 6 s for 3 Press “▲”
“▲” RESET RESET sec.
Press
Press RESET
Press “▼” for 6 s Press “▼”
Press “▼” for 3
“▲” Press sec.
“▼”
Press RESET
Press
“▲”
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“REAR” adjustment
the current compression [C.] and rebound [R.] settings are shown at the top of the circular display (B, fig. 6).
Press buttons (1) “▲” and (2) “▼” to select the parameter to change and press the reset button (3).
The number to be changed is shown on the display;
press buttons (1) “▲” and (2) “▼” to increase or decrease the value (between 1 and 32);
press the reset button (3) to confirm the new level.
Increasing the set value “decreases” the hydraulic “braking”; decreasing the value “increases“ the hydraulic “braking“ of the
shock absorber.
The upper indication [C.] or [R.] will be updated to confirm that the new setting was “received” and stored.
3
2
“S” version
Press RESET
RESET Press “▲” for 12 s Press “▲”

RESET RESET
Press
Press Press “▼” for 12 s RESET Press “▼”
Press “▼” Press “▲” for 6 s for 3 Press “▲”
“▲” RESET
RESET sec.
Press
Press RESET
Press Press “▼” for 6 s Press “▼”
“▼” for 3
“▲” Press
“▼” sec.
Press RESET
Press
“▲”
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“PRE-LOAD” adjustment
- the “preload” and a bar graph indicating the current value set are shown at the top of the circular display.
- use buttons (1) “▲” and (2) “▼” to select “NEW SET” and press the reset button (3).
- the number to be changed is shown on the display;
- press buttons (1) “▲” and (2) “▼” to increase or decrease the value (between 1 and 16);
- press the reset button (3) to confirm the new level.
Note
Increasing the set value “stiffens” the rear shock absorber; decreasing the value “softens“ the rear shock absorber.
The upper indication and the bargraph will be updated to confirm that the new setting was “received” and stored.
3
2
Press RESET
Press
RESET Press “▲” for 4 s RESET Press “▼”
RESET RESET for 3
sec.
Press Press “▼” for 4 s Press “▲”

Press “▼”
“▲”
Press Press
“▲” “▼”
Press RESET
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DEFAULT function (Resetting Ducati default parameters)
This function resets the parameters set by Ducati for each Riding Mode.
To display the function, enter the “Setting“ menu page and access the “SET UP“ page. Use the buttons (1) “▲” and (2) “▼” to
select the riding mode for which you want to restore the settings and access the “DEFAULT” function.
When the function is accessed, “DEFAULT PARAMETER?” is shown on the circular display; To reset the parameters, highlight
“YES” and press the reset button (3).
For the parameter reset, approx. 15 seconds are needed during which “WAIT…” will appear on the display; at the end of the
procedure, “DEFAULT OK“ will appear on the circular display to indicate that the parameters were reset.
Important
This procedure restores the parameters for all Riding Modes.
3
2
“Base” version
“S” version
Press RESET
Press
Press “▼”
“▲”
Press RESET
Press RESET
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Instrument panel backlighting adjustment function
This function adjusts the instrument panel backlighting intensity.
To display the function, enter the “Setting” menu page and access the “B.LIGHT” page.
- the arrows indicate the adjustment currently in use;
- use buttons (1) “▲” and (2) “▼” to select the new adjustment;
- to store the new setting, press the reset button (3); the arrows will move to the new stored condition.
To exit, select “EXIT” and press the reset button (3).
“MAX” adjustment: storing this condition, the backlighting is at maximum brightness;

“MID” adjustment: storing this condition, the backlighting is reduced approximately 30% relative to maximum brightness;
”MIN“ adjustment: storing this condition, the backlighting is reduced approximately 70% relative to maximum brightness.
Note
In the event of an interruption of the power supply from the battery, when power is restored at the next Key-On, the backlighting
will always be set by default to maximum brightness.
Press RESET
Press “▲”
Press RESET
“▼” Press “▼” Press “▼”
RESET
Press Press “▲”

“▼” Press “▼”
RESET Press RESET
Press
“▼”
Press “▲”
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LAP Activation/Deactivation function (lap time)
This function activates and deactivates the LAP function (lap time).
To display the function, enter the “Setting” menu page and access the “LAP” page.
In the next screen, press the reset button (3) with “ON / OFF” highlighted.
the arrows indicate the setting currently in use;
use buttons (1) “▲” and (2) “▼” to select the new setting;
to store the new setting press the reset button (3); the arrows will move to the new stored condition.

Storing the “OFF” condition disables the LAP function;
Storing the “ON“ condition enables the LAP function (see LAP registration operation)
While the “LAP” function is active, the flash headlight button (4) both FLASHES the high beam headlight and Starts/Stops the
lap timer.
Press RESET
Press RESET
Press Press Press “▲”

RESET “▼”
Press “▲”
Press RESET
Press
“▼” Press “▼”
Press “▲”
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LAP registration function
This function describes the “LAP“ time registration.
If the function is activated (see “LAP activation/deactivation description”), the lap time can be registered as follows:
pressing the flash headlight button (4) the first time starts the “lap timer” for the first lap, and the instrument panel shows the
message “START LAP“ on the circular display for 4 seconds, and then returns to the previous display;
from now on, each time the flash headlight button is pressed (4), the circular display automatically shows the lap time for
10 seconds and then returns to the previous display.
You can save a maximum of 30 laps in the memory.

Once the memory is full, the instrument panel no longer stores lap times when the flash headlight button (4) is pressed, and the
flashing message LAP MEMORY FULL is shown on the circular display for 3 seconds until the times are reset.
When the LAP function is set disabled, the current “lap“ is not stored.
If the LAP function is active and suddenly the motorcycle is suddenly turned off (Key-Off), the function will be automatically dis-
abled (even if the lap timer was active, the current “lap“ is not stored).
If the time is never “stopped“, it will roll over upon reaching 9 minutes, 59 seconds and 99 hundredths; the lap timer starts count-
ing from 0 (zero) and will keep running until the function is disabled.
If however the LAP function is switched on and the memory has not been cleared, but fewer than 30 laps have been saved (e.g.
18 laps), the instrument panel will store any remaining laps until the memory is full (in this case, it will store an additional 12 laps).
This function only displays the times for the lap being registered; but other data are also saved (MAX speed, MAX rpm, rev limiter
if reached) for viewing at a later date in the Lap Memory function (stored LAP display).
LAP
Press FLASH Press FLASH

1st time 31st time
LAP
LAP
Press FLASH
32nd time
LAP LAP
Press FLASH
2nd time
LAP
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Stored LAP display function
This function displays the stored LAPs.
To display the function, enter the “Setting” menu page and access the “LAP” page.
In the next screen, press the reset button (3) while “MEMORY” is highlighted.
The instrument panel displays the information as follows:
Circular display:
the number of the displayed lap (ex: no.1);
“NEXT” to display the next LAP;
“RESET” to delete all the stored times;
Main display:
- the time in the upper left (ex: 1:50:97);
- the maximum speed reached in the registered LAP to the upper right;
- the number of maximum RPMs reached in the registered lap at the bottom;
Note
The MAX stored speed is indicated on the main display (A) (increased by 8%).
If the MAX speed reading exceeds 299 Km/h (186 mph) while the information is stored, the speed that was reached is still dis-
played (example: 316 Km/h).
If there is no reading in the memory, the 30 times are shown, with the display showing “0.00.00”, MAX rpm = 0 and
MAX speed = 0.
If the engine reaches the threshold prior to the rev limiter or rev limiter threshold itself while a LAP time is being recorded, the
“Over Rev” indicator is activated while the stored times are displayed.
To display other stored times, highlight “NEXT” and press the reset button (3); the subsequent lap is be displayed each time the
reset button (3) is pressed.
To delete all stored times, select “RESET” and press and hold the reset button (3) for 3 seconds.
Note
If the stored times are deleted while the LAP function is active, it will be automatically deactivated.
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Press RESET
Press RESET
Press
RESET
Press Press
“▼” “▲”
Press
Press
RESET
RESET
Press Press
“▼” “▲”
Press RESET
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DTC (Ducati Traction Control) on/off function
Warning
DTC is a rider aid that can be used both on the track and the road.
The system is designed to make riding easier and to enhance safety, but in no way relieves the rider of the obligation to drive
responsibly and to maintain a high standard of riding in order to avoid accidents, whether caused by his own errors or those of
other road users, through making emergency manoeuvres, in accordance with the prescriptions of the road traffic code.
The rider must always be aware that active safety systems have a preventive function. The active elements help the rider control
the motorcycle, making it as easy and safe to ride as possible. The presence of an active safety system should not encourage
the rider to ride at speeds beyond the reasonable limits, in accordance with the road conditions, the laws of physics, good riding
standards and the requirements of the road traffic code.
This function activates and deactivates the DTC (Ducati Traction Control).
To display the function, enter the “setting” menu page and access the “DTC” page.
In the next screen, press the reset button (3) with “ON / OFF” highlighted.
the arrows indicate the setting currently in use;
use buttons (1) “▲” and (2) “▼” to select the new setting;
to store the new setting press the reset button (3); the arrows will move to the new stored condition.
To exit, select “EXIT” and press the reset button (14, fig. 4).
Storing the “OFF” condition disables the Traction Control;
Storing the “ON” condition enables the Traction Control.
Note
Deactivating the DTC automatically activates the previously described “warning” “DTC OFF”. If a battery is cutoff, when the
voltage is restored and at the next Key-On, the DTC will always be set automatically to “OFF”.
3
2
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Press RESET
Press RESET
Press
Press Press RESET
“▼” “▲”
Press “▲”
Press RESET
Press Press Press “▼”

“▼” “▲”
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Digital RPM indication function
This function displays the number of RPMs for improved accuracy when setting idle rpm.
To display the function, enter the “Setting” menu page and access the “RPM” page.
The display shows the numerical value of the RPM with a precision of 50 rpm.
Press RESET
Press RESET Press RESET Press RESET
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Clock setting function
This function sets the clock.
To display the function, enter the “setting” menu page and access the “CLOCK” page.
In the next screen, press and hold the reset button (3) for 3 seconds with “SET UP” highlighted in order to access the actual
setting mode.
“SET CLOCK ….” appears on the circular display (B) to indicate that the clock is being set; the time is set on the main display.
Clock setting
On entering this mode, the message “AM” will flash;
press button (2) “▼”, the message “PM” starts flashing;
press button (2) “▼” to return to the previous step (if the current time is 00:00, 12:00 will be displayed when switching from
“AM” to “PM”).
press button (1) “▲“ to access the hour setting mode; the hour value starts to flash.
each time button (2) “▼“ is pressed increases the digit by 1 hour; pressing and holding button (2) “▼”, the digit increases by
1 hour every second (the hour value does not flash while the button is kept pressed).
press button (1, fig. 7) “▲” to access the minute setting mode; the minute value starts to flash.
each time button (2) “▼” is pressed increases the digit by 1 minute; pressing and holding button (2) “▼”, the digit increases by
1 minute each second;
pressing and holding the button (2) “▼” for more than 5 seconds, the value increases by 1 every 100 m (the second value does
not flash while button (2) “▼” is kept pressed).
Pressing the button (1, fig. 7) “▲”, the entire time indication flashes and “MEM” is shown on the circular display.
To confirm (store) the new time setting, press the reset button (3).
Note
If a battery is cutoff, when the voltage is restored and at the next Key-On, the clock must be reset (it starts automatically from
00:00).
3
2
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Press
RESET
Press RESET Press
for 3 sec. RESET
Press Press
“▼” “▲”
Press
RESET
Press RESET
for 3 sec.
Press Press
“▼” “▲”
Press
RESET
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Immobilizer override procedure
This procedure makes it possible to “temporarily“ turn on the motorcycle if the HF (Hands Free) System is not working.
Note
The PIN CODE function must be activated by entering your 4 digit PIN in the instrument panel, otherwise the vehicle cannot be
turned on temporarily in the case of a malfunction.
Warning
The PIN code must be activated (stored) by the owner of the vehicle.
PIN CODE activation function

To display the function, enter the “setting” menu page and access the “PIN CODE” page.
Note
If “MODIFY“ appears when accessing this function, this means that there is already a stored PIN and therefore the function is
already active.
When the function is accessed, “NEW PIN“ and four dashes “- - - -“ will appear on the circular display; now enter a 4 digit code.
Entering the code:

Pressing button (2) “▼” repeatedly cycles the highlighted number from “0” to “9” and then back to “0”;
to confirm the number, press the reset button (3).
Repeat the procedure until inserting the fourth digit.
Press the reset button (3) again to confirm.
“OK” and “EXIT” will appear on the display.

To confirm the PIN entered, press the reset button (3) again with “OK” highlighted.
“NEW PIN MEM” will appear on the display for 3 seconds to confirm that the PIN was stored.
At the end of the 3 seconds, the instrument panel exits automatically from the display and returns to the “setting” menu.
From this moment, “MODIFY” will be displayed when accessing the “PIN CODE” function and the PIN can be changed again.
3
2
section
Press Press Press Press

“▼” “▼” “▼” “▼”

“▼” “▼” “▼” “▼”
Press “ Press “ Press “ Press “

▼” x 8 ▼” x 6 ▼” x 2 ▼” x 4
RESET PIN not stored

RESET RESET RESET
“▲”
PIN not stored
“▼”
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PIN CODE change function
This function changes your four number PIN CODE.
To display the function, enter the “setting” menu page and access the “PIN CODE” page.
If “NEW PIN” and the dashes “- - - -” appear when accessing this function, this means that the function was not active as the
PIN CODE was never entered. Enter your PIN as described in the previous paragraph “PIN CODE activation function”.
When the function is accessed, “MODIFY” will appear on the circular display; press the reset button (3) with “MODIFY” high-
lighted to modify the PIN.
Note
To change the PIN, you must know the currently stored PIN.
“OLD PIN” and four dashes “- - - -” will appear on the circular display; enter the old 4 digit code that was stored previously.
Entering the “old” PIN: pressing button (2) “▼” repeatedly cycles the highlighted number from “0” to “9” and then back to “0”.
To confirm the number, press the reset button (3);
repeat the procedure until inserting the fourth digit;
press the reset button (3) again to confirm.
To confirm the “old“ PIN entered, press the reset button (3) again with “OK” highlighted.
If the code is not correct, “OLD PIN WRONG” will appear for 3 seconds and then the instrument panel will return displaying
“MODIFY” so you can repeat the attempt of entering the “old“ code.
3
2
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RESET
RESET

“▼” “▼” “▼” “▼”

“▼” “▼” “▼” “▼”

▼” x 8 ▼” x 6 ▼” x 2 ▼” x 4
RESET RESET RESET

NEW PIN RESET
YES “▲”
OLD PIN
NO
“▼”
If the code was entered correctly the message “NEW PIN” and four dashes “- - - -” will appear on the circular display; now enter
the “new“ 4 digit code.
Entering the “new” PIN: pressing button (2) “▼” repeatedly cycles the highlighted number from “0” to “9” and then back to “0”;
to confirm the number, press the reset button (3).
To confirm the PIN entered, press the reset button (3) again with “OK” highlighted.
“NEW PIN MEM” will appear on the display for 3 seconds to confirm that the PIN was stored.
At the end of the 3 seconds, the instrument panel exits automatically from the display and returns to the “setting” menu.
The PIN CODE modification procedure is complete.
There is no limit to the amount of times you can change your PIN CODE.
3
2
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- - - -
RESET
RESET
9 - - - 97 - - 9 73-
Press Press Press

“▼” “▼” “▼”
0 - - - 9 0- - 97 0- 9 730

“▼” “▼” “▼” “▼”
1 - - - 9 1- - 97 1- 9 731

▼” x 8 ▼” x 6 ▼” x 2 ▼” x 4
9 - - - 9 7- - 97 3- 9 735
RESET NEW PIN

RESET RESET RESET
“▲”
9 735 NEW PIN 9 735 9 735
“▼”
Headlight control
This function allows you to reduce current consumption from the battery, by automatically managing headlight switching-off.
The “control“ is enabled in three instances:
when the system is turned on (Key-On) and the engine is not started within 60 seconds, the headlight is turned off automatically
and will be turned back on next time you start the engine.
after using the motorcycle normally with the lights on, if the engine is turned off using the “RUN” button on the right switch, the
headlight is shut off 60 seconds after the engine is turned off and then turned on again the next time the engine is started.
while starting up the vehicle, the headlight is turned off and back on as soon as the engine is started.
Turn signals (automatic reset)

The instrument panel controls the automatic reset of the turn signals.
Press the RESET button (3) to switch off the turn signals.
If the turn indicator is not “reset“ manually, the instrument panel will automatically switch it off after the motorcycle has travelled
500 m (0.3 miles) from when the turn signal was activated.
The counter for the distance travelled for automatic deactivation is activated at speeds below 80 Km/h (50 mph).
If the calculation of the distance for automatic deactivation is activated and then the motorcycle exceeds a speed of 80 km/h
(50 mph), the calculation is interrupted and will restart when the speed returns below the indicated threshold.
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“Parking” function
This function activates the “PARKING” mode.
The “PARKING” function activates the front and rear parking lights when the vehicle is turned off so it is visible when parked.
The function may be activated by pressing and holding button (2) “▼” for 3 seconds within 60 seconds of switching the motor-
cycle off.
Once the function is activated, the indication will remain on the circular display for 5 seconds and the lights will remain on for 2
hours. After 2 hours, then will turn off automatically.
To interrupt the function, turn the vehicle on and off.
Note
If there is a sudden interruption in the battery while the function is active, the instrument panel will disable the function when
the voltage is restored.
Warning
The frequent use of this function can considerably reduce the battery charge; Ducati recommends using this function only when
necessary.
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“Steering in position for being locked” indication
This function informs that the steering is in position for turning on the steering lock.
The sensors detect that the steering is in position during the first 60 seconds after turning off the vehicle and the instrument
panel activates the indication on the circular display for max. 5 seconds.
“Steering lock” on indication

This function informs that the steering lock was turned on.
The steering lock can be turned on during the first 60 seconds after turning off the vehicle by pressing down on the “RUN” but-
ton.
If the steering lock was turned on correctly, the instrument panel will show the indication in the circular display for 5 seconds.
Note
The steering lock can only be turned on when the steering is in position.
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Change Unit of Measurement
This function changes the units of measurements used for the parameters displayed.
To access this menu, turn the vehicle on while holding the flash headlight button (4) and the reset button (3) for at least 3 seconds.
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“UNITS” is displayed once the menu is open; to set the unit of measurement, press the reset button (3).
The instrument panel displays the modifiable parameters; select the parameter to be modified by pressing buttons (1) “▲” and
(2) “▼” and then pressing the reset button (3) again.
Note
All other functions are disabled when in this MENU.
Press
RESET
3
2
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“SPEED” Setting
The arrows indicate the setting currently in use, to select a new setting press buttons (1) “▲” and (2) “▲”.
To store the new setting press the reset button (3).
Once the setting is stored, the display mode is automatically exited.
1 - Km/h: this setting applies the same unit of measurement to the following parameters:
- TOT, TRIP1, TRIP2, RANGE : Km
- Motorcycle Speed and AVG : Km / h
2 - mph : this setting applies the same unit of measurement to the following parameters:
- TOT, TRIP1, TRIP2, RANGE : miles
- Motorcycle Speed and AVG : mph
“TEMP.” Setting
3 - °C : this setting applies the same unit of measurement to the following parameters:
- Coolant temperature and T_AIR : °C
4 - °F : this setting applies the same unit of measurement to the following parameters:
- Coolant temperature and T_AIR : °F
“CONS.” Setting
5 - Km/h: this setting applies the same unit of measurement to the following parameters:
- CONS I. and CONS M. : km/l
6 - mpgal UK : this setting applies the same unit of measurement to the following parameters:
- CONS I. and CONS M. : mpgal UK
7 - mpgal USA : this setting applies the same unit of measurement to the following parameters:
- CONS I. and CONS M. : mpgal USA
3
2
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Press RESET 1 2
“▲” “▼”
3 4
“▲”
5 6 7
“▼” “▲”
Press RESET
1
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8 - “Hands free” system
The Hands free system consists of:
1 Hands free lock;

2 Antenna;
3 Active key;
4 Passive key;
5 Electric cap (optional).
The “Hands free” lock (1) is located on the front part of the tank. Remove the lid to access it (2).
Note
In the USA version the lid (2) is not present.
3 4
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Hands free system Key-On and Key-Off
Key-On consists in turning on the hands free system and all of its electronic devices.
Key-Off consists in turning off the hands free system and all electronic devices, and makes sure the engine is turned off.
Key-On is done using the button (6) on the handlebar on the right switch or using the emergency button (7) on the Hands free
lock (1).
Key-Off is done using the button (6) on the handlebar on the right switch or using the emergency button (7) on the Hands free
lock (1).
Warning
The button (7) is hidden under the door (8). Remove it to access the button (7). In the USA version the door (8) is not present.
Note
The use of one of the two buttons (6) or (7) does not exclude the other, ex.: if I turn it on with one, I can turn it off with the other
and vice versa.
8 7
Key-On can only occur in the presence of one of the two keys (3) or (4) or using the pin code.
Key-Off can also occur without a key (3) or (4).
Key-Off occurs when the speed of the motorcycle is equal to zero, pressing the button (6) on the handlebar or by pressing the
Hands free button (7); at a speed other than zero, only by pressing the Hands free button (7).
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Note
When the battery is discharged, the active key (3) acts like a passive key (4). The instrument panel displays the discharged battery
status.
The mechanical part (A) of the key (3) is used to open the fuel cap and the seat and bag lock.
The metal part (A) of the key (3) remains hidden inside its housing, it exits by pressing the button (B).
Note
With the vehicle in Key-On and “engine off”, if the presence of the active key (3) is not detected for thirty consecutive seconds,
the motorcycle will turn off automatically without any action by the rider.
A
B
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Key-On/Key-Off using the red key on the handlebar with the active key
A Key-On can be performed by pressing the red button (6) on the handlebar in the HANDS FREE ON/OFF position and in the
presence of the active key (3).
Note
The active key (3) has a range of approx. 1.5 m, therefore it must be located within this range.
Key-Off can be performed by pressing the red button (6) on the handlebar in the HANDS FREE ON/OFF position. It can be done
also without the key (3) only if the motorcycle speed is equal to zero.
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Key-On/Key-Off using the key on the Hands free lock with the active key
Key-On can be performed by pressing the button (7) on the Hands free lock (1) and with the presence of the active key (3).
Note
In the USA version the door (8) is not present.
Note
The active key (3) has a range of approx. 1.5 m, therefore it must be located within this range.
Key-Off can be performed by pressing the button (7) on the Hands free lock (1), also without the key (3).
8 7
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Key-On/Key-Off using the red key on the handlebar with the passive key
A Key-On can be performed by pressing the red button (6) on the handlebar in the HANDS FREE ON/OFF position and in the
presence of the passive key (4).
Note
The passive key (4) has a range of a few cm, therefore the key (4) must be positioned near the immobilizer antenna.
Key-Off can be performed by pressing the red button (6) on the handlebar in the HANDS FREE ON/OFF position. It can be done
also without the key (4) only if the motorcycle speed is equal to zero.
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Key-On/Key-Off using the key on the Hands free lock with the passive key
Key-On can be performed by pressing the button (7) on the Hands free lock and with the presence of the passive key (4).
Note
Note
The passive key (4) has a range of a few cm, therefore the key (4) must be positioned near the antenna.
Key-Off can be performed by pressing the button (7) on the hands free lock (1), also without the key (4).
8 7
Key-On/Key-Off using the pin code (immobilizer release)
Note
Key-On can be performed by pressing the button (7) on the hands free lock (1) without the presence of the keys (3) and (4) and
entering the pin code on the dashboard.
Key-Off can be performed by pressing the button (6) on the handlebar / Hands Free key (7) / engine off no key.
After each Key-Off, at the next Key-On if the key is not present the pin code must be entered.
The pin code is entered by the customer when receiving the motorcycle.
The function is not enabled without the pin code.
When the Hands Free button is pressed (7) the instrument panel activates the backlighting and the circular display to be able to
enter the four digit pin code. Entering the correct pin turns on the instrument panel and enables engine starting.
The pin must be entered within 120 sec, after which a Key-Off occurs automatically.
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Entering PIN CODE function for vehicle release
This function turns on the motorcycle “temporarily“ in the case of HF (Hands Free) system “malfunctions“.
To activate the function, press the “emergency“ Hands Free button (7) lifting the door (8) if the motorcycle cannot be turned on
using the normal starter button.
Note
After pressing the button, the instrument panel activates only the circular display (B) (and the backlighting) to be able to enter the
4 digits PIN code.
Entering the code:

each time you press the button (2) “▼” the displayed number increases from “0” to “9” and then returns to “0”;
to confirm the number, press the reset button (3);
If the code is incorrect, the instrument panel will return to the initial indication in order to enter the code again.
Note
There is no limit to the number of times the code can be re-entered; the instrument panel will turn off automatically 120 seconds
after an attempt to enter the code.
If the code was entered correctly, the message “PIN OK“ will flash on the display for 4 seconds. After 4 seconds, the instrument
panel will return to the “normal“ view (with all indications active).
From this moment, the vehicle can be started using the start button (Key-On).
Note
The vehicle can be started until a Key-Off is performed; if the problem still persists upon the next starting attempt, repeat the
procedure from the beginning in order to start the motorcycle “temporarily“.
Press “▼”
Press Press Press

“▼” “▼” “▼”

“▼” “▼” “▼” “▼”

▼” x 8 ▼” x 6 ▼” x 2 ▼” x 4
RESET
RESET RESET RESET Correct NO
PIN?
The correct PIN will flash on the YES

instrument panel for 4 seconds,
after which the instrument panel
comes back to the “main“ display
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1
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9 - immobilizer and transponder
The immobilizer allows the vehicle to be started only if the rider uses the special ignition key which sends the identification code
to a decoder housed in the instrument panel. The transmission-receiving system is composed of a TRANSPONDER housed in
the ignition key heads and an antenna in the vicinity of the ignition switch.
Keys with transponder

The two keys contain the secret code used for programming the immobilizer and allowing the engine to be started.
The transponder is fitted inside the key grip and consists of a power supply circuit, a ROM (Read-Only Memory) and a transmis-
sion circuit. The transponder is supplied with power by the magnetic field generated by the antenna which is enabled as soon as
the instrument panel is switched on. Since the transponder is very compact and needs no external battery power supply, it is
moulded permanently into the key grip.
Warning
The circuits in the key grips are not shockproof and may therefore be damaged by violent impact.
The key contains a battery that must be replaced when the message “low level“ is displayed under the key and battery symbols
when the instrument panel is turned on.
Note
In this case, replace the battery as soon as possible.
When the charge level goes below a certain limit, the key can only work in passive mode, like the passive key: in this case, the
instrument panel will not display any message.
Warning
Do not ride with the key (1) or (2) is inserted in the lock of the tank cap or in the seat lock as it could come out and represent a
potential danger. Furthermore, if bumped, the key mechanism and the integrated circuit could be damaged.
Also riding in poor weather conditions with the key inserted could cause damage to its integrated circuit.
Do not leave the key on the motorcycle when washing it as it could be damaged, not being watertight.
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Replacing the battery in the active key
Only use 3 Volt CR 2032 lithium ion batteries.
Note
The keys do not need to be reprogrammed after replacing the battery.
Remove the metal part of the battery.

Use a large sized coin to open the plastic shells of the grip (2 € coin) as shown in the figure.
Important
Insert the coil only in the indicated point. Do not other use other objects inserted in points that are different than what is shown,
as it could damage the integrated circuit and/or the protective gasket.
Once the plastic shells have been separated, remove the printed circuit board (1) prying it up gently with a small flat screwdriver,
as shown in the figure.
Important
Insert the point of the flat screwdriver just under the printed circuit board, being very careful not to damage it. Do not apply force
on the battery or battery holder.
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Remove the battery (2) from the printed circuit board (1) and replace it with a new one.
Pay attention to polarity: the positive pole (+) must face upward.
Important
Only use the required type of battery.
Reinsert the printed circuit board (1) from the side with the battery (2) into the plastic shell.
2 +
1
2
1
Apply slight pressure on the antenna (3) of the printed circuit board until you hear a click.
Align the two shells of the grip and press on the area indicated by the arrows to close them.
Make sure that you hear a “click” upon closing and that the key is well closed.
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Immobilizer antenna
The antenna consists of a plastic-coated copper coil connected to a cable that is terminated with a connector.
The antenna (A) is fitted inside the front top fairing (B).
B A
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Removal of the immobilizer
Remove the top fairing 5 - 1, Removing the headlight fairing
Place the ignition key in OFF position.

Disconnect the antenna wiring connector (A) from the main wiring loom.
Undo the screws (1) and remove the immobilizer antenna (A).
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Refitting the immobilizer
Carry out the operations in the reverse order and especially tighten the screws (1) to the specified torque (Sec. 3 - 3, Frame torque
settings).

Refit the top fairing 5 - 1, Refitting the panel
Refit the left and right panel 5 - 1, Refit the headlight fairing
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6 - 10 Electric system and engine control system
10 - Description of the system
Injection and ignition
Ignition is via a single stick coil per cylinder installed in the spark plug well. Each thermal unit is supplied by a single injector, placed
under the throttle valve. The amount of fuel injected and the ignition advances are determined by the control unit specifically for
each cylinder. These basic measures are then corrected by the control unit, according to the information supplied by different
sensors fitted on the engine and applying certain strategies, in order to obtain the definitive signals of activation. It is necessary
to highlight that between these corrections there are those supplied by the DTC (Ducati Traction Control integrated in the BBS)
on the ignition advances, on the fuel injection and on the throttle valve opening, in order to correctly check the vehicle traction.
The DTC communicates with the engine control unit, through the CAN network.
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11 - Fuel injection-ignition system
The electrical components of the fuel injection-ignition system are listed below: indicated reference number refers to the diagram
in Sec. 6 - 1, Wiring diagram.
2 Ignition switch
3 LH fan
4 RH fan
5 Starter motor
6 Solenoid starter
7 Battery
8 Regulator fuse
9 Regulator
15 Fuel tank
16 Stepper motor
17 Injection relay
18 Self-diagnosis
19 Horizontal cylinder coil
20 Vertical cylinder coil
21 Horizontal cylinder spark plug
22 Vertical cylinder spark plug
23 Horizontal cylinder injector 1
24 Vertical cylinder injector 1
25 Throttle position sensor
27 Water temperature sensor
29 Side stand
31 Neutral switch
34 ECU
35 Fuses
53 Horizontal cylinder injector 2
54 Vertical cylinder injector 2
56 Ignition relay
57 DTC
1
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6 - 12 Electric system and motor control system
12 - System components
Positioning of the control system components on the vehicle
B C D
A engine control unit.

B injection relay.
C ETV relay (operating motor of throttle valve).
D fan radiator relay.
E suspension control unit (motorcycle version S only).

F diagnostics socket of the vehicle electronic system.
G BBS (Black Box System or Central electronics).
H ABS hydraulic unit with integrated control unit.
I diagnostics socket for ABS system only.
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Control unit support removing
Remove the clamps (A) that fasten the front wiring branch (B).
Disconnect the control unit connectors (1), undo the fixing screw (2) of the control unit support bracket (3) and remove the control
unit (4).
Undo the screw (5) and remove the pressure sensor (6).
2 4
3
A
1 5
6
Remove the relays (8) from its own compartment on the control unit support (4).
Undo the screws (7) and remove the control unit support (4).
9
7
9
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Refitting the control unit support
Install the cable grommet (7) in the hole of the control unit support (4) and lock it by pressing the pin tightly (C).
Fit the vibration damper mounts (8) in the corresponding holes of the control unit support (4).
7
C
Fit the relay support rubbers (9), positioning them as shown in the figure, according to the openings on the control unit support
(4), indicated by the red arrows.
Note
Relay support rubbers (9) must be fitted by “pulling“ the corresponding pins (D), on the opposite side of the input side, until they
are fixed.
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Fit the rubber pads (10), positioning them as shown is figure, on the corresponding holes of the control unit support (4).
Note
The rubber pads (10) must be fitted by “pulling“ the corresponding pins (E), on the opposite side of the input side, until the bosses
are completely out (F).
10 E
4 F
10
10
F
E
Position the control unit support (4) on the frame inserting and tightening the screws (7) to the specified torque (Sec. 3 - 3, Frame
torque settings).
Refit the relays (8) from their own compartment on the control unit support (4).
9
7
9
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Position the pressure sensor (6) in the compartment on the control unit support (4) inserting the screw (5).
Refit the control unit (3) in its support (9), connect the control unit connectors (1).
Refit control unit support bracket (3) inserting and tightening the screw (2) to the specified torque (Sec. 3 - 3, Frame torque set-
tings).
Refit the clamps (A) that fasten the front wiring branch (B).
2 4
3
A
1 5
6
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Fuel injectors
The injectors (1) deliver the correct quantity of fuel required for optimal engine operation.
The ECU controls injector opening by feeding current to the coil of an electromagnet which creates a magnetic field to attract the
armature, thereby generating fuel spray. If we take the physical characteristics of the fuel to be constant (viscosity, density),
as well as the injector delivery and pressure head (controlled by the fuel pressure regulator), the amount of fuel injected
depends on the duration for which the injector is open.
This time is determined by the ECU in accordance with the engine operating conditions.
In this way correct fuel delivery in ensured.
To remove and refit the injectors, refer to Sec. 8 - 6, Removal of the fuel injectors.
Note
To check correct operation of the injector, use the DDS diagnosis instrument and follow the instructions given in the paragraph
“Guided diagnosis“, Sec. 6 - 13.
The fuel output must be even and the jet should be fully atomised, without droplets.
Do not leave the engine stopped for a long time with the fuel circuit full.
The fuel could clog the injectors and render them inoperable.
Periodically, after lengthy periods without running the engine, we recommend adding TUNAP 231 to the fuel in the tank to help
clean critical sections of the fuel circuit.
Note
Electric injectors are only supplied as part of the “Injectors and pipes” kit, and must not be replaced individually.
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Air pressure sensor
Two air pressure sensors (1 and 2) are fitted on the engine control system, each of them are connected to the intake manifold
of each cylinder (MAP 1 cylinder 1 - horizontal -, MAP 2 cylinder 2 - vertical -). They are used by the control unit to determine the
quantity of fuel to be injected according to the speed-density strategy and to determine the atmospheric pressure (necessary
information to correct the carburation in accordance with the altimetric measurement).
Components assembling position

The absolute pressure sensor (1) of the horizontal cylinder is fitted next to the engine control unit.
The air pressure sensor (2) of the vertical cylinder is fitted next to the filter box.
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Engine temperature sensor
On the engine control system, a sensor (1) is used to detect the temperature of the coolant (engine temperature). This sensor
has a resistance of NTC type (Negative Temperature Coefficient), that reduces its own value when the temperature increases.
The engine temperature sensor, allows the control unit to manage correctly the cold starting and the heating phases.
The engine temperature sensor (1), is fitted according to the left vertical cylinder.
Component replacement methods

The replacement of the engine temperature sensor (1), does not provide any particular arrangement.
Note
To test the operation, use the DDS diagnosis instrument and follow the instructions given in the paragraph “Guided diagnosis“
(Sec. 6 -13).
Removing the engine temperature sensor

Disconnect the wiring connector (2).
Undo the sensor (1) from the vertical cylinder head (Sec. 6 - 1, Routing of wiring on frame).
Refitting the engine temperature sensor

Carry out the reverse procedure of removal, locking the sensor on the vertical cylinder head to the specified tightening torque
(Sec. 3 - 3, Frame torque settings) and applying the recommended threadlocker.
4
LOCK
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Air temperature sensor
On the engine control system, a sensor (1) is used and it detects the air temperature. This sensor has a resistance of NTC type
(Negative Temperature Coefficient), that reduces its own value when the temperature increases. The air temperature sensor (1)
allows the control unit to modify the carburation and the ignition, according the atmospheric temperature.
The air temperature sensor (1), is fitted on the right air intake.
Removing the coils

Undo the nut (1) securing the coil to the cylinder head.
Remove the connector (2) and extract the coils (3) from the spark plugs on both cylinder heads.
Clean the area around the spark plug bores with a compressed air jet before removing the spark plugs themselves.
Remove the spark plugs, making sure that dirt does not fall into the combustion chambers.
5
3
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Spark plugs
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: 0.8±0.1 mm.
0.8±0.1 mm
Important
Check the gap between the central and side electrodes. Replace the spark plug if taken value is different from the specified one
or the spark plug shows clear signs of carbon settling.
Refit the spark plug in the cylinder head, first tightening it fully by hand.
Tighten to the tightening torque (Sec. 3 - 3, Frame torque settings).
Refit the tank (Sec. 8 - 2, Removal of the fuel tank).
Important
Do not use spark plugs with inadequate thermal 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.
Spark plug type

Make: NGK
Type: MAR9A-J / MAR9C-J
Checking the coils

The coils used on this model are known as “cigar” coils.
They are similar in appearance to a spark plug cap. They transform the low voltage from the ECU into high voltage for the spark
plugs.
To test the coils, proceed as follows:
Measure the resistance between the two pins (1-15).
The resistance should be 650 mΩ±50; if not, replace the coil.
Note
To check the coils for faults, use the DDS diagnosis instrument and follow the instructions given in the paragraph “Guided diag-
nosis“ (Sec. 6 - 13).
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Throttle valve operation engine
On the throttle body there is the electric motor (1) that operates the throttle of the vertical cylinder (2) which is connected to the
(3) of the horizontal cylinder, trough the pushrod (4). In the electric motor, the throttle valve position sensor (TPS) is integrated.
On the right, on the throttle body, the electric motor (1) is visible and integrates also the throttle valve position sensor (TPS). On
the left, the throttle position sensor (APS) is visible (5).
3 6 1
5 4
Component assembling position

The figure shows the throttle valve operating engine (1).
Inside of it, it is also placed the throttle valve position sensor (TPS).

The throttle valve operating engine (1) is integrated with the throttle valve position sensor and cannot be replaced as a single
element. If it is damaged, a new throttle body must be fitted (Sec. XX, related to Ride by wire). After replacing the throttle body,
reset the self-adjustable parameters related to the carburation with the DDS (Sec. xx, Throttle position sensor (TPS) zero setting.
Note
To check this component, use the DDS diagnosis instrument following the instructions given in the paragraph “Guided diagnosis“
(Sec. 6 - 13).
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Rpm/timing sensor
The engine control system has a sensor (1) of inductive type, which allows the control unit to determine the number of RPM and
the engine operating phase. The sensor faces a phonic wheel with 48 teeth minus 2.
The engine speed sensor - phase (1), is fitted on the engine crankcase on the flywheel side.
The aluminium cap (2) that closes the hole for the inspection of the air gap, trough the feeler gauge is on the right of the sensor,
on the black crankcase.

Check the air gap between the sensor and one tooth of the phonic wheel, using a feeler gauge introduced through the hole on
the crankcase on the left side of the engine, closed with a cap (2). The value of the air gap must be approximately of 0.6 mm and
cannot be regulated. The screw that fastens the sensor must be tightened to the torque of 8 +/- 2 Nm.
Note
To check the elements for faults, use the DDS diagnosis instrument and follow the instructions given in the paragraph “Guided
diagnosis“ (Sec. 6 - 13).
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Injection relay
The fuel pump, injectors and ignition coils are fed through the injection relay (1). This relay sends voltage also to the control unit
(2) and the latter enables its activation.
1 injection relay;
2 ECU;
3 ETV relay (throttle valve operating engine);
4 fan radiator relay.
1 3
CAN Line
This model utilises a CAN line (Controller Area Network) which has made it possible to greatly simplify the layout of the electrical
system and consequently reduce its overall weight.
The CAN line is connected to two nodes:
the instrument panel and the ECU of the MITSUBISHI (F8TJ). Thanks to this communication line no sensor doubles are required
as sensor signals are shared by both electronic units.
Sensors are connected to closer electronic unit (instrument panel or engine control unit), which sends the signals to the network
to be processed by the control units.
CAN line consists of two wires for digital signal transfer; they both carry precise and perfectly decipherable data. The instrument
panel and the engine control unit, which are connected to the CAN line, are fitted with special hardware which acknowledges
whether a pulse sequence includes pertaining data to be processed by the computing unit.
The signals exchanged over the CAN line between the instrument panel and engine ECU are as follows:
- Motorcycle speed (input to engine ECU)
- Neutral selected (input to engine ECU)
- Engine oil pressure (input to engine ECU)
- Coolant temperature (input to engine ECU)
- Oil temperature (input to engine ECU)
- Starter motor actuation (starter button) (input to engine ECU)
- First level diagnostics generated by ECU
- Engine rotation speed (input to engine ECU)
- Scheduled service limit (light on instrument panel illuminates)
- Intake air temperature (input to instrument panel)
- Battery voltage
- Motorcycle model identification
- EOBD LED control
- Immobilizer recovery
- Atmospheric pressure (sensor integrated in the instrument panel).
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13 - Diagnostic instruments
Using a multimeter to check the electrical systems
Introduction
This instrument allows you to measure resistance, voltages, and current values. Multimeters can be divided into two basic types:
analogue and digital display multimeter. An analogue multimeter has a pointer display. The dial is marked with the scales to be
used for measurement of the various parameters. Digital units are equipped with a dial that displays numbers corresponding to
the values of the measured parameters. The type of measurement to be carried out (voltage, current or resistance) is set by means
of a selector or by means of several different sockets in which to insert the two test probe connector terminals. In certain cases
it is essential to set the full scale value before proceeding. For example, in order to measure a 12 V signal, you need to set a full
scale that is close to this value (e.g. 15 V or 20 V). It would be illogical to set a full scale value of 10 V; the same applies when
setting current (Amperes) or resistance (Ohms). Sometimes the instrument can set the required full scale value automatically.
Never exceed the maximum value allowed by the tester when measuring voltage or current signals.
Note
The DDS diagnosis instrument (Sec. 6 -13, DDS diagnosis instrument) can fulfil the function of digital multimeter.
Voltage measurement
Voltage measurements must be carried out by connecting the terminals of the tester in parallel to the load (e.g. to the wires feeding
a light bulb or a relay, the two battery terminals, or the two wires supplying power to a control unit). Voltages can be constant over
time (DC voltage) or variable over time (AC voltage). In the first case, it is important to consider the negative and positive polarity of
the application. It is therefore necessary to select on the multimeter the type of voltage you intend to measure. (DC voltage is
shown by the symbol = while AC voltage is denoted by ~).
Current measurement
Current measurements must be made by connecting the multimeter terminals in series with the load (e.g. disconnect one of the
wires feeding power to a light bulb and connect one terminal of the multimeter to the free end of wire and the other terminal
to the light bulb. When the lights switch is set to ON, the bulb will illuminate normally and the tester will show the absorbed
current, i.e. the amount of current passing through the wire. Warning: connections in series must be made and removed
only when the power is switched off. Never attempt to make or break a series connection when a device is powered.
Always make sure that the connection in series of the tester terminals on the electrical device is made is a safe manner in
such a way that it cannot be broken accidentally.
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Measurement of resistance values and electrical continuity
Resistance measurements must be taken only when the electrical device or section of the circuit is not powered and isolated
from the main electrical system (i.e. not connected to the main electrical system). These measurements can be utilised to check
the resistance value across several sensors. For example, after disconnecting the electrical wiring to the rpm/ignition-injection
system timing sensor (on the camshaft drive gear) the relative internal resistance can be checked by connecting a multimeter to
its terminals. This makes it possible to check the electrical continuity of the winding inside the sensor (a reading of infinite resist-
ance indicates that the winding is interrupted). Resistance measurement can also be used to check the continuity of sections of
the electrical circuit or relay type switches. For example, to check the condition of a section of the electrical circuit between two
connections, disconnect the connections and connect the terminals of the multimeter to the ends of the electrical cable in ques-
tion to check that the specified resistance value is present. If this value is close to zero (i.e. lower than approximately 0.3 ohm)
this means that the cable is not interrupted. Some instruments feature an audible signal that is emitted when the resistance ap-
proaches a value of zero. The same procedure must be adopted to check whether, for example, two contacts of a switch (relay
or manual type) are making the contact correctly when closed. In this case the terminals of the multimeter must be connected
to the switch terminals, checking that the resistance value is close to zero (or listening for the audible signal) when the switch is
closed. To check that the multimeter is functioning correctly in “electrical continuity test” mode, short out the two test probes.
The resistance value indicated must be almost nil and the audible signal must be activated.
Protections and precautions

The multimeter is equipped with protective fuses and batteries. These components must always be in perfect condition to ensure
that the instrument is functioning correctly. When making electrical measurements always use the maximum caution to avoid
short circuits, which can otherwise cause irreparable damage to the electrical system and constitute a personal injury hazard.
All maintenance work must be performed exclusively when the system is not live (disconnect the battery in advance).
NEVER connect the multimeter in parallel to make current measurements, and NEVER connect it in series to carry out
voltage measurements.
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Description of the diagnosis instrument (DDS)
The “DDS” diagnostic system lets you diagnose any faults in the injection-ignition system via a serial port. The system is also
equipped with functions to test various devices on the motorcycle. The DDS tester can be used to measure current and voltage
on any electrical device, to perform tests on individual components and to measure pressure and temperature values.
The DDS diagnosis instrument (1) is comprised of a Palmtop display unit (A), a BBAD self-diagnosis module (B) and a display
memory card (C).
The touch-screen display unit (A) serves for both data display and input, using the stylus housed on the side of the unit.
The self-diagnosis module (B) enables communication between the DDS diagnosis instrument (1) and the motorcycle’s on-board
electronic control unit (ECU).
The user interface software resides in the display memory card (C) which is housed in the Palmtop display unit (A).
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The display unit is equipped with two connection panels: one at the top of the instrument and one at the bottom.
The top connection panel has 6 connection sockets with the following functions:
- one VGA output (E);
- one port for connection of the measurement module (F);
- one RS232 serial port for connection of peripheral devices (COM1) (G);
- a second RS232 serial port for connection of peripheral devices (COM2) (H);
- two generic USB ports (USB1 and USB2) (L).
F
E
G
H
The bottom connection panel has 3 connection sockets with the following functions:
- one USB port (M);
- one power connection socket (N);
- one diagnostics connection socket (P).
N P
You can connect a printer to the DDS diagnosis instrument (1) to print test reports: connect the printer to the serial port (COM1)
(G) located on the top connection panel of the tester (1).
Technical data
Power supply:
- from the mains - 220 V;
- from the vehicle battery - 12 V.
Components supplied with the DDS diagnosis instrument

The DDS diagnosis instrument (1) is supplied in a kit together with the following items:
- Rechargeable DDS battery
- Battery charger
- Mains power adapter
- USB memory card reader
- Power and diagnostic cable complete with fuse
- CD containing DDS installation software for PC
- USB cable
- Belt tension sensor
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Tester power supply
The DDS diagnosis instrument (1) may be powered in any one of the following ways:
- from the mains power supply: by connecting the mains adapter (14) to the power connection socket (N);
- from the motorcycle: connecting the corresponding cables (see paragraph “Connection to the motorcycle”);
- from the tester's internal battery: the battery (Q) is housed in the top part of the tester. To operate the tester (1) using
the internal battery and to recharge the battery, refer to the “User Manual” supplied with the DDS diagnosis instrument.
To switch on the display, press the button (T).
14
section
Connection to the motorcycle
The tester requires a power supply voltage within 9 and 16 Volts C.C.
Make sure voltage never drops below this limit during operation: this situation could occur during engine starting and idling on
motorcycles in which the battery is not in perfect working order. If the tester detects a power supply voltage lower than 9 Volts,
the current procedures will be reset; when the voltage returns to the acceptable tolerance limits the procedure must start again
from the beginning.
The DDS diagnosis instrument (1) may be powered from the motorcycle in any one of the following ways:
- connect the battery power adapter (13) to the power connection socket (N) on the tester and to the motorcycle battery;
13
section
- connect the power and diagnostic cable (2) to the diagnostic connection socket (P) on the tester; then connect the battery
socket adapter (8) to the connection socket (R) on the power and diagnostics cable and to the motorcycle battery.
N P
Note
For connection of the various devices required for self-diagnostic procedures, consult the instruction handbook supplied with the
tester.
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DDS diagnosis instrument
The main functions of the DDS diagnosis instrument can be summarised as follows:
- Retrieval of errors (faults) of the ignition-injection system stored in the engine control unit memory and their subsequent dele-
tion, if required.
- Reading of engine parameters (rpm, coolant and air temperature, atmospheric pressure, throttle opening, battery voltage, injec-
tion times and ignition advance, etc.).
- Active diagnostics. Activation of ignition-injection system transducers to test functionality and control signals (fuel pump, igni-
tion coils, rev counter, injectors, etc.). With this function it is also possible to enter the code to override the immobilizer.
- Road test. Allows the technician to store engine parameters recorded within a previously specified engine speed range interval.
The resulting parameters can then be analysed and displayed once they have been acquired.
- With specific sensors connected, the DDS diagnosis instrument can read electrical voltages, current, temperature, timing belt
tension, and pressure values (lubrication and fuel supply circuits for example).
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Checking and adjusting timing belt tension
Note
The on-screen icons used during this procedure are explained in a table at the end of this section.
Note
This operation, which is performed using the DDS diagnosis instrument, has the advantage that it can be carried out on both
timing belts with the engine still installed on the frame. An optical reader is connected to the DDS diagnosis instrument. The
optical reader has a green LED that serves to determine that the reader is correctly positioned in front of the belt to be tested. It
is also equipped with an infrared transmitter (A) and receiver (B) designed to detect oscillations of the belt when caused to vibrate
with the flick of a finger.

Remove the seat 5 - 3, Removal of the seat
Remove the rear right side panel 5 - 3, Removal of the side panels and seat
cowling
Remove the tank fairing 5 - 2, Removal of the fuel tank fairings
Remove the timing belt covers 9 - 4.2, Removal of the timing belt covers
Remove the cover (19) undoing the screws (20).
20
19
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Remove the fastening clamps (21) of the abs tubes (22) and release the fasteners (23) of the frame.
22 23
23
21
Disconnect the connectors (24) of the stepper motor and (25) of the vertical cylinder absolute pressure sensor from the filter box.
24
25
Undo the fixing screw (26) of the intake duct (27) and remove it.
26
26 27 26
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Loosen the fastening clamp (28) of the pipe (29) to the blow-by valve.
29
28
Undo the fixing screws (30) of the oil breather tank (31) and remove it.
30
31
Loosen the clamps (32) and position the filter box on the vehicle without removing the cables of the throttle twistgrip.
32
32
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Position the crankshaft so that the piston of the horizontal cylinder is at TDC of its power stroke.
This is achieved by aligning the timing mark (C) of the timing driveshaft pulley (33) with the reference notch (D) on the clutch
cover (34).
33
34
Measure the horizontal timing belt on the section (35) as described in paragraph “Measuring the timing belt tension values”.
Turn the crankshaft 270° in the engine rotation direction (TDC of the vertical cylinder, in the combustion stroke) and repeat the
procedure used for the horizontal cylinder, measuring the voltage on branch (36) of the vertical belt.
Vertical
Steady Movable
Horizontal
36
Steady
Driving
gear
35 Movable
Remove the belt tension sensor and disconnect the DDS diagnosis instrument from the motorcycle.
Refit the filter box tightening the clamps (32) to the specified fastening torque (Sec. 3 - 3, Frame torque settings).
32
32
section
Refit the oil breather tank (31) inserting and tightening the screws (30) to the specified tightening torque (Sec. 3 - 3, Frame torque
settings).
30
31
Refit the pipe (29) of the blow-by valve fastening the clamp (28) to the specified tightening torque (Sec. 3 - 3, Frame torque set-
tings).
29
28
Refit the intake duct (27) tightening the screws (26) to the prescribed tightening torque (Sec. 3 - 3, Frame torque settings).
26
26 27 26
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Connect the connectors (24) of the stepper motor and (25) of the vertical cylinder absolute pressure sensor.
24
25
Block the ABS pipes (22) to the fasteners (23) of the frame, replacing the clamps (21).
22 23
23
21
Refit the cover (20) tightening the screws (19) to the prescribed tightening torque (Sec. 3 - 3, Frame torque settings).
20
19
section

Refit the timing belt covers 9 - 4.2, Refitting the timing covers
Refit the tank covers 5 - 2, Refitting the fuel tank fairings
Refitting the front half-fairing 5 - 2, Refitting the front half-fairing
Refit the rear right side panel 5 - 3, Refitting the side panels and seat
cowling
Refit the seat 5 - 3, Refitting the seat
Measuring the timing belt tension values

Turn on the DDS diagnosis instrument (1) referring to the paragraph “Tester power supply”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (F) on the DDS di-
agnosis instrument (1).
1 3
section
Connect the belt tension sensor (15) to the connector (V) of the power and diagnostics cable (Measurement Module) (3).
V 15
Fix the bracket of the belt tension sensor support (15) using the timing belt cover screw (35).
Direct the central green LED of the sensor (15) at the midpoint of the belt section, placing the sensor (15) parallel to the belt and
at a distance of about 1÷1.5 cm from it.
35
On the DDS diagnosis instrument (1), select the “Measurement module” function by pressing the corresponding icon; then press
the “Belt Tension” icon followed by the “Start” icon to access the “Mechanical belt tension” screen.
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The socket to which the cable (Measurement Module) (3) is to be connected is indicated on the screen with a capital letter:
A, B or C.
Flick the belt lightly with your finger and read the frequency value (Hz) on the DDS diagnosis instrument.
Note
Do not stress the belt several times repeatedly, since the necessary minimum time for the DDS diagnosis instrument to take a
reading is 1 second.
The tension values are those detailed in Sec. 3 - 1.1, Timing system/valves and must be checked when the engine is cold: as-
sembly values must be applied with when installing a new belt, while service values must be applied when belt tension reaches
70 Hz.
Warning
The timing belts can become slack during normal operation. When checking belt tension, if the reading is less than 70 Hz, reten-
sion the belt to restore the specified nominal values (Sec. 3 - 1.1, Timing system/valves).
If the tension value is incorrect, increase or reduce belt tension, moving the adjustable tensioner pulley (36), loosening the nut
(37).
Tighten the nut (37) securing the tensioner pulley.
Recheck the timing belt tension.
Repeat the above procedure until the correct belt tension is obtained.
Once the desired tension is reached, fasten the fixing nut (37) of the tensioner pulley (36) to the specified torque (Sec. 3 - 3,
Engine torque settings).
37
36
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Check the engine oil pressure
Note
To measure the pressure of the lubrication circuit, use the engine oil pressure test point (19) as described below.
Disconnect the wiring connector (A) and remove the pressure switch (19), taking care to recover the seal.
19
Insert the fitting (9) into the connection on the hose (12), interposing the two copper sealing washers (20). Screw the connector
(9) of the hose (12) into the threaded hole (M10x1mm) in the RH cover. Refit the pressure switch (19) on the fitting (9) along with
its seal, and reconnect the wiring connector (A).
19 9
20
12
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Connect the pressure sensor (5) to the pipe (12) to transform the pressure signal into an electrical signal.
12
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (B) on the DDS di-
1 3
Connect the pressure sensor (5) to socket (A) or (C) of the cable (3).
A 552.1.039.1A
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the “Pressure Test” icon (D) followed by the “Start” icon (E).
A, B or C.
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Start the engine.
The values may be displayed in three different ways: in one numeric form and in two graphic forms; to select the desired display
type, press the “Value display” icon.
The measured value is indicated alongside the letter (A) or (C) identifying the cable used for the measurement: i.e. if you used
connector (A) of the cable (3), the value measured will displayed next to the letter (A) on the screen.
Oil pressure test values:

Warm engine
(Minimum oil temperature = 80 °C)
1100÷1300 min-1
greater than 0.8 bar.
3500÷4000 min-1
greater than 4 bar.
Important
The maximum pressure must never exceed 6.0 bar.
Excessively high pressure may indicate that the relief valve is stuck. Excessively low pressure, on the other hand, may be
caused by the relief valve being stuck in the open position, the relief valve spring being too weak, or a faulty oil pump.
Other causes are excessively worn seals and gaskets or a badly worn engine.
Remove the gauges and refit the pressure switch (19) with its seal. Block it to the specified torque (Sec. 3 - 3, Engine torque
settings).
Reconnect the electrical system connector (A) to the pressure switch.
19
Disconnect the DDS diagnosis instrument.
section
Cylinder compression test
Note
Engine performance is directly correlated to the pressure that can be measured in the combustion chambers of the two cylinders.
Pressure which is too high/low or an excessive difference between the two cylinders will cause a drop in engine performance
and can cause engine breakdowns.

Remove the seat E 3, Removing the seats
Remove the front half-fairing E 2, Removing the front half-fairing
Remove the tank fairing E 2, Removing the tank fairing
To access the vertical cylinder head spark plug raise the tank by undoing the screws (19) and (20) and installing a pad under it.
19
20
20
section
Disconnect the fuel probe connector (21), the fuel pump connector (22) and the quick couplings (23) from the flange.
23
21
22
To access the horizontal spark plugs head, undo the fixing screws (24) of the water radiator placing it slightly up.
24
24
section
Fix the radiator to the support inserting and tightening the screws (24) to the specified tightening torque (Sec. 3 - 3, Frame torque
settings).
24
24
Connect the fuel probe connector (21), the fuel pump connector (22) and the quick couplings (23) of the flange.
23
21
22
section
Refit the tank tightening the screws (19) and (20) to the specified tightening torque (Sec. 3 - 3, Frame torque settings).
19
20
20

Refit the tank covers E 2, Refitting the fuel tank fairing
Refitting the front half-fairing E 2, Refitting the front half-fairing
Refit the seat E 3, Refitting the seats
section
Run the engine so that it warms up to the point that the fan is tripped at least once.
Open the throttles completely.
Remove the HT leads (25), unscrewing the nuts (26) of both spark plugs.
Remove the spark plug from the cylinder to be tested.
26
25
26
25
Connect the HT lead to earth to prevent sparking.

Screw the cylinder compression cable (11) into the spark plug compartment.
Connect the pressure sensor (5) to the cable (11).
Turn on the DDS diagnosis instrument (1) referring to the paragraph “Connection to the motorcycle”.
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (B) on the DDS di-
1 3
section
Note
Measure the compression on one cylinder at a time.
the “Cylinder Compression” icon (D) followed by the “Start” icon (E).
section
A, B or C.
Turn over the engine with the starter motor until the pressure stops rising.
Check the pressure in each cylinder:
- standard value: 11 to 12 bar;
- minimum value: 10 bar;
- maximum permissible difference between cylinders: 2 bar.
An excessively high pressure value can be caused by:

- build up of deposits in the combustion chamber.
An excessively low pressure value can be caused by:
- gas escaping between the cylinder head and the barrel;
- worn valve seats;
- bent valve stems;
- incorrect valve clearances;
- worn cylinder or piston rings.
Refit the spark plugs and position the HT leads (25) in the corresponding compartments and tighten the nuts (26) to the specified
torque (Sec. 3 - 3, Frame torque settings).
26
25
26
25
section
Fuel pressure test
Note

Remove the seat E 3, Removing the seats
Remove the front half-fairing E 2, Removing the front half-fairing
Remove the tank fairing E 2, Removing the tank fairing
Slightly lift the tank by undoing the screws (19) and (20) and install a pad under it so that it can be operated on the flange couplings.
19
20
20
section
Remove one of the two pipes of the fuel system (21).
21
Use the fuel pressure pipe (17) connecting one end (D) to the coupling of the delivery pipe to the tank and the other end (E) to
the fuel system pipe (21): in this way you create a pressure pick-up socket (F).
E
17
F
Connect the pressure sensor (5) to the test outlet (F) of the pipe (17) to transform the pressure signal into an electrical signal.
552.1.039.1A
section
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (E) on the DDS
diagnosis instrument (1).
1 3
the “Pressure Test” icon (F) followed by the “Start” icon (G).
F G
section
A, B or C.
The values may be displayed in three different ways: in one numeric form and in two graphic forms; to select the desired
display type, press the “Value display” icon (H).
The measured value is indicated alongside the letter (A) or (C) identifying the cable used for the measurement: i.e. if you used
connector (A) of the cable (3), the value measured will displayed next to the letter (A) on the screen.
The maximum pressure must be equal 3 bar (nominal).
Once the test is over, remove all the components of the test instrument and refit the fuel system pipe (21).
21
Refit the tank tightening the screws (19) and (20) to the specified tightening torque (Sec. 3 - 3, Frame torque settings).
19
20
section
20

Refit the tank covers E 2, Refittig the fuel tank fairing
Refitting the front half-fairing E 2, Refitting the front half-fairing
Refit the seat E 3, Refitting the seats
section
immobilizer override procedure
Note
In the event of a malfunction of the immobilizer system, it is possible to start the engine using the emergency procedure; entering
the secret code using the DDS diagnosis instrument.

Removing the rider seat 5 - 3, Removal of the seat
Connect the power and diagnostics cable (2) to the diagnostics connector (H) on the tester and to the diagnostics socket (L)
on the motorcycle.
Enter the general functions menu by pressing the icon “Menu 1” (A).
1 A
section
Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and
confirm, then select the version and confirm.
Press the icon “Select system” to display a list of the bike’s systems that can be analysed.
Select “Engine electronics” and press the “Confirm” icon (B). Next, press the “Self-diagnosis” icon to access the corresponding
function.
section
The DDS diagnosis instrument will interrogate the electronic control unit and display the parameters analysed with their relative
values.
Note
Make all connections with the motorcycle ignition key in the OFF position.
Press the “Actuators” icon (C) to display the actuators and other components connected to the ECU.
Select the option “immobilizer Override” and then press the icon “Apply” (D).
section
A screen will appear in which you can enter the 5 digit secret code. Use the red arrows (E) and (F) to enter each digit:
after entering each digit, press the “Confirm” icon (B).
One the entire code has been entered, press the “Confirm” icon (B) again.
On completion of the operation, the message “Was the operation completed successfully?” will appear; press “Confirm”.
If any problems were encountered during the operation, the tester will display the relative error messages: each message
must be confirmed by pressing the “Confirm” icon, or rejected by pressing the “Exit” icon (G).
B G E F
Disconnect the tester.

Refitting the rider seat 5 - 3, Refitting the seat
section
Guided diagnosis
Note
The DDS diagnosis instrument guides the operator step-by-step through the various diagnostic procedures,
providing descriptions and documentation for motorcycle components, wiring diagrams for the electronic systems and informa-
tion on the locations of specific components.

Connect the power and diagnostics cable (2) to the diagnostics connector (F) on the tester and to the diagnostics socket (G)
on the motorcycle.
Enter the general functions menu by pressing the icon “Menu 1” (A).
1 A
section
Press the “Select vehicle” icon and, on the next screen, press the “Select motorcycle” icon; select the motorcycle model and
confirm, then select the version and confirm.
Press the icon “Select system” to display a list of the bike’s systems that can be analysed.
Select “Engine electronics” and press the “Confirm” icon (B).
Press the “Guided diagnosis” icon (C) to access the corresponding function.
section
A series of screens are displayed indicating the operations required for correct diagnosis.
To determine whether the system has any internal problems, you can access the “Self-diagnosis” function by pressing the cor-
responding icon. If any errors are present, the symbol (D) will be displayed. To determine the type of errors present, press the
“Errors” icon (E). Once errors are detected, it is possible to solve them using the Step-by-step diagnosis; press “Step-by-step
diagnosis“ icon (C).
values.

section
Testing the battery charging system
Note
You can determine the engine rpm required for generator to produce just enough current to charge battery, feed the injection
ignition system and all electric items fitted to motorcycle. When applied to a cable, the clamp-type amperemeter (18) detects the
magnetic field generated by the current passing through that cable.
18

Remove the seat cover or the passenger 5 - 3, Removal of the seat
seat
Connect the power and diagnostics cable (Measurement Module) (3) to the measurement module connector (D) on the DDS
diagnosis instrument (1).
1 3
Connect the clamp-type amperemeter to the connector (E) of the power and diagnostics cable (Measurement Module) (3).
E 15
Warning
The clamp-type amperemeter must not be connected to wires through which electrical current is flowing.
Insert the clamp-type amperemeter into the battery positive terminal lead with the arrow on the clamp pointing towards the bat-
tery positive terminal (+).
section
the “Ammeter” icon (F) followed by the “Start” icon.
A, B or C.
section
If the measured current is a positive quantity, it means that generator is feeding all electric items and charging battery at the same
time. If the current has a negative sign, this means that the charging system is not able to power the electrical loads and a
significant amount of the current required must be supplied by the battery, which is therefore discharging.
Important
If polarity is reversed when clamping the ammeter onto the cable, the sign of the readings will also be reversed, giving rise to
incorrect diagnosis.

Refitting the seat cover or the passenger 5 - 3, Refitting the seat
seat
section
Deactivating the “service” indication on the instrument panel
The message “SERV” is displayed on the instrument panel, indicating that the motorcycle should be serviced in accordance with
the programmed maintenance plan. This indication is activated after the first 1000 km and thereafter at intervals of 12000 km.
After the scheduled service has been carried out, the indication must be switched off as follows:
Note

Turn on the DDS diagnosis instrument referring to the paragraph “Tester power supply”.
Connect the power and diagnostics cable (2) to the diagnostics connector (A) on the tester and to the diagnostics socket (E) on
the motorcycle.
Enter the general functions menu, pressing “Menu Key 1“ icon (B).
section
Press the “Vehicle selection“ icon and press “Vehicle selection“ icon in the following page; select the motorcycle model and
confirm, then select the version and confirm.Press the “Select system” icon.
A list of the motorcycle’s systems that can be analysed will appear on the display.
Select “Engine electronics”.
Press the “Confirm” icon (C). Next, press the “Self-diagnosis” icon to access the corresponding function.
values.
Press the “Settings” icon to display the special parameters.
section
Select “Service light OFF“ and press “Execute“.
On completion of the operation, the message “Was the operation completed successfully?” will appear; press “Confirm” (C).
If any problems were encountered during the operation, the tester will display the relative error messages: you need to confirm
or reject each message by pressing “Confirm“ (C) or “Exit“ (D), respectively.
C D
Note
Once the “service“ light has been reset with the DDS diagnosis instrument, set the ignition switch to OFF and wait for at least
30 seconds before switching it ON again.

section
Icons table
Symbol Description
Confirm
Exit
Measurement module
Belt tension
Start/stop
Menu 1
Select vehicle
Select motorcycle
Self-diagnosis
Settings
Apply
Cylinder synchronisation
Value display
Reset
Pressure test
Cylinder compression
Actuators
section
Symbol Description
Guided diagnosis
Select system
Errors
Clamp-type amperemeter
7 - Chassis 0
section
6- Chassis
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
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
section
6- Chassis
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

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
section
6- Chassis
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
1
section
7-1 Chassis
1 - Front wheel
2 1
8 3
11
4 “S” version
5
10 7
8 5 6
4
9
1 Nut
2 Washer
3 Left spacer
4 Sealing ring
5 Bearing
6 Front wheel rim
7 Inner spacer
8 Screw
9 Right spacer
10 Front wheel axle
11 Valve

1200 ABS FRONT AND REAR WHEELS
1200 S ABS FRONT AND REAR WHEELS
Important
section
7-1 Chassis
Removal of the front wheel
Support the bike so that the front wheel is raised from the ground.
Remove the front brake calliper (B) by unscrewing the two screws (A) securing the calliper to the fork leg; do not disconnect the
calliper from the hose.
Warning
Do not operate the brake lever when the callipers are removed. This can cause the brake pistons to be expelled.
Loosen and remove the nut (1) on left side of the axle.
Recover the washer (2).
1 2
section
7-1 Chassis
Loosen the wheel shaft screws (8) on the fork legs.
1200 S ABS
1200 S ABS
1200 ABS
8 8
Working from the left-hand side, use a plastic mallet to drive the axle (10) out from the opposite side and remove it.
10
section
7-1 Chassis
Remove the wheel and recover the spacers (3) and (9).
Working from both sides, remove the oil sealing ring (4).
section
7-1 Chassis
Overhauling the front wheel
Wheel bearings
Before checking the dimensions, check the wear on wheel bearings. Check for wear by hand after cleaning and degreasing the
bearings in their seats.
Turn the inner race.
Check the amount of radial and axial play. Excessive play will cause vibration and make the bike unstable.
Endfloat
Radial
clearance
To remove the bearings (5) and the sealing rings (4) from the wheel hub follow the instructions below.
Position a drift (A) against the inner race of the bearing (5).
Tap with a hammer until knocking out the bearing (5).
Apply the drift at different points to keep the bearing square during removal.
Important
Once removed, the used bearings and sealing rings must not be refitted.
Before fitting new bearings, check that the housing is clean and free from scoring and damage.
Grease the bearing seat and then push the new bearing into its seat.
Using a tubular drift (B) that only bears on the outer race of the bearing, drive the bearing (5) fully into its seat.
C 7
section
7-1 Chassis
Use the same method to install the sealing rings (4).
Ensure that spacer (7) is fitted between the two wheel bearings.
C 7
Note
Wheels must be rebalanced after repair, maintenance and overhaul operations.
section
7-1 Chassis
Inspecting the wheel axle
Check the wheel axle for straightness.
Turn the pin on a reference surface and measure maximum distortion using a feeler gauge (see Sec. 3 - 1.1, Front wheel).
Overhauling the wheel

After you have checked the bearings, check the rim as follows.
Visually inspect the rim for cracks, scoring and deformation: change the wheel if damaged.
Insert the axle in the wheel and mount it on two fixed reference blocks.
Using a dial gauge, measure rim runout and out-of-round relative to the pin axle (see Sec. 3 - 1.1, Front wheel).
If the values measured are not within the tolerance limits, renew the wheel.
section
7-1 Chassis
Refitting the front wheel
When all the necessary inspections have been completed, refit the wheel as follows.
Lubricate and fit the spacers (3) and (9) to the sealing rings on the sides of the wheel hub.
Install the complete wheel between the fork legs.

Lubricate the shank and thread of the wheel axle (10).
Take the pin (10) fully into the wheel hub.
B
10
Fit the washer (2) on the end of the axle.

Grease the thread and the underside of the head of the axle lock nut (1), then screw it on.
Tighten the nut (1) to the torque of 63 Nm ± 5% (Sec. 3 - 3, Frame torque settings).
1 2
B
section
7-1 Chassis
Grease the threads and undersides of the heads of screws (A).
Screw in the two screws (A) securing the brake calliper (B).
Operate the front brake lever two or three times.
Hold the lever pulled towards the handgrip and simultaneously tighten the screws (A) to a torque of 45 Nm ± 5% (Sec. 3 - 3,
section
7-1 Chassis
Before tightening the screws (8), lower the motorcycle to the ground and push up and down the handlebars to load the
suspension; so the fork legs will become properly seated onto the wheel axle.
Lubricate the screws (8).
Tighten the screws (8) to the torque of 10 Nm ± 5% (1200 ABS) / 19 Nm ± 5% (1200 S ABS) (Sec. 3 - 3, Frame torque settings)
following the sequence 1-2-1.
8 8
1200 ABS
8
1200 S ABS
1200 S ABS
1
section
7-2 Chassis
2 - Rear wheel
6 1 2 3
1 Right-hand wheel nut

2 Washer
3 Spacer
4 Valve
5 Wheel
6 Circlip

Important
section
7-2 Chassis
Removing of the rear wheel
Remove the exhaust silencers 8 - 8, Removal of the exhaust system
Place the motorcycle on the rear service stand and engage the 1st gear.
Remove the clip (6).
Using a suitable socket wrench, loosen the wheel nut (1).
Fully unscrew the nut (1), then remove the washer (2) and the spacer (3).
Remove the rear wheel from the motorcycle.
3
6
2
Overhauling the rear wheel

Inspect the condition of the rear wheel.
As the wheel rim has no bearings, it should be supported using the service tool code 88713.2951.
Note
This service tool can also be used to install the wheel on a balancing machine.
88713.2951
section
7-2 Chassis
Overhauling the wheel
Inspect the wheel as described below.
Visually inspect the rim for cracks, scoring and deformation: change the wheel if damaged.
Fit the wheel rim on service tool code 88713.2951 using the original fasteners.
Using a dial gauge, appropriately supported, measure wheel rim runout and out-of-round according to the wheel axle (Sec. 3 -
1.1, Rear wheel).
If the values measured are not within the tolerance limits, renew the wheel.
section
7-2 Chassis
Refitting the rear wheel
Clean the mating surfaces and lubricate the threaded end of the wheel shaft with the recommended grease.
B
Fit the wheel centring it in the pin and in the driving pins (A).
Install the spacer (3) and the washer (2) and insert the nut (1) manually.
Tighten the nut (1) to a torque of 230 Nmn ± 10% (Sec. 3 - 3, Frame torque settings) checking that the hole on the nut is aligned
with those in the wheel axle.
Fit the clip (6), inserting the end of one of the holes in the axle, orienting it a shown in the figure.
3
6
2
section
7-3 Chassis
3 - Front brake control
8 22
11 23
14 19
15 17 16
10
12 13
1 20
4
22 9
2 23
21
19
4
3 4
5
24 6
21 7
18
1 Front brake master cylinder 13 Control unit - front callipers pipe

2 Brake lever 14 Screw
3 Banjo bolt 15 Screw
4 Sealing washer 16 Screw
5 screw 17 Bracket
6 Phonic wheel 18 Right brake calliper
7 Brake disc 19 Banjo bolt
8 Screw 20 Front brake hose
9 Left brake calliper 21 Screw
10 Dust cap 22 Dust cap
11 Bleed valve 23 Bleed valve
12 Right terminal 24 Front pump - control unit pipe

1200 ABS FRONT BRAKE
1200 S ABS FRONT BRAKE
Important
section
7-3 Chassis
Removal of 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 of these critical safety components can endanger rider and passenger safety.
Maintenance operations on these units are limited to renewal of the following parts: control lever, fluid reservoir assembly and
relative fasteners and master cylinder fasteners.

Drain the braking system 4 - 3, Draining the brake circuit
Remove the rear-view mirrors 7 - 8.1, Removal of the rear-view mirrors
Remove the right hand guard 7 - 8.1, Removing of the hand guards
Note
For the ABS front braking system, also refer to Sec. 7 - 5, ABS system operating information, Sec. 7 - 6, System components,
Sec. 7 - 7, ABS components maintenance.
Undo the banjo bolt (3), collect the washers (4), and release the front brake pump unit (1) from the pipe (24).
4
24
1
3
Undo the fixing screws (14) and (15) of the terminal (12) and then remove the front brake pump unit (1) from the handlebar.
12
15
For disassembly of components of the master cylinder unit (1), refer to the exploded view at the beginning of this chapter.
section
7-3 Chassis
Refitting the front brake master cylinder
Insert the front brake pump unit (1) on the right side of the handlebar to bring the terminal internal edge in correspondence to the
bolted joints (A).
Fit the terminal (12) on the handlebar inserting the screws (15).
Tighten the fixing screws (15) to a torque of 10 Nm ± 10% (Sec. 3 - 3, Frame torque settings) following the sequence 1-2-1 start-
ing from the upper screw.
12
15
Locate the pipe (24) and washers (4) on the pump unit (1) and fix it with the banjo bolt (3), without tightening.
4
24
1
3
Warning
An incorrectly positioned hose can cause clutch faults and interfere with moving parts.
section
7-3 Chassis
Orientate the pipe (24) as illustrated in the figure and then tighten the banjo bolt (3) to the specified tightening torque (Sec. 3 - 3,
106°±
10
°
17°± 2°
3
24
In order to fit the pipe (24) and the retaining clips, follow instructions in Sec. 7 - 6, Flexible wiring/hoses positioning.

Refit the right hand guard 7 - 8.1, Refitting the hand guards
Refit the rear-view mirrors 7 - 8.1, Refitting the rear-view mirrors
Fill the brake circuit 4 - 3, Filling the brake system with fluid
section
7-3 Chassis
Maintenance operations
Warning
Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In case of accidental contact, wash the
affected area with abundant running water and consult a doctor if necessary.
For all the maintenance operations (wear check and replacement of brake pads and brake fluids, etc.) see Sec. 4 - 3, Maintenance
operations.
Removal of the front brake system

Empty the front braking system 4 - 3, Draining the clutch hydraulic circuit
Remove the rear-view mirrors 7 - 8.1, Removal of the rear-view mirrors
Remove the right hand guard 7 - 8.1, Removing of the hand guards
Note
Undo the banjo bolt (3), collect the washers (4), and release the front brake pump unit (1) from the pipe (24).
4
24
1
3
Undo the two screws (C) and remove the protection (B).
section
7-3 Chassis
Tighten the screw (16) and slide the front brake pipe (13) from the bracket (17) on the yoke base.
16
13
17
Remove the protection of the front brake pipe (D) undoing the screws (E).
Unscrew the two fixing screws (21) of the left front brake calliper (9) to the fork leg.
Repeat the operation for the right brake calliper (18).
21
21
18
section
7-3 Chassis
Undo the banjo bolts (19) and collect, from both callipers, the gaskets (4).
Detach the front brake callipers from the pipe (13) and (20).
13
20 19
20
19
section
7-3 Chassis
Removal of the brake disks
The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor. Both parts must be changed
together as a pair.
Remove the front wheel (Sec. 7 - 1, Removal of the front wheel).

Undo the fixing screws (5) of the disk to the wheel, remove the disk (7) and, on its left side, the phonic wheel (6).
7 5
6
Overhauling the front brake components
Important
Critical safety components. The brake calliper manufacturer recommends that you do not attempt to service the internal compo-
nents of the brake callipers. Incorrect overhaul of this component could endanger rider safety.
Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly.
Refer to the exploded view at the beginning of this section for indications on renewal of the above components.
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 disks follow the data detailed in Sec. 3 - 1.1, Hydraulic brakes.
Refitting the brake disks

Before refitting the brake disc to the wheel, clean all contact surfaces thoroughly and smear a medium strength threadlocker on
the threads of retaining screws (5).
Operating on the left side, fit the phonic wheel (6).
Tighten the fixing screws (5) of the brake disk (7) to the wheel following this sequence: 1-3-5-2-4.
2
LOCK
5
7 5
6
Tighten the screws to the specified torque (Sec. 3 - 3, Frame torque settings).
Refit the wheel on the motorcycle (Sec. 7 - 1, Refitting the front wheel).
section
7-3 Chassis
Refitting the front brake system
While refitting the system, pay special attention to the orientation of the pipe couplings (24) on the pump and the pipes (13) and
(20) on the callipers (9) and (18).
Warning
If incorrectly positioned, the hose can affect brake operation and foul moving parts. Position the hose as shown in the figure.
106°±
10
°
17°± 2°
3
24
12°
0°
±
±2 °
2°
0°
±2 °
9 18
(8
6°)
22
22
When reconnecting the brake hose to the calliper or master cylinder, make sure to install the sealing washers (4) either side of
the hose end fitting.
After orientating the coupling, tighten the screw (3) to the specified torque (Sec. 3 - 3, Frame torque settings).
4
24
1
3
section
7-3 Chassis
Refit the pipes (24) and (20) on the front brake callipers (18) and (9) tightening the banjo bolts (19) to the specified torque (Sec. 3
- 3, Frame torque settings).
Note
Make sure that internal pipe coupling (13) and the external pipe coupling (20) are installed in the right brake calliper (10).
13
20 19
20
19
Fit the left calliper (9) over the disk.

Apply the recommended grease to the screws (21).
Hand tighten the bolts (21) to secure the callipers to the fork legs.
Operate the brake lever (2) two or three times to pressurise the circuit so that the brake pads are brought into contact with the
brake disk.
Repeat the operation for the right brake calliper (18).
21
section
7-3 Chassis
Hold the lever pulled in towards the grip and tighten the calliper screws (21) to the torque of 45 Nm ± 5 % (Sec. 3 - 3, Frame
torque settings).
Refit the front brake pipe protection (D) inserting and tightening to a torque of 3 Nm ± 10 % (Sec. 3 - 3, Frame torque settings)
the screws (E).
Apply the recommended grease to the screws (16).

Fit the front brake pipe (13) in the bracket (17) on the mudguard, fixing it with the screw (16).
Tighten the screw (16) to a torque of 22 Nm ± 5% (Sec. 3 - 3, Frame torque settings).
16
13
17
B
In order to position the pipes (13), (20), (24) and the retaining clips, follow the instructions in Sec. 7-6, Flexible wiring/hoses po-
sitioning.

Refit the right hand guard 7 - 8.1, Refitting the hand guards
Refit the rear-view mirrors 7 - 8.1, Refitting the rear-view mirrors
Filling of the front braking system 4 - 3, Filling the brake system with fluid
1
section
7-4 Chassis
4 - Rear brake
8 2
1
33
12
23 22 17
3
4 21
15 11
30
31 5
26 29
14 28
32 17
25
24 18
10
11
13 9 20
27
7
6 19 16 23 22
1 Rear speed sensor (ABS)

2 Screw
3 Washer
4 Spring
5 Brake switch (rear)
6 Brake lever (rear)
7 Rear pump - control unit pipe
8 Sealing washer
9 Pin
10 Bush
11 O-ring
12 Screw
13 Screw
14 Rear brake disc
15 Rear brake calliper
16 Rear brake master cylinder
17 Hose clip
18 Pushrod
19 Screw
20 Bracket
21 Hose
22 Banjo bolt
23 Sealing washer
24 Screw
25 Phonic wheel
26 Rear wheel axle
27 Nut
28 Screw
29 Nut
section
7-4 Chassis
30 Screw
31 Pivot
32 Spacer
33 Control unit - rear calliper pipe

1200 ABS REAR BRAKE
1200 ABS ANTILOCK BRAKING SYSTEM (ABS)
1200 S ABS REAR BRAKE
1200 S ABS ANTILOCK BRAKING SYSTEM (ABS)
Important
section
7-4 Chassis
Removing of the rear brake control
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 the rider and passenger.
Maintenance operations on these units are limited to renewal of the following parts: control lever, fluid reservoir assembly and
relative fasteners and master cylinder fasteners.

Empty the rear braking system 4 - 3, Draining the brake circuit
Note
Disconnect the rear stop switch (5) from the main wiring (Sec. 6 - 1, Routing of wiring on frame).
Undo the fixing screws of the rear brake pump (19).

Remove the rear brake pump (16) from the pushrod (18) and collect the fixing bracket (20) of the rear stop (5).
18
16
19
20
section
7-4 Chassis
Undo the fixing pin (9) of the brake lever (6), collecting the spring (4).
6
9
Remove the brake lever (6) and collect the pin (9), the washer (3), the bush (10) and the O-ring (11).
9
3
6
Undo the banjo bolt (22) from the pump (16) and remove the pipe grommet (17); slide the pipe (7) recovering the gaskets (23)
and the pipe (21).
Remove the rear brake pump (16) from the motorcycle.
21
17
16
23 22
section
7-4 Chassis
Disassembly of the rear brake control
The brake master cylinder is supplied only as a complete unit; internal components cannot be replaced.
To disassemble the master cylinder's outer parts, follow the indications given in the exploded view at the beginning of this Sec-
tion.
If the bush (10) inside the brake pedal (6) 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 2 mm from the pedal external face.
2 mm
6
2 mm
D 10
To disassemble the various parts of the system, refer to the exploded view at the beginning of this chapter.
Warning
After performing an operation on the rear brake control, check the brake pedal position following the instructions detailed in
Sec. 4 - 3, Adjusting the position of the gear change and rear brake pedals.
section
7-4 Chassis
Refitting the rear brake control
Apply grease the inner surface of the bush (10) and threadlocker on the pin (9).
Fit the O-ring (11) in the pin (9).
Insert the pin (9) on the brake lever (6), place the other O-ring (11) and the washer (3).
2
LOCK 9 D
3
6
Refit the pipe (7), placing the gaskets (23) in both sides of the coupling and tighten it with the banjo bolt (22), and the pipe (21)
fixing it with the pipe grommet (17).
Tighten the banjo bolt (22) to a torque of 5 Nm ± 10% (Sec. 3 - 3, Frame torque settings).
2
LOCK
21 D
17
16
23 22
Note
Pay special attention to the pipes (7) and (21) orientation on the rear brake pump (16).
7
22
5°
21 1
16
section
7-4 Chassis
Fit the brake lever (6) with spring (4) inserting the pin (9).
Place the end (A) of the spring (4) as shown in figure.
Tighten the pin (9) to the specified torque (Sec. 3 - 3, Frame torque settings).
6
9
Refit the fixing bracket (20) of the rear stop (5) on the rear brake control (16).
27
Apply the recommended threadlocker on the screw (19).

Position the rear brake pump (16) on the vehicle inserting the fixing screws (19).
Insert the rod (18) inside the pump (16), after applying the recommended grease.
Tighten the screws (19) to a torque of 10 Nm ± 10% (Sec. 3 - 3, Frame torque settings).
2
LOCK
18 B
16
19
section
7-4 Chassis
Connect the rear stop switch (5) to the main wiring.
In order to fit the pipes (7), (21) and the retaining clamps, follow the instructions in Sec. 7-6, Flexible wiring/hoses positioning.

Filling the rear braking system 4 - 3, Filling the brake system with fluid
section
7-4 Chassis
Removal of the rear brake calliper
Important
The brake manufacturer advises against any servicing of the internal components of brake callipers or the master cylinder. Incor-
rect overhaul of these critical safety components can endanger rider and passenger safety.
Before removing the parts in question, you must first carry out the following operations:

Drain the rear brake circuit 4 - 3, Draining the brake circuit
Note
Unscrew and remove the banjo bolt (22) fixing the pipes (33) to the rear brake calliper and the corresponding couplings (23).
Remove tube (33).
Undo the two fixing screws (12) of the rear brake calliper (15) to the calliper holder bracket and remove the brake calliper (15).
If it is necessary to remove the calliper holder bracket (A) refer to Sec. 7 - 13, Removal of the rear wheel eccentric hub and rear
wheel axle.
Note
To replace the brake pads follow instructions in the paragraph “Checking brake pad wear and changing brake pads” (Sec. 4 - 3).
To remove the speed sensor (1), undo the fixing screw (2) paying attention to the airgap spacer (8).
33 A 8 1
12
7
22
23
15
Only the following parts should be renewed:

- brake calliper: pads, fasteners and bleed valve assembly;
- master cylinder: control pedal, bleed valve assembly, reservoir and its components.
Refer to the exploded view at the beginning of this section for indications on renewal of the above components.
section
7-4 Chassis
Removal of the rear brake disc
Remove the rear eccentric hub (Sec. 7 - 13, Removal of the rear wheel eccentric hub and rear wheel axle).
Undo and remove the four fixing screws (13) of the brake disk to the wheel axle and remove the rear brake disk (14).
The brake disc must be perfectly clean, with no rust, oil, grease or other dirt and no deep scoring.
To check the wear limit of the brake disk refer to Sec. 3 - 1.1, Hydraulic brakes.
Refit the rear brake disk (14), tightening the screws (13) to a torque of 27 Nm ± 10% (Sec. 3 - 3, Frame torque settings) following
the sequence 1-2-3-4.
Refit the rear eccentric hub as described in Sec. 7 - 13, Removal of the rear wheel eccentric hub and rear wheel axle.
14
13
section
7-4 Chassis
Refitting the rear brake calliper
When replacing the brake pipes (33) or removing one of the rear braking system components, pay special attention to the position
of the couplings on the pump and the calliper.
Warning
If incorrectly positioned, the hose can affect brake operation and foul moving parts. Position the hose as shown in the figure.
33
°
23° ±2
22
Remember to fit the copper faced sealing washers (23) to the hose end fitting when reconnecting the brake pipe to the brake
calliper (15).
After orientating the coupling, lock the banjo bolt (22) to the specified torque (Sec. 3 - 3, Frame torque settings).
If the speed sensor (1) was removed, fit it on the calliper holder bracket (A) with the spacer (8) and tighten the screw (2) to
the specified torque (Sec. 3 - 3, Frame torque settings).
Note
The gap between the sensor (1) and the brake disc fixing screw must be within 0.6 to 2.2 mm.
If it is necessary to remove the calliper holder bracket (A) in order to refit it, see Sec. 7 - 13, Refitting the rear wheel eccentric
hub and rear wheel axle.
Insert the rear brake calliper (15) on the brake disk, aligning it with the holes of the calliper mounting bracket (A).
Grease the screws (12) and tighten to the specified torque (Sec. 3 - 3, Frame torque settings).
33 A 8 1
12
2
22
23
15 B
In order to fit the pipe (33), the speed sensor (1) and the retaining clamps follow instructions in Sec. 7-6, Flexible wiring/hoses
positioning.

Fill the rear brake circuit 4 - 3, Filling the brake system with fluid
1
section
7-5 Chassis
5 - ABS system information
Operating principle
The Ducati ABS brake system manages the front and rear brakes separately. A pulse generator (phonic wheel), with a ring of
slots, is fixed onto each wheel. On the left calliper mounting bracket of the front fork and on the rear brake calliper holder plate
are HALL effect sensors which detect the full sections and voids on the phonic wheel as the vehicle moves, providing and in-
stantaneous wheel speed reading. These sensors transmit the data to the ABS control unit, which contains software implement-
ing a specific control algorithm developed by Ducati. The software compares the average speed of the vehicle against the
instantaneous wheel speed values to determine the degree of skidding. If the pressure applied to the calliper by the rider causes
the control limits to be exceeded, the control unit intervenes in the braking circuit relative to the wheel for which incipient lock-
up is detected. The ABS modulates the calliper pressure with a system of solenoid valves that initially prevents any further in-
crease in hydraulic pressure (EV valve closed), and then reduces pressure (AV valve opened). The AV 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
rotate again in response to the diminished braking force applied and the wheel speed reaches the reference value, the AV release
valve is closed.
Simultaneously, the EV inlet valve is reopened, restoring normal operation of the brake system. The ABS control unit can monitor
and modulate brake force accordingly in the three following different conditions: dry road surface (high grip), wet or greasy road
surface (poor grip) and uneven road surface. ABS functionality is disabled at vehicle speeds lower than 5 km/h.
A diagram illustrating how the ABS system functions is given below.
Rear pump Front pump
EV rear EV front
Brake
master
cylinder
AV rear AV front
Accumulators
Rear calliper LH front RH front
calliper calliper
Electronic unit
Sensor ABS Sensor
speed speed
rear front
The hydraulic component of the ABS system consists of a primary circuit (from the pump to the control unit and from the control
unit to the calliper) and a secondary circuit (completely within the control unit). The hydraulic layout of the ABS system is given
below.
Key for ABS hydraulic system layout

EV rear Rear calliper inlet valve
AV rear Rear calliper outlet valve
EV front Front calliper inlet valve
AV front Front calliper outlet valve
section
7-5 Chassis
ABS system operating information
The response 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 response 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 in the vicinity of these components; dam-
age to the phonic wheels damages may compromise the operation of the system and cause dangerous malfunctions.
ABS diagnosis
The diagnostic function of the ABS 8M ascertains the functionality of the main system components via hardware/software tests,
but cannot modify the operating parameters of the ABS system. The DDS diagnostic instrument is connected by cable to the
ABS control unit communication link connector (A), located beneath the saddle. The connection cable between the tester and
the ABS control unit has another branch with a negative and a positive clamp that must be connected to the vehicle battery to
power the tester itself and enable communication with the ABS control unit.
From the AUTODIAGNOSIS menu of the DDS instrument, select the ABS system model and wait until the correct configuration
loads for analysing the configuration of the vehicle. After switching the vehicle to key-on state, the tester communicates with the
ABS control unit.
Once in this configuration, a number of parameters and states relative to the ABS control unit and information concerning the
control unit itself may be selected and displayed.
If the tester receives notification from the ABS control unit that there are diagnostic errors dating from a prior test session still
stored in its memory, the user is warned by specific message on the display and an audible alarm.
The ABS control unit identification number, identified by the prefix ID ECU, may be viewed from the INFO menu.
Select the function “View parameters and states”

This function allows the tester to display the following ABS system parameters and states:
Viewable parameters
Front wheel speed The speed value for the front wheel is displayed in Km/h.
Rear wheel speed The speed value for the rear wheel is displayed in Km/h.
System voltage value The system voltage value, measured across the terminals of the ABS unit, is displayed
in Volts
Viewable states
Hydraulic pump motor state Indicates if the electric motor of the hydraulic pump inside the ABS unit is functioning
or not.
Valve relay state Displays the state of the main valve relay inside the ABS unit.
Rear input valve state Displays the state of the normally open EV1 rear inlet valve (OFF if open, ON if closed).
Front input valve state Displays the state of the normally open EV4 rear inlet valve (OFF if open, ON if closed).
Front output valve state Displays the state of the normally closed AV4 rear outlet valve (OFF if closed, ON if
open).
ABS switch state Displays state of the analogue input of the ABS unit for the strategy switch off request
(1 state to Uz, 0 state to GND).
section
7-5 Chassis
Select the function “View errors”
This tester function provided the user with information concerning the error list in the ABS control unit memory, indicating if er-
rors have been stored previously stored or if they are current. The following codes are given after a short description of the diag-
nosis 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 diagnosed 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 reopening 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:
Errors Description
Front ABS speed sensor signal Disconnected/short circuit to GND/short circuit to Uz of rear wheel speed sensor
Plausibility of signal from front wheel Front wheel speed sensor fault – Plausibility
speed sensor
Rear ABS speed sensor signal Disconnected/short circuit to GND/short circuit to Uz of front wheel speed sensor
Plausibility of signal from rear wheel Rear wheel speed sensor fault – Plausibility
speed sensor
Plausibility of difference between Speed difference between front and rear wheel (WSS_GENERIC)
front and rear wheel speeds
Front inlet valve fault Front inlet valve (EV) fault
Rear outlet valve fault Rear outlet valve (AV) fault
Rear inlet valve fault Rear inlet valve (EV) fault
Front outlet valve fault Front outlet valve (AV) fault
ABS pump fault ABS pump motor fault
Valve relay fault Valve relay fault (Failsafe relay)
ABS unit electronic control unit fault ECU fault
ABS unit power circuit fault ABS power circuit fault
section
7-5 Chassis
Select the function “ABS system information”
This tester function displays the identification data for the ABS system, such as Supplier reference, Software version and BAR-
CODE.
e.g.:
Supplier ref.: DUCM696
Software version: 67890
Bar Code Data: HQOJM98200RA
ABS system deactivation

Carry out the procedure described in section Sec. 6 - 7, ABS disabling function.
Warning
If the vehicle front wheel remains off the ground for a prolonged period while the vehicle is in motion, the speed difference de-
tected between the two wheels causes an ABS fault (warning light activated) and makes it impossible for the control unit to es-
tablish a reference speed.
1
section
7-6 Chassis
6 - System components
11 15 4
17 17 16 12 16
11
11 7
14
10
13 8 1200 ABS
18
9
3
2
1200S ABS
20
21 18
2
22
3 19 1
3
1 Screw 12 ABS support
2 Front ABS speed sensor 13 Rubber mounting
3 Calibrated gasket 14 Hose clip
4 Cover 15 Rubber mounting
5 Rear ABS speed sensor 16 Screw
6 ABS control unit 17 Banjo bolt
7 Front pump - control unit pipe 18 Guide
8 Control unit - front callipers pipe 19 Calliper holder bracket (ABS)
9 Rear pump - control unit pipe 20 Rear phonic wheel
10 Control unit - rear calliper pipe 21 screw

1200 ABS ANTILOCK BRAKING SYSTEM (ABS)
1200 ABS REAR WHEEL AXLE
1200 S ABS ANTILOCK BRAKING SYSTEM (ABS)
1200 S ABS REAR WHEEL AXLE
Important
section
7-6 Chassis
Replacing the front phonic wheel sensor

Remove the left panel 5 - 1, Removing the panel
Disconnect the front ABS sensor (2) connector (A) from the main electric wiring.
Open all the retainer clamps of the front ABS sensor cable (2): refer to table of Sec. 7 - 6, Flexible wiring/hoses positioning.
Undo the fixing screw (1) and remove the front ABS sensor (2) with the calibrated gasket (3), sliding the cable from the cable
grommet (18).
section
7-6 Chassis
Before refitting, make sure that the contact parts between the front ABS sensor (2) and its seat are not damaged and are perfectly
clean.
Fit the new front ABS sensor (2) on its seat inserting the screw (1).
Check the air gap between the front ABS sensor (2) and the front phonic wheel (19) as indicated in Sec. 7 - 7, Adjusting of the
AIR-GAP phonic wheel sensor.
Tighten the screw (1) to the specified torque (Sec. 3 - 3, Frame torque settings).
Connect the connector (A) to the main wiring.

Restore all the retainer clamps of the front ABS sensor cable (2): refer to table of Sec. 7 - 6, Flexible wiring/hoses positioning.

Refit the left panel 5 - 1, Refitting the panel
section
7-6 Chassis
Replacing the rear phonic wheel sensor
Remove the rider seat 5 - 3, Removal of the seat
Remove the rear mudguard 5 - 4, Removal of the front mudguard
Disconnect the rear ABS sensor (5) connector (C) from the main electric wiring.
Open all the retainer clamps of the rear ABS sensor cable (5): refer to table of Sec. 7 - 6, Flexible wiring/hoses positioning.
C 5
Remove the rear ABS sensor (5) from its seat on the rear calliper holder bracket (7), undoing the fixing screw (1) and collect the
calibrated gasket (3).
Check the air gap between the new rear ABS sensor (5) and the rear phonic wheel (11) as indicated in Sec. 7 - 7, Adjusting of the
AIR-GAP phonic wheel sensor.
Fix the sensor to the calliper holder bracket tightening the screw (1) to the specified torque (Sec. 3 - 3, Frame torque settings).
5
7
1
Connect the connector (C) to the main wiring.

Restore all the retainer clamps of the rear ABS sensor cable (5): refer to table of Sec. 7 - 6, Flexible wiring/hoses positioning.
C 5

Refit the rear mudguard 5 - 4, Removal of the front mudguard
Refit the rider seat 5 - 3, Refitting the seat
section
7-6 Chassis
Removing of the ABS control unit
Remove the seat 5 - 3, Removal of the seat
Drain the brake fluid in the pipes disconnecting these from the pump and from the calliper (Sec. 4 -3, Draining the brake circuit).
Remove the ABS pipes cover (4) undoing the fixing screws (16).
16
Disconnect the connector (A) of the ABS control unit (6), lift it from the vehicle.
Undo the four banjo bolts (17) fixing the pipes (10), (9), (8) and (7), on the ABS control unit (6), removing the gaskets (11).
Warning
Every time that gaskets (11) are removed, they must be replaced with new gaskets (11).
17 11
11
8
11 7
17
10
Remove the ABS control unit (6).
Important
Do not open the ABS control unit: if it is faulty, replace it.
Note
If it is necessary to replace one or more pipes, follow the instructions indicated in paragraph “Flexible wiring/hoses positioning”
of this section.
section
7-6 Chassis
Refitting the ABS control unit
Pipes (7), (8), (9) and (10) fixing must be carried out by placing new gaskets (11) between the couplings.
17 11
11
8
11 7
17
10
9
6
Refit the ABS control unit (6) on the vehicle inserting the pin (B) in the rubber (C) present on the support bracket.
Connect the connector (A) of the ABS control unit (6).
section
7-6 Chassis
To fill up the system, carry out the instructions for replacement of fluid of the pump or calliper to which the pipe is connected
(Sec. 4 - 3, Filling the brake system with fluid).
Important
If the ABS control unit is replaced, this must be supplied with secondary circuit already full of fluid; the control unit must be fitted
and the system filled and purged as a traditional system.

Refit the seat 5 - 3, Refitting the seat
Flexible wiring/hoses positioning

The routing of the ABS 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.
Table Position Description

Table C 2 ABS speed sensor (Front)
Table B 5 ABS speed sensor (Rear)
Table A 6 ABS control unit
Table A - Table B 7 Front pump - control unit pipe
Table A - Table B 8 Control unit - front calliper pipe
Table A - Table C 9 Rear pump - control unit pipe
Table A - Table C 10 Control unit - rear calliper pipe
Table B 25 Front brake hose
section
7-6 Chassis
Table A
10
8
7 6
10
section
7-6 Chassis
Table B
section
7-6 Chassis
section
7-6 Chassis
25
section
7-6 Chassis
10
25
section
7-6 Chassis
Table C
10
section
7-6 Chassis
25
section
7-6 Chassis
10
section
7-6 Chassis
10
1
section
7-7 Chassis
7 - ABS components maintenance
Adjusting of the AIR-GAP phonic wheel sensor
(For front as well as rear sensor) In each case of maintenance that foresees:
- replacement or refitting of the wheel
- replacement or refitting of the phonic wheel (1) or (2)
- replacement or refitting of the brake discs
- replacement or refitting of the speed sensor (3) or (4)
- (front) replacement or refitting of the sensor holder bracket
- (rear) replacement or refitting of the calliper holder bracket
it is necessary to check the air-gap between the speed sensor and the phonic wheel, once the components are refitted.
For this purpose, use a feeler gauge to check the air-gap; then, carry out 4 measures of the air-gap, one every 90° of wheel turn.
If the difference between the minimum and maximum values detected is higher than 0.40 mm, replace the phonic wheel.
Once checked that the difference is lower than or equal to 0.40 mm, carry out the shimming of the phonic wheel sensor (2) or
(5) by the appropriate calibrated thickness spacers (B).
section
7-7 Chassis
Phonic wheels cleaning
It is important to check that both phonic wheels (21) and (20) are always clean.
Otherwise: gently remove any possible dirt deposits with a cloth or metal brush. Avoid using solvents, abrasives and air or water
jets directly on the phonic wheel (21) or (20).
21
20
section
7-7 Chassis
Bleeding of the ABS hydraulic system
If some “sponginess” is detected on the brake control, due to air bubbles in the system, bleed the system, as indicated in Sec. 4
- 3, Changing the brake fluid.
Before bleeding a brake pump, move back the calliper pistons, as indicated in (Sec. 4 - 3, Filling the brake system with fluid) to
drain in the pump the air collected near the ABS control unit.
Purge must be carried out by means of the corresponding joints (A) placed near the callipers and the brake pumps.
Important
Do not undo the fixing screws of the joints of the pipes on the ABS hydraulic control unit, unless control unit replacement is nec-
essary.
Important
If the ABS control unit is replaced, this must be supplied with secondary circuit already full of fluid; the control unit must be fitted
and the system filled and bleeded as a traditional system.
1
section
7 - 8.1 Chassis
8.1 - Handlebar assembly - Hand guards - Rear-view mirrors - Throttle grip
23
33 34
26
25 30 22
27 28
29
21
15 38
31
32 38
24
7 35 15
13
11 14 12 26
9
8 A
6
1
5 10
37
20 A 16
17
2 25
4
3
19 18
1 Front brake master cylinder

2 Brake lever
3 Banjo bolt
4 Sealing washer
5 Microswitch
6 Right terminal
7 Pin
8 Screw
9 Screw
10 Screw
11 Bleed valve
12 Vibration damper mounts
13 Screw
14 Fluid reservoir assembly
15 U-bolt
16 Nut
17 RH hand guard
18 Turn signal
19 Screw
20 Spacer
21 Plug
22 RH rear-view mirror
23 LH rear-view mirror
24 Vibration damper mount
25 Washer
26 Throttle twistgrip
27 Grip
28 Switch
29 Handlebar
section
7 - 8.1 Chassis
30 U-bolt
31 Screw
32 Washer
33 Screw
34 Left screw
35 Stud bolt
36 Steering head
37 Throttle cables
38 Right-hand handlebar switch

1200 ABS HANDLEBAR AND CONTROLS
1200 ABS FRONT BRAKE
1200 S ABS HANDLEBAR AND CONTROLS
1200 S ABS FRONT BRAKE
Important
section
7 - 8.1 Chassis
Removal of the rear-view mirrors
Undo the screws (33) and (34) and remove the rear-view mirrors (23) and (22).
Warning
The screw (3) of the left mirror has a left-handed thread.
23
33
22
34
section
7 - 8.1 Chassis
Refitting the rear-view mirrors
Insert the screws (33) and (34) in the rear-view mirrors (23) and (22).
Insert the rear-view mirrors (1) and (2) in the u-bolts (15).
23
33
22
34
section
7 - 8.1 Chassis
Removing of the hand guards
The removal procedure is the same for both hand guards. Find below the description for the right hand guard.
Remove the rear-view mirrors as indicated in section “Removal of the rear-view mirrors“ of this section.
Loosen and remove the fixing screws (9) of the hand guard to the terminal.
Loosen and remove the fixing screw (13), collect the vibration damper mount (12).
Undo the screw (10) and collect the spacer (20).
17
13
12
10 9
Disconnect the connector (D) of the front arrow (Sec. 6 - 1, Routing of wiring on frame) and remove the complete right hand
guard.
If necessary, disassemble it undoing and removing the screws (19).
19
Refitting the hand guards

To refit the hand guards, carry out the operations in reverse order, and remember to fasten the corresponding screws to the
specified torque (Sec. 3 - 3, Frame torque settings).
Refit the rear-view mirrors as indicated in section “Refitting the rear-view mirrors“ of this section.
section
7 - 8.1 Chassis
Removal of the handlebar
Remove the throttle twistgrip 7 - 8.1, Removal of the gearchange control
Remove the right-hand handlebar switch 6 - 5, Checking the right-hand handlebar
switch
Remove the front brake lever 7 - 3, Removal of the front brake master
cylinder
Remove the left-hand handlebar switch 6 - 5, Checking the left-hand handlebar
switch
Remove the clutch lever 7 - 8.2, Removal of the clutch master cyl-
inder assembly
Undo and remove the fixing screws (21) of the u-bolt (30).
Remove the upper u-bolt (30).
Remove the handlebar (29) from its seat on the steering head.
To remove the grips (39), refer to the exploded view at the beginning of this chapter.
29
21
30
Undo the screws (31) and remove the stud bolts (35) of the steering head; recover the washers (32).
31
35
35
32
31
section
7 - 8.1 Chassis
Refitting the handlebar
If the spacers (24) were removed from the steering head, lubricate with silicone spray.
Seat the spacers (24) in the bores (A) in the steering head, orienting them as indicated.
On completion of the operation, clean all excess lubricant from the components.
24
35
32
31
Apply the recommended grease to the threads and undersides of the heads of the screws (3).
31
35
Insert the screws (31) with the washers (32) in the stud bolt (35).
Locate the stud bolts (35) on the steering head.
Position the handlebar (4) in its seat on the stud bolt (35).
Refit the u-bolt (30) and insert the screws (3).
Tighten the screws (21) to the specified torque (Sec. 3 - 3, Frame torque settings), applying sequence 1-2-3-4-3, as indicated.
Refit the grips (39) referring to the exploded view at the beginning of this chapter.
4
3
section
7 - 8.1 Chassis

Refit the front brake lever 7 - 3, Refitting the front brake master cyl-
inder
Refit the right-hand handlebar switch 6 - 5, Checking the right-hand handlebar
switch
Refit the throttle twistgrip 7 - 8.1, Refitting the throttle twistgrip
Refit the clutch lever 7 - 8.2, Refitting the clutch master cylinder
assembly
Refit the handlebar switch 6 - 5, Checking the left-hand handlebar
switch
section
7 - 8.1 Chassis
Adjusting the throttle cable
To operate on the set screws of the throttle grip cables, consult Sec. 4 - 3, Adjusting the throttle cable.
Removal of the throttle twistgrip

Remove the end plug (25) from the handlebar.
Peel back the rubber sleeve (A) protecting the throttle control cables.
25
Undo the screws (B) of the throttle grip (26) and open the command.
26
Disconnect the throttle grip cables (37) by unhooking the cable ends (C) from their seats.
Remove the throttle twistgrip (5) from the handlebar.
37 26
Note
To replace the throttle grip cables, it is necessary to remove it from the throttle body (Sec. 8 - 6, Removal the airbox and throttle
body).
Replacement throttle cables are supplied complete with adjusters.
section
7 - 8.1 Chassis
Refitting the throttle twistgrip
Lubricate the ends of the throttle grip cables (37) and the twistgrip race with the recommended grease.
37 26 A
To refit the throttle control components, proceed in inverse order to the removal procedure, making sure that the twistgrip hous-
ings locate in the reference hole in the handlebar.
Note
Refer to the tables on the next page for correct routing of the throttle grip cable.
section
7 - 8.1 Chassis
Routing the throttle cables
1
section
7 - 8.2 Chassis
8.2 - Handlebar unit: clutch hydraulic control
10
5
7
3
6
16
17
18
8
19 15
2
1
4
14 12 11
13
1 Banjo bolt 11 Screw

2 Sealing washer 12 O-ring
3 Clutch master cylinder 13 O-ring
4 Clutch hydraulic pipe (metal braid) 14 Clutch control rod
5 Screw 15 Transmission unit
6 Retaining clip 16 Dust cap
7 Screw 17 Bleed valve
8 Microswitch 18 Banjo bolt
9 Pin 19 Sealing washer
10 Bleed valve

1200 ABS CLUTCH CONTROL
1200 ABS CLUTCH
1200 S ABS CLUTCH CONTROL
1200 S ABS CLUTCH
Important
section
7 - 8.2 Chassis
Removal of the clutch master cylinder assembly
Warning
The clutch master cylinder manufacturer advises against servicing of the clutch master cylinder (1) due to the safety-critical nature
of this component. Incorrect overhaul of this component could endanger rider safety.
Maintenance operations of the master cylinder are limited to replacing the following parts: control lever, reservoir unit, and master
cylinder fasteners.

Drain the clutch system 4 - 3, Draining the clutch hydraulic circuit
Remove the LH mirror 7 - 8.1, Removal of the rear-view mirrors
Remove the left-hand hand guard 7 - 8.1, Removing of the hand guards
Unscrew the banjo bolt (1) collecting the gaskets (17), to release the clutch pump unit (3) from the clutch control pipe (4).
3
1 4
Undo the fixing screws (5) of the mounting u-bolt (6) and then remove the clutch pump unit (3) from the handlebar.
Refer to the exploded view at the beginning of this section for indications on disassembly and replacement of the master cylinder
components.
section
7 - 8.2 Chassis
Refitting the clutch master cylinder assembly
Insert the clutch pump unit (1) on the left side of the handlebar to bring the terminal internal edge in correspondence to the bolted
joints (A).
Tighten the fixing screws (19) to the specified torque (Sec. 3 - 3, Frame torque settings) following the sequence 1-2-1 starting
from the upper screw.
19
Locate the pipe (6) and gaskets (17) on the pump unit (1) and secure with the banjo bolt (16), but do not tighten at this stage.
17
1
16 6
Warning
section
7 - 8.2 Chassis
For the positioning of the clutch hose (6) and retaining clips, see the illustration at the end of this section.
Orientate the pipe (6) as illustrated in the figure and then tighten the banjo bolt (16) to the specified tightening torque (Sec. 3 - 3,

Refit the left-hand hand guard 7 - 8.1, Refitting the hand guards
Refit the LH mirror 7 - 8.1, Removal of the rear-view mirrors
Fill the clutch circuit 4 - 3, Filling the clutch circuit
section
7 - 8.2 Chassis
Removal of the clutch transmission unit
Warning
The manufacturer of the clutch transmission unit (15) advises against servicing of its internal parts due to the safety-critical nature
of this component.
Incorrect overhaul of these critical safety components can endanger rider and passenger safety.
The only components that should be renewed are the complete clutch transmission unit, the bleed valve, the seals and the com-
plete clutch pushrod assembly.

Drain the clutch system 4 - 3, Draining the clutch hydraulic circuit
Remove the clamps (A) and release the clutch pipe (14) from the side stand wire (B).
Loosen the screws (11) and slide off the clutch transmission unit (15) paying attention to the O-ring (12) positioned on its inside.
A
11
14
B
15
11
Remove the dust gaiter (16) and the bleed valve (17) and unscrew the screw (18), taking care to recover the gaskets (19): the unit
(15) is now disconnected from the pipe (14).
Push in the piston to force out all the fluid from inside the cap.
17 16
18
19 14
15
section
7 - 8.2 Chassis
At this point, it is possible to slide also the clutch gear rod (17). Check the wear state of the two O-rings (13) and replace them,
if necessary.
Note
If the two O-rings (13) need be replaced, it is necessary to replace also the O-ring (12) of the unit (15).
12
14
23
section
7 - 8.2 Chassis
Refitting the clutch transmission unit
Note
If the clutch pushrod (14) is replaced, it is necessary also replace the two O-ring (13) and (12) of the unit (15).
Grease and refit the clutch pushrod (14) with the two O-rings (13).
14
13
B
Lubricate the gasket (12) and locate it along with the transmission unit (15) in the crankcase.
25
B
Fit the transmission unit (15) on the crankcase, tightening the screws (11) to the specified torque (Sec. 3 - 3, Frame torque set-
tings).
Bind the clutch pipe (14) to the side stand wire (B) and insert the latter into the recess (C).
A
24
C
6
B
23
24
section
7 - 8.2 Chassis
Locate the pipe (6) on the clutch transmission unit (23), paying attention to the pipe retainer direction in the unit (23).
Warning
Position the two gaskets (19) and tighten the screw (18) to the specified torque (Sec. 3 - 3, Frame torque settings).
Refit the bleed valve (17) and the dust gaiter (16).
To position the pipe retaining clamps (14) refer to the table on the following page.
17 16
18
19 14
15

Fill the clutch circuit 4 - 3, Filling the clutch circuit
section
7 - 8.2 Chassis
Positioning of the clutch hose
section
7 - 8.2 Chassis
1
section
7-9 Chassis
9 - Gearchange mechanism
9
5
2 6
5
4
3
8 10
7
1 Gearchange pedal
2 Bush
3 Rubber
4 Pin
5 O-ring
6 Gearchange lever tie-rod
7 Screw
8 Gearchange pedal
9 Washer
10 Screw

1200 ABS FRAME
1200 S ABS FRAME
Important
section
7-9 Chassis
Removal of the gearchange control
Undo and remove the fixing pin (4) of the gear pedal (1) paying attention to the O-rings (5), the washer (9) and the bushing (2).
Undo and remove the fixing screw (7) of the lever (8) to the gear shaft.
Withdraw the lever (8) together with the gear change control assembly.
8
1
Note
Mark the position of lever (8) relative to the gear selector shaft.
To remove the lever (8) from the gear transmission rod assembly (6), undo the screw (10), and then slide off the lever (8).
6 10 8
Disassembly of the gearchange mechanism

Refer to the exploded view at the beginning of this section for indications on disassembly and renewal of gearchange compo-
nents.
If the bushing (2) inside the pedal (1) needs replacing, grease the external surface and drive the new bushing into place using a
press. The bushing must be seated 2 mm below the outer face of the pedal.
D
2 mm
2 mm
2 1
Warning
After working on the gearchange control, check the position of the gearchange pedal.
To adjust the gearchange pedal position, follow the instructions indicated in Sec. 4 - 3, Adjusting the position of the gear change
and rear brake pedals.
section
7-9 Chassis
Refitting the gearchange mechanism
Apply grease on the internal surface of the bushing (2) and threadlocker on the pin (5).
Install O-ring gasket (5) onto pin (4).
Insert the pin (4) in the gear lever (2), and place the other O-ring (5) and the washer (9).
Fit the gear lever (1) on the footrest plate inserting and tightening the pin (4) to the specified torque (Sec. 3 - 3, Frame torque
settings).
2
LOCK
D
5
4
9 5
2
1
Fit the lever (8) on the gear pushrod unit (6) inserting the screw (10).
6 10 8
Fit the gear control unit inserting the lever (8) on the gear control pin, apply threadlocker on the screw (7) and insert it on the lever
(8).
2
LOCK
4
8
1
section
7 - 10.1 Chassis
10.1 - Fork - Steering head: front fork (1200 ABS)
2
5
6
7
8
15
14
16
9
10
13 11
3
13 1
4 17
18 12
14
19 15
20
1 Screw 15 Screw
2 Screw 16 Washer
3 Steering head 17 Adjuster screw
4 Bottom yoke 18 Special washer
5 Left fork leg assembly 19 Inner tube assembly
6 Right fork leg assembly 20 Dust cap
7 Counter nut 21 Sealing ring
8 Damper assembly 22 Circlip
9 Bush 23 Bush
10 Spring 24 Outer tube
11 Hose 25 Bush
12 Washer 26 Bush
13 Washer 27 Collar
14 Top cap assembly

1200 ABS FRONT FORKS
Important
Note
Not all parts shown are available separately as spares: however they are indicated for clearer explanation of the procedure.
section
7 - 10.1 Chassis
Refitting the front fork (1200 ABS)
Before removing the front forks, it is first necessary to remove the following parts:

Remove the front brake callipers 7 - 3, Removal of the front brake system
Remove the front mudguard 5 - 4, Removal of the front mudguard
Remove the front wheel 7 - 1, Removal of the front wheel
Remove the top fairing 5 -1, Removing the headlight fairing
Loosen the clamp screws (1) holding the fork legs to the steering head (3).
Loosen the clamp screws (2) securing the fork legs to the bottom yoke (4).
Withdraw the fork legs (5) and (6) downwards in order to carry out to all the necessary overhaul operations.
1 1
5
6
4
2
2
section
7 - 10.1 Chassis
Overhauling the front fork (1200 ABS)
Note
It is advisable to loosen the top cap (14) when the fork is still fitted to the motorcycle.
Note
The specific tools for the revision of the fork, are described in Sec. 3 - 4, Specific tools for the frame.
Loosen the spring preload adjuster before unscrewing the plug (14).
Unscrew the top cap (14) complete with the rebound damping adjuster.
14
Disassembly of the front fork

Restrain the counter nut (7) with a hex wrench.
Using another hex wrench, unscrew and remove the plug (14), with its seal, from the cartridge (8).
14
Unscrew the counter nut (7) up to the final threads on the damper (8).
8
7
section
7 - 10.1 Chassis
While restraining the spring (10) with one hand, withdraw the bush (26) sideways and then slowly release spring (10).
26
10
Withdraw the spring (10) and the washer (12).
10
12
Withdraw the preload pipe (11) and collect the washer (16) and the bush (9).
11
Drain the oil from inside the leg by pumping with the outer tube (24) and the damper (8).
24 8
Warning
This movement generates pressure so that the oil will be rapidly expelled from the fork leg.
Aim the jet of oil into a previously prepared container and avoid contact with fork oil.
section
7 - 10.1 Chassis
Clamp the inner tube (19) in a vice with soft-faced jaws.
19
Unscrew the compression damping adjuster (15).

Remove the adjuster screw (15) and recover the seal (13).
13 15
Withdraw the damper assembly (8).
Slip the dust seal (20) off the outer tube (24), prising it off with a screwdriver.
20
24
section
7 - 10.1 Chassis
Remove the circlip (22).
22
24
Important
Take care not to damage the inner tube (19) and the seat of circlip (22) in the outer tube (24).
To separate the outer tube (24) from the inner tube (19), pull the inner tube sharply outwards repeatedly to gradually displace the
bottom bush (23).
Insert the tip of a screwdriver in the slit in the bush (25) and open it up sufficiently to slide the bush off the inner tube.
Remove the following parts from the inner fork tube:
- bush (23);
- collar (27);
- sealing ring (21);
- circlip (22);
- dust seal (20).
20 21 25
19 22
23
27
section
7 - 10.1 Chassis
Inspection of the front fork
Place the spring on a flat surface and measure the free length (L).
Service limit:
270 mm.
Renew the spring if the length is not within the specified limit.
Inspect the outer surfaces of both fork inner tubes and the internal surfaces of both outer tubes. They must be free from scoring,
steps, or dents.
Check that the outer tubes are straight:
maximum allowed error 0.10 mm.
Whenever the inner tube is removed from the outer tube it is good practice to renew the bushes (26) and (23).
26
23
Check the collar (27) for distortion in the area indicated. Renew if distorted.
27
section
7 - 10.1 Chassis
Reassembly of the front fork
Clamp the inner tube in a vice.
Protect the end of the inner tube with tape.
Important
Before installation, smear the sliding edges of sealing ring (21) with fork oil or oil seal grease.
Install the sealing ring (21) with the marked surface facing the dust seal (20).
Fit the following components to the inner tube (19):

- dust seal (20);
- circlip (22);
- sealing ring (21);
- collar (27);
- bush (23);
- bush (25).
20 19
20 21 25
19 22
23
27
Note
Before assembling the inner and outer fork tubes, lubricate the sliding surfaces of the bushes with fork oil.
Push the guide bush (23) and the cap (27) into the external sleeve (24) using the sealing ring tool (F, cod. 88713.3204).
Drive the sealing ring (21) into the outer tube using the same tool.
Fit the circlip (22) and the dust seal (20).
88713.3204
21
24
19
section
7 - 10.1 Chassis
Important
The outer sleeve must slide freely along the slider. Only support the sliders and the outer sleeve with your hands so not to dam-
age the sealing rings and the pilot bushes.
Insert the cartridge assembly (8) in the inner tube (19), screwing the tool 88713.3203 onto the cartridge.
19
Install the gasket (13) and the compression set screw (15) and tighten to the torque (Sec. 3 - 3, Frame torque settings).
13 15
Insert half of the prescribed quantity of oil in each fork leg (Sec. 3 - 2, Fuel, lubricants and other fluids).
Pump with tool 88713.3203 to force the oil to fill internal volume completely.
Slide both the damper and outer tube fully down the inner tube.
Pour the remaining oil into the fork leg and measure the oil level.
Important
Keep the fork leg vertical when measuring the oil level. Make sure the oil level is the same in both fork legs.
Recommended oil:
SHELL ADVANCE FORK 7.5 or DONAX TA.
Standard capacity:
0.480 dm3 for each fork leg.
Standard oil level:
104 mm.
The quantity of oil affects fork response during the final part of the compression stroke.
High oil level increases compression loading, low oil level will decrease it.
Clean off any oil from the spring (10) and the counter nut (7) before refitting.
section
7 - 10.1 Chassis
Fit the following components:
bush (9), washer (16) and preload pipe (11).
Insert the spring (10), washer (12), bush (26) and lock nut (7), with the conical side facing counter nut (23) and washer (8).
12
11
26
10
Screw the counter nut (7) onto the damper (8) with a wrench.
8
7
Using the same wrench, restrain the counter nut and screw the top cap (14) complete with the O-ring onto the damper (8).
Tighten the upper plug (14) to the specified torque (Sec. 3 - 3, Frame torque settings).
14
section
7 - 10.1 Chassis
Refit the front fork (1200 ABS)
Refit the fork legs, positioning them at the height shown in the figure relative to the upper surface of the bottom yoke.
267,6 ± 0,5 mm
Warning
The difference in height between the two legs must not exceed 0.1 mm.
Position the fork legs (5) and (6) on the yoke base (4) and on the steering head (3).
Tighten to the specified torque (Sec. 3 - 3, Frame torque settings) the screws (1) and (2) securing the fork legs to the bottom yoke
(4) and to the steering head (3): tighten the screws (2) in the sequence 1-2-1.
Important
If the clamp screws (1) and (2) were removed on disassembly, smear the threads with the specified grease before tightening.
B 3
1 1
5
6
4
2
2
Refit any parts removed from the frame:

Refit the front mudguard 5 - 4, Refitting the front mudguard
Refit the front wheel 7 - 1, Refitting the front wheel
Refit the top fairing 5 - 1, Refit the headlight fairing
Refit the front brake callipers 7 - 3, Refitting the front brake system
Warning
Do not ride with the front mudguard removed. The brake hoses are retained to the front mudguard to keep them from touching
the wheel under braking.
section
7 - 10.2 Chassis
10.2 - Front fork - Steering head: front fork (1200 S ABS)
1
2
6
7 8
1 Screw
2 Screw
3 Steering head
4 Bottom yoke
5 Left fork leg assembly
6 Right fork leg assembly
7 Overhaul kit
8 Sealing kit

1200 S ABS FRONT FORK
Important
section
7 - 10.2 Chassis
Removal of the front fork (1200 S ABS)
Remove the forks as described in the removal of the forks of model 1200 ABS (Sec. 7 - 10.1, Refitting the front fork (1200 ABS)).
Overhauling the fork
Disassembly of the forks

Unscrew the upper plug, using service tool no. Öhlins 00797-04.
Slacken the counter nut of the upper plug retaining the damper rod.
section
7 - 10.2 Chassis
Remove the spring preload tube.
Remove the rebound damping adjuster rod and then the counter nut.
section
7 - 10.2 Chassis
Turn the leg upside down to let the oil run out.
Remove the spacer and spring.
Recover the tapered pin and respective spring.
section
7 - 10.2 Chassis
Separate the leg from the outer tube.
It is now possible to renew the seals.

Remove the dust seal from its seat in the outer tube.
section
7 - 10.2 Chassis
Remove the circlip.
Remove the oil seal and spacer.
Remove the first sliding bush with the tool with code Öhlins 01757-01 and the bush with code Öhlins 01559-07.
section
7 - 10.2 Chassis
Then remove the second sliding bush, using a plastic mallet.
section
7 - 10.2 Chassis
Reassembly of the fork
To refit the sliding bushes, install the tool, Öhlins code 01759-08, onto the tool with Öhlins code 01757-01, using a plastic mallet.
Warning
Refit the sliding bush with the smaller outside diameter first and then fit the sliding bush with the larger outside diameter.
section
7 - 10.2 Chassis
Insert the spacer and oil seal with tool no. Öhlins 01758-04.
section
7 - 10.2 Chassis
Refit the circlip.
Fit the dust seal.
It is now possible to join the leg with the outer tube.
section
7 - 10.2 Chassis
Insert the tapered pin and respective spring in the damper rod and then insert the rebound adjuster rod in the damper rod.
Note
Take care to fit the tapered pin the right way up, with the conical part facing the bottom of the fork.
Fill the fork with new oil to the correct level.
Move the damper rod up and down until oil comes out.
section
7 - 10.2 Chassis
Insert the spring and spacer.
Fit the counter nut and pre-load spacer.
Refit the upper plug completely and tighten the counter nut to the tightening torque (Sec. 3 - 3, Frame torque settings).
section
7 - 10.2 Chassis
Tighten now the upper plug to the tightening torque (Sec. 3 - 3, Frame torque settings).
Refit the fork (1200 S ABS)

Refit the forks as described in the refitting of the forks of model Streetfighter (Sec. 7 - 10.1, Refit the front fork (1200 ABS)).
268,6 ± 0,5 mm
section
7 - 10.3 Chassis
10.3 - Fork - Steering head: yoke
2 1
4 12
11 5
6
5 7
10
1 Screw
2 Screw
3 Steering head
4 Bottom yoke
5 Washer
6 Sealing ring
7 Bearing
8 Screw
9 Front splashguard
10 Screw
11 Nut
12 Banjo bolt

Important
section
7 - 10.3 Chassis
Adjusting the steering head bearings
Note
To adjust the steering bearing clearance, follow what is described in Sec. 4 - 3, Adjusting the steering head bearings.
If the problems found are not solved, check the wear of steering bearings (7) and replace them, if necessary, as described in
paragraph “Removal of the steering head components” of this chapter.
section
7 - 10.3 Chassis
Steering angle adjustment
Loosen the nuts (11).
Loosen the adjusting grub screws (12) on both sides of the bottom yoke.
Use a 6 to 6.5 mm spacer (A) fitted to the fork outer tube, or use a gauge.
Turn the front forks to the right until the spacer (A) is seated against the frame top tube.
11 12
Turn the adjuster screw (12) on the opposite side to bring it into contact with the stop on the steering head.
Apply threadlocker to the thread of nut (11).
Hold the dowel (12) firmly and tighten the nut (11).
Turn the forks to the opposite side: and repeat the process to adjust the other screw and tighten the relative lock nut.
2
LOCK
11 12
section
7 - 10.3 Chassis
Removal of the steering head components
Drain the braking system 4 - 3, Draining the brake circuit
Remove the front brake callipers 7 - 3, Removal of the front brake system
Remove the front mudguard 5 - 4, Removal of the front mudguard
Remove the fork legs 7 - 10.1, Refitting the front fork (1200 ABS)
Remove the light support subframe as- 7
7 --18,
18,Scomposizione
Light support frame disassembly
telaietto supporto
sembly faro
Remove the handlebar and the u-bolts 7 - 8, Removal of the handlebar
Note
All parts fitted to the top and bottom yokes, including the wiring and control cables, can remain on the motorcycle provided they
do not hinder the following operations.
Loosen the screw (2) fastening the steering head (3) to the ring nut (5).
Remove the steering head (3).
section
7 - 10.3 Chassis
With the tool with code. 88713.1058 loosen the ring nut (5) and unscrew it from the steering pin.
Slide the sealing ring (14), the inner ring (A) and the ball race (B) of the upper bearing (15) off the steering pin.
88713.1058
14
A
B
Remove the bottom yoke (1) complete with the steering stem from the frame tube.
Remove the ball race (B) of the lower bearing (15).
The inner ring (A) of the lower bearing (15) and the relative sealing ring (2) will remain on the pin.
B
1 A
2
Using a universal puller (of the type shown in the figure) remove the ring (A) from the steering stem, taking care not to damage
the seat.
Important
Once removed, the sealing rings (14) and the bearings (15) must not be refitted.
section
7 - 10.3 Chassis
Using a suitable drift, remove the outer bearing races (C) from the steering head. Proceed with extreme care to avoid damaging
the seats.
section
7 - 10.3 Chassis
Refitting the steering head components
Important
The steering tube bearings (3) are identical but in no case may their components be swapped around during reassembly.
Clean all contact surfaces and lubricate with the recommended grease.
To fit the external rings (C) of the bearings (3) to the steering head, use the tool with code 88713.1062 and proceed as follows:
- heat the steering head to 150 °C;
- fit the outer races (C) in their seats on the steering head;
- fit the fixed bush (E, with threaded hole) of the tool into the lower race;
- fit the other movable bush (F) into the upper end of the tool and drive it fully home against the upper bearing race;
- tighten the nut (G) and use a wrench to seat the outer rings (C) fully in the steering head;
- leave the tool assembled until the steering head has cooled down to ensure that bearings are properly seated.
88713.1062
G
section
7 - 10.3 Chassis
Fit the sealing ring (2) (with the rim facing upwards) and inner race (A) of bottom bearing (3) onto the steering stem (D) after
heating it for about 10 minutes to 120 °C.
Insert the tool, code 88713.1072, into the steering pin 88713.1072. Press the inner ring (A) on the sealing ring (2), manually
pressing for at least 10-15 seconds.
Lubricate the inner bearing race (A) with the recommended grease.
Fit the ball race (B) to the steering stem (D) with the smaller diameter of the cage facing upwards and grease the ball race.
Insert the steering stem in steering head and push it in until it is axially seated.
B
1 A
2
88713.1072
A
Fit the bottom yoke assembly to frame.
Grease the ball race (B) and fit it to outer race (C) of the top bearing.
Fit the inner ring (A) of the upper bearing (3) to the steering head, with the larger diameter facing upwards.
Install the dust sealing ring (2) with the flat side facing upwards.
Tighten the steering stem nut (4) by hand until it seats against the sealing ring (2).
Fit special bush with code 88713.1058 to the ring nut (4) and apply the torque wrench to the bush.
Tighten the set ring nut (4) to the specified torque (Sec. 3 - 3, Frame torque settings).
88713.1058
2
A
B
section
7 - 10.3 Chassis
Fit the steering head (7) on the steering stem nut (4), aligning the fork leg bores with the corresponding bores on the bottom
yoke. Refit the fork legs.
Grease the screw (6) with the recommended grease.
Tighten the screw (6) on the steering head to the specified torque (Sec. 3 - 3, Frame torque settings).

Refit the handlebar and the u-bolts 7 - 8, Refitting the handlebar
Refit the light support subframe assem- 7 - 18, Light
Ricomposizione telaietto
support frame supporto
reassembly
bly faro
Refit the front mudguard 5 - 4, Refitting the front mudguard
Refit the front brake callipers 7 - 3, Refitting the brake disks
Fill the brake circuit 4 - 3, Filling the brake system with fluid
1
section
7 - 12 Chassis
12 - Rear shock absorber assembly
2
6
5
1
1 Screw
2 Shock absorber
3 Bush
4 Screw
5 Bracket
6 Screw
7 Screw

1200 ABS REAR SUSPENSION
1200 S ABS REAR SUSPENSION
Important
section
7 - 12 Chassis
Rear suspension system
The rear suspension system uses a hydraulic monoshock absorber (2) with rebound and spring preload adjustment.
The shock absorber is pivot-mounted to the swingarm at the lower end and to the rear subframe frame at the upper end.
This system gives the motorcycle excellent stability.
To adjust the rear shock absorber refer to Sec. 4 - 3, Rear shock absorber adjustment (MTS 1200 ABS).
section
7 - 12 Chassis
Removal of the rear shock absorber
Remove the rear left side panel 5 - 3, Removal of the side panels and seat
cowling
Remove the rear mudguard 5 - 4, Removal of the front mudguard
Remove the exhaust silencer 8 - 6, Removal of the exhaust system
Remove the rear wheel 7 - 2, Removing of the rear wheel
For 1200 ABS model undo the screws (7) to remove the preload adjusting knob (A).
1200 ABS
For 1200 S ABS model remove the rider seat (Sec. 5 - 3, Removal of the seat).
Disconnect the connector (B) of the shock absorber expansion reservoir (10) from the main wiring.
10
1200 S ABS
Undo the fixing screws (8) of the bracket (9) and remove the expansion reservoir (10) of its seat.
1200 S ABS
8
10 9
section
7 - 12 Chassis
Remove the clamp (B) to release the rubber gaiter and disconnect the connectors (C) and (D) of the rear shock absorber.
1200 S ABS
B
1200 S ABS
To remove the rear shock absorber from the vehicle, undo the upper (1) and lower (4) screws.
Overhauling the rear shock absorber
Important
Contact an authorised ÖHLINS Service Centre in case of problems with the shock absorber.
section
7 - 12 Chassis
Refitting the rear suspension
Lubricate the threads and undersides of the heads of the upper (1) and lower screws (4) with the recommended grease.
Insert the upper part of the shock absorber in the rear subframe tightening the screw (1) and the lower end of the shock absorber
in the swingarm tightening the screw (4).
For 1200 ABS model position the adjusting knob (A) of the preload on the support bracket tightening the screws (19) to the
specified torque (sec. 3 - 3, Frame torque settings).
1200 ABS
For 1200 S ABS model position the bracket (9) on the expansion reservoir (10); insert the tab (F) in the slot (E) on the rear
subframe.
10
section
7 - 12 Chassis
Tighten the fixing screws (19) of the bracket (17) to the specified torque (sec. 3 - 3, Frame torque settings).
1200 S ABS
8
10 9
Connect the connector (B) of expansion reservoir (10) of the shock absorber to the main wiring.
10
1200 S ABS
Refit the rider seat Sec. 5 - 3, Refitting the seat.
section
7 - 12 Chassis
Connect the connectors (C) and (D) of the rear shock absorber, refit the rubber gaiter and tighten it with the clamp (B).
1200 S ABS
B
1200 S ABS

Refit the rear wheel 7 - 2, Refitting the rear wheel
Refitting the left rear side panel 5 - 3, Refitting the side panels and tail
guard
Refitting the exhaust silencer 8 - 4, Refitting the exhaust system
Refitting the rear mudguard 5 - 4, Refitting the rear mudguard
1
section
7 - 13 Chassis
13 - Swingarm
31
30
28
27
35
32
29 33
32
8
3
34
1 38
26 25
14
9
10 37
11 36
23
7
10
12
4
5 13 24
6 5
2
15
3 13
1 Swingarm pivot shaft

2 Washer
3 Banjo bolt
4 Bush
5 Sealing ring
6 Roller bearing
7 Banjo bolt
8 Rear swingarm
9 Spacer
10 Bearing
11 Spacer
12 Spacer
13 Screw
14 Pin
15 Chain slider (lower)
16 Guard
17 Splashguard
18 Screw
19 Splashguard (rear)
20 Banjo bolt
21 Rear mudguard
22 Banjo bolt
23 Chain guard
24 Chain slider (upper)
25 Guide
26 Screw
27 Screw
28 Phonic wheel (rear)
29 Screw
section
7 - 13 Chassis
30 Brake disc (rear)
31 Wheel axle (rear)
32 Washer
33 O-ring
34 Calliper holder bracket (ABS)
35 Circlip
36 Spacer
37 Inner ring
38 Hub

1200 ABS REAR SWINGARM
1200 S ABS REAR SWINGARM
Important
section
7 - 13 Chassis
Removal of the rear wheel eccentric hub and rear wheel axle
Before removing the eccentric hub, you must first remove the parts listed below.

Remove the rear sprocket 7 - 14, Replacing of the rear sprocket
Remove the rear brake calliper 7 - 4, Removal of the rear brake calliper
Slacken off the screws (18).

Remove the spacer (36) and the inner ring (37) on the chain side and remove the wheel axle (31) with the brake disc (30) from
the opposite side.
Wheel side
18
30 31
36
Chain side 26
Remove the circlip (35) on the wheel side of the eccentric hub.
Remove the washer (32) and the calliper holder bracket (34) with the O-rings (33).
33 35 34
section
7 - 13 Chassis
Remove the other washer (32).
32
Withdraw the eccentric hub (17) from the chain side of the swingarm.
38
Chain side
Note
The rear hub is a component particularly critical to the dynamic safety of the motorcycle. under no circumstances may the internal
components of the hub be serviced or repaired. The hub may be ordered as a complete assembly, spare part No. 756.2.013.1A.
section
7 - 13 Chassis
Refitting the rear wheel eccentric hub and rear wheel axle
Refitting is the reverse of removal, with attention to the following points.
If the calliper bracket locating pin (14) was removed, apply the recommended threadlocker on reassembly.
8
LOCK
14
Before refitting, apply the recommended grease on the seat on the eccentric hub (38) of the calliper holder bracket (34) on which
the rings (33), also greased, will be installed. Fit the mounting bracket (34), aligning the point indicated with the anti-rotation pin
(14).
Install the first washer (32), with the sharp edged side facing towards the eccentric hub (38).
38
Sharp 32
edge
34
33
section
7 - 13 Chassis
Refit the other washers (32) with their sharp edges also facing the eccentric hub.
Sharp 32
edge
Apply an even coating of the recommended grease in the areas (A) of the axle (27).
31
B
Insert the rear wheel stub axle (31) in the hub.
Ensure the stub axle (31) is seated in the hub.
section
7 - 13 Chassis
Fit the inner ring (37) on the wheel axle (31).
Insert the inner ring (37) in the hub.
Apply the recommended grease to the screws (18) and tighten to the specified torque (Sec. 3 - 3, Frame torque settings) follow-
ing the sequence 1-2-1.
36
Chain side 31
B Wheel side
2
1
18
30 31
Rotate the eccentric hub (38) to bring the horizontal centreline (A) of the hub hole (B) below the horizontal centreline (C) of the
hub seat.
38
B A

Refit the rear brake calliper 7 - 4, Refitting the rear brake calliper
Refit the rear sprocket 7 - 14, Refitting the rear sprocket
Refit the exhaust silencers 8 - 8, Refitting the exhaust system
Set the chain tension as described in paragraph “Adjusting the chain tension”, Sec. 4 - 3.
section
7 - 13 Chassis
Removal of the swingarm
Before removing the parts in question, you must first carry out the following operations:

Remove the sprocket 7 - 14, Replacing of the rear sprocket
Remove the rear brake calliper 7 - 4, Removal of the rear brake calliper
Detach the shock absorber 7 - 12, Rear suspension system
Refitting the rear mudguard 5 - 4, Removal of the front mudguard
Remove the rear wheel eccentric hub as described in chapter “Removal of the rear wheel eccentric hub and rear wheel axle” of
this section.
Undo the screw (7) and remove the upper pipe grommet (16). release the rear brake pipe and the rear speed sensor cable from
the swingarm, undoing the screws (26) and retrieving the cable grommets (25).
16
7
26
You can check the play in the swingarm bearings while the swingarm (8) still installed on the motorcycle frame.
Grasp the rear of the swingarm (8) and try to move it in the four directions shown by the arrows.
section
7 - 13 Chassis
Any abnormal movement is a sign of worn bearings that could cause instability when riding.
To check the free play of the support bearings, refer to Sec. 7 - 1, Wheel bearings.
Once the play in the swingarm bearings has been checked, the swingarm (8) may be removed from the motorcycle.
Hold the swingarm pivot (1) on the left side of the vehicle to prevent it from turning while undoing the screw (3) on the opposite
side: retrieve the washer (2).
Using the punch 88713.1074, fully extract the swingarm pivot.

Remove the swingarm (4) assembly from the frame.
Undo the screw (13) to remove the lower chain slider (15) from the swingarm (8).
15
13
section
7 - 13 Chassis
Undo the screws (7) to remove the chain guard (7) from the swingarm (4).
8 7 23
23
Undo the screws (13) to remove the upper chain slider (24) from the swingarm (8).
13
24
8
13
24 8
section
7 - 13 Chassis
Inspecting the swingarm pivot shaft
Before refitting the swingarm pivot shaft (1), check it carefully for distortion.
Roll the pin on a reference surface and measure maximum distortion using a feeler gauge (Sec. 3 - 1.1, Rear wheel).
section
7 - 13 Chassis
Overhauling the rear swingarm
Inside the swingarm (8), in correspondence with the pivot point on the frame, are a pair of ball bearings (10) and a shim (4) on the
right-hand side, and a pair of roller bearings (6), with sealing rings (5), on the left-hand side.
10
4
10 8
10 4 10
5 6 5
section
7 - 13 Chassis
To change the bearings, proceed as follows.
Remove the shims (12) and (21) fitted on the right hand side of the swingarm, and the bush (22) on the left hand side.
Remove the ball bearings (19), sealing rings (23) and roller bearings (25) with a suitable punch and press. Support the swingarm
and take care not to damage the bearing bores.
Important
Once removed, the bearings (19), sealing rings (23) and roller bearings (25) must not be reinstalled.
9
10
11
10
5
12
4
6
6 5
section
7 - 13 Chassis
Heat the entire swingarm up to 150 °C while supporting its weight adequately.
Insert the new roller bearings (6) in the punch tool with code 88713.1068 and install them into the bore on the left-hand side of
the swingarm, working from the outside.
Drive them in until the tool is fully seated against the swingarm.
Use the same tool to fit the new sealing rings (5), positioned as shown in the sectional view, so that they seat against the newly
installed roller bearings.
C 88713.1068
25
section
7 - 13 Chassis
To install the ball bearing (19) you will need the tool with code 88713.2409 with:
(A) – drift for internal bearings;
(B) – drift for external bearings;
(C) – guide pin.
Fit a new bearing (10) and the internal shim (4) onto the punch tool (A) and install on the inner side right-hand swingarm mounting.
Insert the guide pin (C) into the previously mounted roller bearings and insert the other end in the bore in the tool (A).
Drive the bearing (10) fully into the swingarm.
Fit the other new bearing (10) at the outer end of tool (A).
Using tool (A) as a stop, use tool (B) to drive the external bearing up against spacer (4): remove the tools.
Before refitting the swingarm (8), grease the ball bearings (10), the roller bearings (6) and the sealing rings (5) with the recom-
mended grease.
88713.2409
5
10
8
4
C
B
10
C
section
7 - 13 Chassis
Refit the shims (12) and (9) from the right-hand side of the swingarm (8) and refit the bush (4) from the left-hand side.
9 12 4
section
7 - 13 Chassis
Refitting the swingarm
Apply the recommended threadlock to the screws (26) and (13).
Install the upper chain slider (7) in the aperture (8) in the swingarm, and fasten with the screws (7).
2
LOCK
23
8 7 23
LOCK
2
Install the upper chain slider (24) in the slot (8) in the swingarm, and fasten with the screws (13).
2
LOCK
13
24 8
2
LOCK
13
24
8
section
7 - 13 Chassis
Install the upper chain slider (15) on the swingarm (8), fastening with the screws (13).
2
8 LOCK
15
13
Fit the rear brake pipe and the rear speed sensor cable onto the swingarm, hand tightening the screws (26).
Refit the upper pipe grommet (16), hand tightening the screws (7).
16
7
26
2
LOCK
Tighten the screws (7) and (26) to the specified torque (sec. 3 - 3, Frame torque settings).
section
7 - 13 Chassis
Locate the swingarm (8) on the frame.
Lubricate the swingarm pivot shaft (1) with the recommended grease and drive it home in the frame.
On the opposite side of the vehicle, fasten the swingarm pivot (1) with the nut (5), installing the washers (2) and after applying
the recommended grease.
Tighten the nut (3) to the specified torque (Sec. 3 - 3, Frame torque settings).
D
3

Refit the rear mudguard 5 - 4, Refitting the front mudguard
Reconnect the shock absorber 7 - 12, Refitting the rear suspension

Refit the rear brake calliper 7 - 4, Refitting the rear brake calliper
Refit the sprocket 7 - 14, Refitting the rear sprocket
1
section
7 - 14 Chassis
14 - Final drive
22
6
7 5
9 4
8 3
2
12
13
14
15 1
16 11
18 17
19 10
20 21
1 Circlip 12 Nut
2 Nut 13 Lock washer
3 Washer 14 Front sprocket Z=15
4 Nut 15 Spacer
5 Rear sprocket flange 16 O-ring
6 Cush drive bush 17 Shim washer, thickness 0.8 mm
7 Inner ring 18 Gearbox secondary shaft
8 Open chain 107+1 19 Shim washer, thickness 0.5 mm
9 Spacer 20 Needle roller bearing
10 Chain cover 21 Complete secondary shaft
11 Screw 22 Rear sprocket Z=40

1200 ABS GEARBOX
1200 S ABS GEARBOX
Important
section
7 - 14 Chassis
Inspecting the final drive
To check the wear of the final drive, visually check the pinion (14) and sprocket (22). If the teeth are found to worn as shown in
the figure (dotted line), the sprocket must be renewed.
14
Normal
Worn
22
Normal
Worn
To check the amount of wear on the chain (8), keep the chain taut and measure 16 links.
If the length (L) is greater than 256.5 mm, the chain should be replaced.
Important
The sprocket (22), engine pinion (14) and chain (8) must all be replaced together as a set.
8
0 1s 2n 3r 4t 15th 16t
section
7 - 14 Chassis
Removing of the front sprocket
Undo the screws (11) and remove the chain cover (10).
Loosen the chain (Sec. 4 - 3, Adjusting the chain tension).
11
10
Remove the chain with the tool code 88713.1344.

The tool is composed of a holder (A), punch (B), body (C) and two wrenches (D) and (E).
Fit the link to be opened into the holder (A).
Fit a punch (B) into the body (C) and manually unscrew the screw until the punch no longer protrudes.
Fit the holder (A) and link into the body (C).
Manually turn the screw (F) on body (C) so that the punch (B) locates against the pin, taking care that they are aligned with each
other.
Fit hex wrench (D) into the hexagonal part of the body (C) and wrench (E) onto the bolt.
Turn the bolt (F) clockwise to push out the pin.
88713.1344
C
F
Remove the chain.
section
7 - 14 Chassis
Engage a low gear and unscrew the nut (12).
Remove the nut (12) and the safety washer (2) on the pinion.
Remove the engine pinion (14) with the chain (8) from the gearbox secondary shaft.
12 13
14
Remove the spacer (15) with the O-ring (16) and the washer (17) from the secondary shaft (18).
Important
The O-ring (16) must be renewed on reassembly.
15
17
16
section
7 - 14 Chassis
Refitting the front sprocket
Refit the ring (17) (Sec. 9 - 9.2, Reassembly of the crankcase halves).
Grease the O-ring (16) and install it on the front sprocket spacer (15).
Fit the spacer onto the secondary shaft (18) and push it into contact with the bearing inner ring. The spacer face with the O-ring
must be facing the bearing.
Before refitting the front sprocket, check that the spacer (15) is installed on the gearbox secondary shaft.
15
17 16
Check that the splines of the gearbox secondary shaft and the sprocket are in perfect condition.
Fit the engine pinion (14) and install the safety washer (13).
Tighten the nut (12) to the specified tightening torque (Sec. 3 - 3, Frame torque settings).
12 13
14
section
7 - 14 Chassis
Fit the chain and close it using the tool with code 88713.1344 that was used to open the chain.
The tool is composed of a holder (A), punch (B), body (C) and two wrenches (D) and (E) and link plate holder (F). Connect the two
halves 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) locates against the pin, taking care that they are aligned with each other.
Use wrenches (D) and (E) to turn the bolt clockwise until the punch (B) is seated against the chain plate.
To complete reassembly, repeat the entire procedure with the second pin.
Warning
Carefully check the two pins: the figure shows the correct result of the procedure.
88713.1344
A
B
F
C
G
E E
D D
G
YES NO NO NO
Adjust the chain tension (Sec. 4 - 3, Adjusting the chain tension).

Fit the sprocket cover (10) tightening the screws (11) to the specified torque (Sec. 3 - 3, Frame torque settings).
11
10
section
7 - 14 Chassis
Replacing of the rear sprocket
Slacken the chain 4 - 3, Adjusting the chain tension
Lock the wheel axle rotation.

Remove the clip (1).
Loosen the locking nut (2) with a socket wrench.
Fully unscrew the nut (2) and remove the washer (3) and the flange (5) with the sprocket (22).
Collect the spacer (9).
Using a mallet, tap the sprocket flange (5) with the cush drive bushes (6) off the sprocket (22).
18
11
7
9 22
2
1
section
7 - 14 Chassis
Refitting the rear sprocket
Check the cush drive bushes (6) condition and, if necessary, replace them by removing them from the flange.
Refitting is the reverse of removal.
If it is necessary to remove the cush drive bushes (6), grease all the coupling surfaces and the undersides of the fixing nuts (4)
of the cush drive bushes (6) with the recommended grease.
7
9 22
2
1
B
Check for wear following the instructions given at the beginning of this section.
To refit the nut (8) follow the specifications for the wheel fixing nut, in Sec. 7 - 2, Refitting the rear wheel.
B
8
18
11

Adjust the chain tension 4 - 3, Adjusting the chain tension
section
7 - 14 Chassis
Washing the chain
Chains with O-rings must be washed in oil, diesel fuel or paraffin (kerosene).
Do not use fuel, trichloroethylene or other solvents which will damage the rubber O-rings. For the same reason use only sprays
specifically formulated for use with O-ring chains.
Lubricating the chain

O-ring chains have sealed, life-lubed link studs and bushes. However, these chains need lubricating at regular intervals to protect
metal parts of the chain and the O-rings.
Lubrication also serves to keep the O-rings soft and pliable to ensure the maximum sealing efficiency.
Using a brush, apply a thin protective layer of high-density gearbox oil along the entire length of the chain both inside and outside
(Sec. 3 - 2, Fuel, lubricants and other fluids).
1
section
7 - 15 Chassis
15 - Footrest brackets
20
2223 13
18 19
21 24
25
17
16
15
4 6
5 25 24
3 7 27
14
8 13 30 14
16
2 18 28
17
29
23 22
9
15
1
2 9
12 11
10
12
7
1 Screw 16 Spring stop
2 Pin 17 Pin
3 RH bracket 18 Screw
4 Screw 19 Right rear footrest bracket
5 Front right footrest rubber 20 Rear right footrest rubber
6 Rear bracket 21 Right rear footrest
7 Spring 22 Spring
8 Right front footrest 23 Ball
9 Circlip 24 Plug
10 Rear banjo bolt 25 Ring
11 Front left footrest rubber 26 Plug
12 Left front footrest 27 Left rear footrest bracket
13 Rear right subframe 28 Right footrest rubber
14 Rear left subframe 29 Left rear footrest
15 Banjo bolt 30 Power outlet

1200 ABS FRAME
1200 S ABS FRAME
Important
section
7 - 15 Chassis
Removal of the front footrests
Note
The removal of the front footrests is described for the right side but it is the same for both.
Remove the seeger ring (9) releasing the pin (2).

Slide off the pin (2) of the footrest bracket (3), holding the footrest (8).
Slide off the footrest (8) from its seat and collect the spring (7).
2
3
section
7 - 15 Chassis
Refitting the front footrests
Note
The fitting of the front footrests is described for the right side but it is the same for both.
Place the spring (7) bringing the end (A) onto the footrest (8).
Place the footrest (8) in the correct position, inserting the end (C) of the spring (7) in the hole (D) of the front right footrest bracket
(3).
Insert the pin (2) orienting it as illustrated.
Lock the pin by inserting the seeger ring (9).
section
7 - 15 Chassis
Removing of the rear footrests
Note
The removal of the rear footrests is described for the right side but it is the same for both.
If necessary, remove the footrest rubber (20).

Remove the seeger ring (25) releasing the pin (17).
Remove the pin (17) of the footrest bracket (19), holding the footrest (21) and taking care not releasing the ball (23) and the spring
(22).
Remove the footrest (21) from its seat, collecting the spring (22) and the ball (23).
Remove the spring stop (16).
19
19
17
B
20
23
C B
A
B
C
16
25
22 4
D D
Refitting the rear footrests
Note
The refitting of the rear footrests is described for the right side but it is the same for both.
Insert the spring stop (16) in the hole (A) of the rear right footrest rubber bracket (19), orienting it as illustrated.
Note
If needed, apply the recommended grease on the pin (B) of the spring stop (16), so as to keep it in the correct position.
Insert the spring (22) in the corresponding hole of the footrest (21).
Locate the ball (23) on the spring (22).
Fit the footrest (21) on the rear right footrest rubber bracket (19) inserting the pin (17), orienting the parts as illustrated.
Lock the pin by using the seeger ring (25).
If previously removed, refit the footrest rubber (20) inserting the pads (B) in the corresponding slots of the footrest (21), pressing
until the teeth (C) of the footrest platform trim engage over the edges (D) of the footrest platform itself (21).
1
section
7 - 16 Chassis
16 - Stands
5 1
2
3
9
6
4
10
8
1 Sidestand switch connector

2 Sidestand switch
3 Screw
4 Plate
5 Screw
6 Inner spring
7 Spring assembly
8 Nut
9 Rotation pivot
10 Sidestand

1200 ABS STAND
1200 S ABS STAND
Important
section
7 - 16 Chassis
Removing of the sidestand
Disconnect the connector (1) of the sidestand switch (2) from the main wiring.
Undo the two fixing screws (3) of the sidestand support bracket (4) to the engine and remove the complete sidestand.
3
3
Disassembly of the sidestand

Undo the fixing screw (5) and remove the sidestand switch (2).
2
8
5
Release the sidestand return springs (6) and (7) of the fasteners (A) and (B).
Undo the sidestand fixing pin (9) to the bracket and remove the side stand (10) and the nut (8).
7
9
10
A
6
B
section
7 - 16 Chassis
Inspecting the sidestand
Fit the sidestand leg to the bracket and check that there is no excessive clearance. Ensure that the ends of the sidestand are
not bent with respect to the shank.
A stand which shows signs of cracking must be renewed immediately.
To check the switch (2) refer to Sec. 6 - 6, Checking the sidestand switch.
Reassembling of the sidestand

Insert the sidestand (10), properly greased, in the bracket (4) and fix it with the pivot (9) and the nut (8).
Tighten the pin (9) to the specified torque (Sec. 3 - 3, Frame torque settings).
Position the sidestand return springs (6) and (7) and fix them to the fasteners (A) and (B) on the bracket and on the stand.
B
8
7
9
10
A
6
B
Place the switch (5) on the bracket, on its pin (9).

Fit the fixing screw (4) and tighten it to the specified torque (Sec. 3 - 3, Frame torque settings).
section
7 - 16 Chassis
Refitting the sidestand
Position the sidestand plate (4) to the frame and fit the two screws (3) applying specified threadlocker.
3
3 5
LOCK
Connect the connector (1) of the sidestand switch to the main wiring harness.
To place the stand switch wiring refer to the table (Sec. 6 - 1, Routing of wiring on frame).
1
section
7 - 17 Chassis
17 - Frame inspection
7 16 17 18
48 2
8 20
17
16
19 6
1 3
7
22
9
23
4 6
13
24
12
10
11
10
5
25
15
14
1 Frame 14 Screw
2 Rear right subframe 15 Wiring protection
3 Rear left subframe 16 Grub screw
4 Headlight support 17 Nut
5 Screw 18 Front banjo bolt
6 Banjo bolt 19 Nut
7 Rear banjo bolt 20 Screw
8 RH bracket 21 Bracket
9 LH bracket 22 Screw
10 Bulb 23 Power outlet
11 Spacer 24 Screw
12 Rubber 25 Screw
13 Screw

1200 ABS FRAME
1200 S ABS FRAME
Important
section
7 - 17 Chassis
Disassembly of structural components and the frame
Before carrying out dimensional checks on the frame, you must remove all the superstructures fitted, referring to the removal
procedures outlined in the sections of this manual.
The structural component of the frame (2) is the rear subframe (3).
Both serve to support motorcycle superstructures and must therefore be in perfect condition.
section
7 - 17 Chassis
The flow chart below illustrates the logical sequence in which the parts are to be removed from the motorcycle and gives a ref-
erence to the section of the manual in which the removal procedure is described.
COMPLETE
MOTORCYCLE
GEARCHANGE FUEL TANK REAR SEAT

CONTROL 8-1 HYDRAULIC 5-3
7-9 BRAKE
CONTROL
7-4
PROBES EXHAUST
5-2 8-8
REAR LICENSE PLATE
BRAKING HOLDER UNIT
SYSTEM 7 - 17
7-4
AIR INTAKE
DUCTS
RH AND LH 8-3
CONTROLS SIDE STAND
TO THE
HANDLEBAR 7 -16
6-5 REAR REAR TAIL
WHEEL GUARD
UNIT AND
7-2 FAIRINGS
5-3
FRONT FRONT HYDRAULIC

HEADLAMP
AND HYDRAULIC CLUTCH
INSTRUMENT BRAKE CONTROL
PANEL CONTROL 7-8 CLUTCH AIR FILTER REAR COMPLETE
6-4 7-3 TRANSMISSION BOX, SUSPENSION BATTERY
7-8 RESONATOR 7 - 12 SUPPORT
AND THROTTLE 6 - 13
BODY
8-2
HANDLEBAR FOOTREST
7-8 7 -15
REAR
SWINGARM
AND REAR
MUDGUARD
7 - 13
FRONT UPPER
MUDGUARD WATER
5-4 RADIATOR ENGINE WIRING UPPER
AND HORN PINION CONNECTIONS
7 - 14 REMOVAL
9 - 3.2
6-1
WIRING FRONT STEERING, WIRING REAR

CONNECTIONS FORK AND CONNECTIONS
REMOVAL FRONT REMOVAL
WHEEL UNIT
6-1 6-1
7 - 10 / 7 - 1
ENGINE
REMOVAL
9-1
FRAME
section
7 - 17 Chassis
Removing of the headlight assembly
Remove the clamps (A) and release the front wiring branch of the light support (4).
A
Undo the screws (5) and remove the complete headlight assembly support (4).
Refitting the headlight assembly

Apply the recommended threadlock to the screws (5).
Place the headlight assembly (4) on the headstock and lock it inserting the screws (5).
9
LOCK
Spread the front wiring branch on the light support (4) and lock it with the clamps (A).
section
7 - 17 Chassis
Removal of the rear subframe
Remove the saddle (Sec. 5 - 3, Removal of the seat) and the lower cowling.
Undo the upper and lower fixing screws (6) of the rear right (2) and left (3) subframe.
Remove the rear right and left subframes.
3
6
section
7 - 17 Chassis
Checking the frame
Check the dimensions of the frame against the dimensions shown here to determine whether it needs to be realigned or re-
newed.
Important
Damaged frames must be changed, not repaired. Any work carried out on the frame can give rise to potential danger, infringing
the requirements of EC directives concerning manufacturers' liability and general product safety.
Frame general dimensions (mm)
Ø5
5
15
194,2
23,8
285,8
26°
181
156,5
62,5
32
106
108,5 12
315
697
205,3
102,6
86
section
7 - 17 Chassis
Reassembly of structural components and the frame
Refitting the rear subframe

Install the rear right (2) and left (3) subframe.
Insert the upper and lower fixing screws (6) and tighten to the specified torque (Sec. 3 - 3, Frame torque settings).
Install the saddle (Sec. 5 - 3, Refitting the seat) and the lower cowling.
3
6
1
section
7 - 18 Chassis
18 - Licence plate holder
16
22
15
6 18
25 23 3
5
17 4
20
21 25
24
5
4 7
19 1
13 14 9
12 11 10 8
1 Reed 14 Bulb 12V-5W C5W

2 Screw 15 Vibration damper mounts
3 Rear turn signal 16 Banjo bolt
4 Bulb 12V-10W RY10W 17 Clip nut
5 Spacer 18 Clip nut
6 Licence plate holder 19 Screw
7 Screw 20 Splashguard
8 Plate 21 Rear turn signal
9 Reflector 22 Rear tail light
10 Bracket 23 Screw
11 Washer 24 Clip nut
12 Nut 25 Screw
13 Cover

1200 ABS LICENCE PLATE HOLDER
1200 S ABS LICENCE PLATE HOLDER
Important
section
7 - 18 Chassis
Removal of the licence plate holder

Refitting the left rear side panel 5 - 3, Removal of the side panels and seat
cowling
Undo the license plate holder fixing screws (16) collecting the vibration damper mounts (15).
16
Remove the clamps (A) and disconnect the tail light connector (B) from the main wiring.
Undo the screws (7) to remove the plate (8) from the license plate holder (6).
For USA version, the plate (8) has a different shape.
section
7 - 18 Chassis
Tighten the license plate holder (6) from the splash guard (20) undoing the three screws (19).
16 19
16 20
19
Raise the splash guard (20) from the license plate holder (6) paying attention to the internal wiring.
Disconnect wiring fastons (A) from the license light reeds.
Remove the fixing clamps (B) of the rear turn signals connectors (C) and disconnect the connectors (C) from the main wiring
connectors (D).
20 B
C C
D
6
Undo the screws (23) and remove the rear taillight from the license plate holder (6).
23
section
7 - 18 Chassis
Refitting the licence plate holder
Check the presence of clips (17) on the license plate holder (6).
17
17
Refit the rear tail light (6) on the license plate holder inserting and tightening the screws (23) to the specified torque (Sec. 3 - 3,
23
Connect the rear turn signal connectors (C) to the main wiring connectors (D).
Place the fixing clamps (B) of the connectors (C).
Connect the wiring fastons (A) to the license plate light reeds on the splash guard (20).
Store the left turn indicator wiring and the license plate light wiring placing them in the license plate holder seat.
20 B
C C
D
6
Put the splash guard (20) next to the license plate holder (6).
section
7 - 18 Chassis
Fit the splash guard (20) on the license plate holder (6), paying attention not to press the wires underneath.
Apply the recommended threadlocker to the screws (16).
Check for the rubbers (15).
Tighten the splash guard (20) inserting the screws (16) and (19).
Fit the plate (8) on the license plate holder (6), tightening the screws (7) to the specified torque (Sec. 3 - 3, Frame torque settings).
8 - Fuel system / Exhaust system 0
section
8 Fuel system / Exhaust system
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
1
section
8-2 Fuel system / Exhaust system
2 - Fuel tank
A
2 12
3
1 11
4
B
10
6
5 C
4
9 8
7
7
21 D
15
16 14
E
13
17
18
21 F
19 20
G
1 Fuel tank 12 Screw
2 Screw 13 Fuel pump
3 Spacer 14 Sealing washer
4
5
Rubber mounting
Rubber mounting
15
16
Thermistor
Clamp
H
6 Washer 17 Fuel filter
7 Screw 18 Fuel level sensor
8 Washer 19 Nut
9 Rubber mounting 20 Complete hose guide
10
11
Sealing washer
Filler cap
21 Breather pipes
L
1200 ABS FUEL TANK
1200 ABS
1200 S ABS
FUEL SYSTEM
FUEL TANK
M
1200 S ABS FUEL SYSTEM
Important
N
section
Removal of the fuel tank
A Working from both sides, loosen and remove the rear fixing screw (7)
7
B
D
7
F Working from both sides, loosen and remove the front fixing screw (2)
G 2
section
Slightly lift the tank to facilitate the following operations.
Disconnect the fuel pump connector (A) and the fuel sensor connector (B).
A
B
A
B
C
Disconnect the two quick release couplings (3) of the fuel pipes.
E
c
F
Remove the clamp (D) to release the wiring of the fuel sensor (B) from the fuel pump wiring (A).
A G
D
H
B
Operating on both sides of the tank plug, slide the two fixing clamps (E) of the two breather pipes (8). L
21 E
N
section
On both sides of the tank plug, paying attention not to damage them, slide the two breather pipes (21).
B
21
21
E
Remove the tank (1).

F
1
G
section
Removing the filler plug unit
Undo and remove the six fixing screws of the tank plug (12).
Remove the complete plug (11) paying attention to collect the two breather pipes (21).
A
Collect the gasket (10).
11
12 B
12 C
D
Refitting the filler plug unit
Grease the new gasket (10) and the corresponding groove in the fuel tank.
Place the complete plug (11) paying attention to position in the corresponding seat of the two breather pipes (8).
Position and tighten the six fixing screws (12) to the specified torque (Sec. 3 - 3, Frame torque settings).
E
11
12
F
12
section
Renewal of the fuel tank flange
A Undo the six fixing nuts (19) of the fuel tank flange. Remove three of the bolts, leaving three in position in order to help lift the
flange.
Remove the fuel pump (13) from the fuel tank.
19
B
C
19 13
D Collect the gasket (14).

Undo and remove the two fixing screws (G) and move the protection (F).
Loosen the clamps (16) and slide the fuel filter (17).
Before reassembly, carefully remove any deposits or scale from all parts.
E Important
When installing the new filter, position it so that the arrow stamped on the outer casing points towards the flange.
Note
The flange is supplied as a spare part complete with the fuel pump and pressure regulator: the entire flange assembly must be
F replaced in the event of malfunction.
F 14
16
G
17
G
H
section
Refitting the fuel tank flange
Introduce the flange with the gasket (26) properly greased and refit by reversing the steps of the removal procedure.
A
Warning
Orientate the fuel pump (13) with the arrows (H) facing the rear part of the tank (1).
Apply threadlocker and tighten the screws (19) to the specified torque (Sec. 3 - 3, Frame torque settings), following the fitting
order: 1-2-3-4-5-6, shown in figure. B
2
LOCK H
19
2
C
4 5
3
6
1
D
19
13
section
Refitting the fuel tank
A Position the tank (I).
B I
On both sides of the tank plug, place the two breather pipes (21) and insert them on the plug.
E
21
21
H
Operating on both sides of the tank plug, position the two fixing clamps (E) of the two breather pipes (21).
L
21 E
N
section
Position a clamp (D) to connect the wiring of the fuel sensor (B) to the fuel sensor wiring (A).
A
A
D
B
C
Keep slightly raised the tank to facilitate the following operations.
Connect the two quick releasing couplings (C) of the fuel pipes following the removal order, paying attention to insert the delivery
on the filler marked with OUT and the return on the filler marked with IN.
OUT
E
IN
C
F
section
Connect the fuel pump connector (1) and the fuel sensor connector (2).
B
A
B
C
Operating on both sides, position the front fixing screw (5), without tightening it.
D
2
F Operating on both sides, position the rear fixing screw (7), without tightening it.
Check correct position of the tank and tighten the two front fixing screws (2) and the two rear fixing screws (4) to the specified
torque (Sec C3, Frame tightening torque).
G
7
7
M
section
Positioning of the fuel tank breather and drain hoses
section
Positioning of the fuel hoses
1
section
6 - Airbox – Throttle Body
A
4
5 19
20
17 9 B
8 18 10
6 10
11
C
5
7 9
8
14 E
13
14
15 16
3 2 F
16
15
3
2 G
1 Airbox 11 Clamp
2 O-ring 12 Hose
3 Injector 13 Sealing washer
4
5
Throttle body assembly
Screw
14
15
Intake manifold
Sealing washer
H
6 Clamp 16 Screw
7 Intake manifold 17 Screw
8 Screw 18 Spacer
9 Pressure sensor 19 Bracket
10 Screw 20 Nut L
1200 ABS THROTTLE BODY
1200 ABS AIR INTAKE - OIL BREATHER
1200 ABS FUEL SYSTEM
M
1200 S ABS THROTTLE BODY
1200 S ABS AIR INTAKE - OIL BREATHER
1200 S ABS FUEL SYSTEM
Important
N
section
Removal the airbox and throttle body
A Disconnect the connector (A) from the air pressure sensor (9).
C 9
Undo and remove the fixing screw (10) and remove it from the air pressure sensor (9).
D
9
10
F
Operating on the right side of the vehicle, disconnect the connector (B).
H
B
section
Operating on the left side of the vehicle, disconnect the connector (C).
A
C
C
Loosen the clamp (6).
D
6
Loosen the clamp (6).

F
6
G
Slide the filter box (1).

L
1
section
Operating on both throttle grip cables (E) and (F), loosen the nuts (D) and, turning the throttle body pulley (G), slide the two throttle
grip cables (E) and (F).
A
G
B
D
E
C F
Removal of the fuel injectors
D Operating on both intake manifolds, disconnect the two connectors (H).

Operating on both intake manifolds, undo and remove the two fixing screws of the fuel pipe (I).
H I
F
I
Operating on both intake manifolds, slide the two injectors (3).

G
section
Refitting the injectors
Operating on both injectors (3), before inserting them in their seat, grease them properly with specified grease.
A
3
B
Operating on both intake manifolds, insert the two injectors (20).
E
3
F
Operating on both intake manifolds, place the fuel pipes on the injectors following the removal order and tighten the fixing screw
(I) to the specified torque (Sec 3 - 3, Frame torque settings).
Connect the connectors (H).
G
H I
I
L
section
Disassembly of the airbox – throttle body
Undo the six screws (16).
A
16
B
16 16
Remove the throttle body (4) from the airbox (I).
D
4
section
Reassembly of the airbox – throttle body
If removed, fit the gaskets (13) in the seats (J) on the filter housing (1).
A
13
C
1
If removed, insert the gaskets (15) in the seats (K) of the intake ducts (26).
15
D
E
K
14 F
If removed, refit the air intake ducts (14) on the throttle body (15) and apply threadlocker to the screws (5) and tighten them to
the specified torque (Sec. 3 - 3, Frame torque settings) following the sequence indicated in figure.
15 G
H
14
L
5 2
LOCK
5
5 4 M
2
1
6
3 5 N
5
section
Fasten the throttle body (4) to the airbox (1).
Position and tighten the fixing screws (16) and tighten them to the specified torque (Sec 3 - 3, Frame torque settings), following
A the sequence indicated in figure.
B 16
16 16
section
Refitting the airbox and throttle body
Position the filter box (15).
A
1
If removed, refit the throttle grip cable as indicated: insert the opening cable (F) and the closing cable (E) in the corresponding
plate seats (L) on the throttle body (4) as shown in figure.
Insert the bolts (Q) in the corresponding seats of the pulley. Keep oriented as shown in figure, fasten the cables (F) and (E) in- D
serting the nuts (D).
Tighten the nuts (D) to the specified torque (Sec. 3 - 3, Frame torque settings).
Position the dust gaiter (S) taking it into contact with the nuts (D).
G E
D
F
E
F
G
Operating on the left side of the vehicle, connect the connector (C).
C
H
section
Operating on the right side of the vehicle, connect the connector (B).
C
Position the air pressure sensor (9) and tighten the fixing screw (10) to the specified torque (Sec 3 - 3, Frame torque settings),
D 9
10
F Connect the connector (A) to the air pressure sensor (9).
A
G
H
9
Tighten the clamp (6).

L
section
Tighten the clamp (6).
A
6
section
Positioning of the airbox drain hose
1
section
7 - Air intake
A
4 B
5
9 1
2
C
3
13
6 7
D
8
12
9 E
10
11
G
1 Air filter
2 O-ring
3 Oil breather tank
4 Banjo bolt H
5 Breather hose
6 Clamp
7 Right air scoop
8 Screw
10 Screw L
11 Duct extension
12 Hose
13 Sealing washer
Spare parts catalogue M

Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the N
section
Removal of the air filters
A On the right side, undo and remove the three fixing screws (8).
Remove the air duct (7) with the gasket (13).
8
7
B
C
8
Remove the air filter (1).

D
section
Refitting the air filters
Apply universal sealant in the air duct (7) grooves (A).
Insert the gasket (13) in the groove (A) paying attention to correctly position the locating nibs (B) in their corresponding seats.
A
13
14
C
7 A
Position the air filter (1) in its seat.

D
F
Position the air duct (7) with the gasket (13).
Tighten the three fixing screws (8) to the specified torque (Sec. 3 - 3, Frame torque settings).
G
1
3
1
L
section
1
section
8 - Exhaust system
A
23 4
28 13
27 11 B
26 16 17 18
21 3
25
12 9
10 C
29
20 19
13 4 D
14 21
30 8
6
3
22 E
7
7 8 5
8 6
1
F
33 32 31
2 22 7 8 5 7 15 24
G
1 Screw
2 Exhaust protection
3 Nut
4 Exhaust gasket H
5 Support
6 Bush
7 Spacer
9 Plug
10 Sealing washer, thickness 1 L
11 Horizontal cylinder head exhaust pipe
12 Lambda sensor
13 Exhaust spring (long)
14 Vertical cylinder head exhaust pipe
15
16
Clip nut
Rubber pad
M
17 Spacer
18 Screw
19 Screw
20 Exhaust valve motor cable
21
22
Screw
Screw
N
23 Exhaust valve motor
24 Compensator
25 Rubber pad
26 Support
27 Washer P
28 Screw
29 Silencer
section
30 Clamp
31 Exhaust protection (central)
A 32
33
Exhaust protection (upper)
Exhaust protection (lower)

1200 ABS EXHAUST SYSTEM
B 1200 S ABS EXHAUST SYSTEM
Important
C
section
Removal of the exhaust system
Undo and remove the four upper fixing screws (1).
Remove the protection (2).
A
1
B
D
1
1
2
F
Turn the exhaust valve pulley (A) to facilitate the throttle grip cable (20) output
Slide the throttle cable (20) from the pulley (A).
G
20
H
20
section
Undo the nut (C).
Release the control cable (20) from the plate (B).
A
C
20
B
C
Remove the two fixing springs (13).
13
G
13
Hold the catalytic converter (24) and operating on the left side of the vehicle, undo and remove the screw (22).
L
22
N 24
section
On the right side, undo and remove the screw (22).
Remove the catalytic converter (24)
A
22
B
24 C
Undo and remove the horizontal cylinder lambda probe (12).
E
12
F
Undo and remove the three fixing nuts (3) and remove the horizontal manifold (11) with the gasket (4).
3
G
3
M
11
N
section
4
A
11
B
C Undo and remove the vertical cylinder lambda probe (12).
12
Undo and remove the three fixing nuts (3) and remove the manifold (14) with the gasket (4).
F
3
G
L 14
M
3
section
Refitting the exhaust system
Position the vertical exhaust manifold (14) on the vertical cylinder head with the gasket (4).
Fasten the fixing nuts (3) to the specified torque (Sec. 3 - 3, Frame torque settings).
A
3 B
D
14
E
3
F
If removed, tighten the vertical lambda probe (12) to the specified torque (Sec. 3 - 3, Frame torque settings).
12
G
section
Position the horizontal exhaust manifold (11) on the horizontal cylinder head with the gasket (4).
Fasten the fixing nuts (3) to the specified torque (Sec. 3 - 3, Frame torque settings).
A
D
3
E
11
F
4
G
11
H
If removed, tighten the horizontal lambda probe (12) to the specified torque (Sec. 3 - 3, Frame torque settings).
M
12
section
Position the catalytic converter (24) and operating on the left side of the vehicle, insert the screw (22).
A
22
24
C
Holding the catalytic converter, operating on the right side of the vehicle, insert the screw (22).
D
22
E
24
Position the two fixing springs (13).

F
Tighten the two fixing screws (22) to the specified torque (Sec. 3 - 3, Frame torque settings).
H
13
13 M
section
Position the control cable (20) in the plate (B).
A
4
C
Turn the exhaust valve pulley (A) to facilitate the throttle grip cable (20) introduction.
D 20
E
A
F Fasten the fixing nut (C) to the specified torque (Sec. 3 - 3, Frame torque settings).
C
G
Position the protection (2).

L Tighten the four fixing screws (1) to the specified torque (Sec. 3 - 3, Frame torque settings).
section
1
1
A
If removed, fit the copper washers (10) to the plugs (9), screw the plugs into the vertical (14) and horizontal (11) head exhaust
C
manifolds and tighten them to the specified torque (Sec. 3 - 3, Frame torque settings).
F
9
10
G
1
section
8 - 10 Fuel system / Exhaust system
10 - Evaporative emissions canister
A
2 11
7 12
8 13
B 11
7
11
C 12
13
4
D
11
7 17
15
E 10 18
9 16
1
F
14
3 5 6
G
1 Evaporative emissions canister
2 Complete hose guide
3 Hose clip
H 4 Hose
5 Hose
6 Special nut
7 Clamp
8 Tee fitting
9 Screw
L 10 Spacer
11 Hose clip
12 Union
13 Sealing washer
14 Screw
M 15
16
Screw
Bracket
17 Plate
18 Rubber pad

N 1200 ABS EVAPORATIVE EMISSIONS CANISTER
1200 S ABS EVAPORATIVE EMISSIONS CANISTER
Important
P Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the
section
Evaporative emissions canister system (USA versions only)
USA models are equipped with an additional system with an evaporative emissions canister that prevents fuel fumes from being
discharged into the atmosphere.
A
The hose (4) is connected to the evaporative emissions canister (1); when the fuel has been filtered, it is returned through the
hose (6) to the horizontal (A) and vertical (B) cylinder intake manifolds via the hoses (9) and (10). Drainage pipes (15) and (2) vent
to the ground.
For correct positioning of the connection hoses consult the indications given below.
B
D
15
6
E
B
1 10
F
9
G
2
section
Removal of the evaporative emissions canister
A Disconnect the hose (4), removing the clamp (11).

Disconnect the hose (2), removing the clamp (7).
4
B 2
11
7
C
Remove the evaporative emissions canister (1) sliding it upwards on the guides (A) of the plate (17).
D
A
F
To remove the hoses which deliver fuel to the intake manifolds, first remove the clamps (11) and withdraw the hoses (2).
G
11
H
2
N
11
2
P
Refitting the evaporative emissions canister
section
To refit, carry out the removal operations in reverse order, making sure to locate the hoses as shown in the figures at the end of
the chapter.
A
Reposition the fuel tank 8 - 2, Refitting the fuel tank
section
Positioning the hoses, clamps and evaporative emissions canister
A
1
B 2
E
5
4
M
section
D
2
2
H
section
9 - Engine 0
section
9 Engine
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

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
section
9 Engine
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
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
section
9 Engine
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
Shimming the shafts 233
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
1
section
9-1 Engine
1 - Removal–refitting of the engine assembly
2 3
6
4
73
5
1 Screw
2 Nut
3 Screw
4 Swingarm pivot shaft
5 Screw
6 Screw
7 Washer

1200 ABS FRAME
1200 ABS REAR SWINGARM
1200 S ABS FRAME
1200 S ABS REAR SWINGARM
Important
section
9-1 Engine
Removal of the engine
In order to remove engine you must first remove a series of other components from the motorcycle.
Most of these removal procedures are described in the relative sections of this manual.
The following flow chart illustrates the logical sequence in which the parts are to be removed from the motorcycle and a reference
to the section where the removal procedure is described.
This section describes only the operations to be carried out after having removed all the parts listed in the flow chart.

Remove the saddles E 3, Removal of the seat
Remove the side fairings E 3, Removal of the side panels
Remove the front half-fairings E 2, Removing of the front half-fairing
Remove the half-fairings E 2, Removing of the half-fairings
Remove the oil sump guard unit E 2, Removing of the oil sump guard
Remove the instrument panel internal E 1, Removing of the instrument panel
bulkheads
Remove the fuel tank L 2, Removal of the fuel tank
Remove the air filter L 7, Removal of the air filters
Disconnect the throttle cable F 1, Removal of the throttle twistgrip
Remove the airbox, the throttle body, the L 6, Removal the airbox and throttle body
blow by and the oil breather tube
Remove the fuel system and the injectors L 6, Removal of the injectors
from the intake manifolds
Disconnect the cables from the coils M 3, Ignition
Bobine di accensione
coils
Remove the exhaust unit L 8, Removal of the exhaust system
Bleed the lubrication system D 4, Changing the engine oil and filter car-
tridge
Remove the oil pipes of theoil radiator N 2.2, Removal of the lubrication system
from the engine block
Empty the coolant out of the cooling sys- D 4, Change the coolant
tem
Remove the pipes and the cooling system N 3.2, Removal of the cooling system hos-
joints from the engine block es and unions
Remove the water radiator lower retainer N 3.2 Removal of the water radiator
from the engine
Connect the starter motor/solenoid cable P 3, Removing the starter motor
Remove the gearchange control F 5, Removal of the gearchange control
Remove the clutch transmission unit F 2, Removal of the clutch transmission
unit
Remove the front sprocket G 8, Removing of the front sprocket
Remove the sidestand H 5, Removing of the sidestand
Disconnect wiring connectors on the en- P 1, Routing of wiring on frame
gine block
section
9-1 Engine
Place a stand beneath the engine to support it during removal from the frame.
Loosen the nuts (2) on the right side of the frame, in reference to the engine upper supporting screws (1) and (6).
Loosen the screws (5).
Block the screw (3) of the swingarm pivot on the left side of the frame and at the same time undo the screw (3) on the right side,
with washer (5).
Using the pad 88713.1074, fully extract the swingarm pivot.
In this way the swingarm is not fixed to the engine any more, leave it connected to the frame.
Remove the upper supporting screws (1) and (6).
2
5
3
1 6
3
5
Withdraw the complete engine assembly from the frame by lowering it and pushing it forwards.
section
9-1 Engine
Refitting the engine
Important
Apply recommended grease and tighten the nuts (2) to the specified torque (Sec. 3 - 3, Frame torque settings).
Refit the removed parts by performing the steps shown in the table and in the specific sections of the manual in reverse order.
2
5
3
section
9-1 Engine

Connect wiring connectors on the engine P 1, Routing of wiring on frame
block
Refit the sidestand H 5, Refitting the sidestand
Refit the front sprocket cover G 8, Refitting the front sprocket
Refit the clutch transmission unit F 2, Refitting the clutch transmission unit
Refit the gearchange control F 5, Refitting the gearchange mechanism
Connect the starter motor/solenoid cable P 3, Refitting the starter motor
Refit the lower retainer of the water N 3.2, Refitting the water radiator
radiator on the engine block
Refit the pipes and the cooling system N 3.2, Refitting the cooling system hoses
joints on the engine block and unions
Refill the cooling system D 4, Change the coolant
Refit the oil pipes of theoil radiator on N 2.2, Refitting the lubrication system
the engine block
Refill the lubrication system D 4, Changing the engine oil and filter car-
tridge
Refit the exhaust unit L 8, Refitting the exhaust system
Connect the cables of the coils M 3, Ignition
Bobine dicoils
accensione
Refit the oil breather pipe, the blow by, L 6, Refitting the airbox and throttle body
the throttle body and the airbox
Connect the throttle cable F 1, Refitting the throttle twistgrip
Refit the air filter L 7, Refitting the air filters
Refit the fuel tank L 2, Refitting the fuel tank
Refit the instrument panel internal E 1, Refitting of the instrument panel
bulkheads
Refit the oil sump guard unit E 2, Refitting of the oil sump guard
Refit the side fairings E 2, Refitting the half-fairings
Refit the front half-fairings E 2, Refitting of the front half-fairings
Refit the side fairings E 3, Refitting the side panels
Refit the saddles E 3, Refitting the seat
1
section
9 - 2.1 Engine
2.1 - Lubrication system: oil pump
15
4
15
6
8 12
1
3
9 9
13
7
5
11
17
1
16 10
14
1 Complete oil pump assembly

2 O-ring
3 Circlip
4 O-ring
5 Pump body
6 Circlip
7 Reducer bush
8 Spring washer
9 Screw
10 Screw
11 Spring washer
12 Pump drive gear
13 Key
14 By-pass plug
15 Locating bush
16 By-pass spring
17 By-pass valve

1200 ABS FILTERS AND OIL PUMP
1200 S ABS FILTERS AND OIL PUMP
Important
section
9 - 2.1 Engine
Removal of the oil pump

Drain the oil from the lubrication system D 4, Changing the engine oil and filter car-
tridge
Remove the right side oil sump guard E 2, Removing of the oil sump guard unit
Remove the clutch-side crankcase cover 9 - 6.2, Removal of the clutch-side crank-
case cover
Undo and remove the screws (9) and (10) securing the pump assembly.
Remove the oil pump assembly (1) and extract the O-rings (2) and (4) from the crankcase half together with two locating bushes
(15).
9 10
15
4 2
section
9 - 2.1 Engine
Disassembly of the oil pump
Hold the oil pump (1) in a vice taking care not to damage the drive gear (12).
12
Warning
Make sure that vice jaws are faced with soft material.
Remove the plug (14) and extract the spring (16) and by-pass valve (17).
17
16
14
Check the condition of the above components.

Remove the circlip (6) and withdraw the pump drive gear (12).
12
6
section
9 - 2.1 Engine
Reassembly of the oil pump
Check that the circlip (3) and tongue (13) are present on the pump.
Fit the pump drive gear (12) on to the oil pump and secure it by installing the circlip (6) in its groove.
12
6
Insert in the pump the by-pass valve (17), the spring (16) and screw and tighten the plug (14) to the specified torque (Sec. 3 - 3,
Engine torque settings) by applying a threadlocker of medium strength.
5
LOCK 17
16
14
Refitting the oil pump

If removed, apply specific threadlock on the bushing (7) and screw it in the crankcase half, observing the height.
Position the reference bushings (15) and the oil sealing O-rings (2) and (4) according to the crankcase lubrication channels.
15
4 2
0
1 -0,2 mm
5
LOCK
section
9 - 2.1 Engine
Position the oil pump on the crankcase and tighten the screws (9) and (10) to the specified torque (Sec. 3 - 3, Engine torque set-
tings).
9 10
Check the gear clearance with the driving pinion by fixing a dial gauge (A), equipped with the appropriate traces, to the crankcase
half.
Position the dial gauge stylus on one tooth of oil pump gear and set the gauge to zero in this position.
Move the gear slightly to measure the backlash; take four readings in diametrically opposed positions of the gear.
The clearance should be 0.10 mm.

Refit the clutch-side crankcase cover 9 - 6.2, Refitting the clutch-side crankcase
cover
Refit the right oil sump guard E 2, Refitting of the oil sump guard unit
Fill the lubrication system with oil D 4, Changing the engine oil and filter car-
tridge
1
section
9 - 2.2 Engine
2.2 - Lubrication system: oil cooler
7 2
5 6
11
2
3
4
13
12
8
9 10
7 7
1 Oil cooler
3 Spacer
4 Screw
5 Nipple
6 Aluminium gasket
7 Oil hose
8 Screw
9 Plate
10 Quick-release fastener
11 Hose clip
12 Engine oil pressure sensor
13 Sealing washer

1200 ABS OIL COOLER
1200 S ABS OIL COOLER
Important
section
9 - 2.2 Engine
Removal of the lubrication system
Remove the front half-fairings Removal of side
E 2, Smontaggio fairings
carene laterali
Drain the oil from the lubrication system D 4, Changing the engine oil and filter car-
tridge
Disconnect the sensor (12) of the main wiring.
12
Loosen the screw (8) of the plate (9) and slide off the plate (9).
Slide off the pipes (7) of the crankcase half paying attention to the pipes O-rings.
9
7
During removal pay attention not to loose the O-ring gaskets (D) which guarantee the coupling sealing.
section
9 - 2.2 Engine
Loosen and remove the screw (4) with the spacer (3) fixing the radiator to the headlamp support. Remove the radiator by sliding
it from the pin (F) of the headlamp support.
Loosen the nuts (G) of the pipes (7) from the nipples (5) and disconnect it from the radiator.
Loosen the nipples (5) on the radiator and collect the gaskets (6).
7
5
G
5 7
Oil cooler inspection

Visually inspect the oil cooler. Renew the cooler at any sign of damage or leaks.
section
9 - 2.2 Engine
Refitting the lubrication system
Note
Before fitting the pipes (7), it is recommended to check the presence of the O-rings (D). Lubricate them by using engine oil.
D D
If the nipples (5) have been removed from the radiator insert a washer (6) on each nipple (5) and apply specific threadlocker on
threads on the radiator side.
Note
The washer (6) should be positioned with the square edge side facing the cooler.
Insert the nipples (5) on the oil radiator (1) and tighten them, counterholding the hex nuts (E), to the specified torque (Sec. 3 - 3,
Engine torque settings).
1
LOCK 5
E
6 E
section
9 - 2.2 Engine
Lubricate the O-rings (D) of the two oil pipes (7) and the nipple threads (5) with engine oil.
Attach the hoses to the nipples (5) on the cooler, finger-tightening the union nuts (E).
Tighten the ring nuts (E) to the specified torque (Sec. 3 - 3, Engine torque settings) counterholding the hex nuts on the nipples.
D D
7
5
E
5 7
Check that the vibration damper mounts are present on the oil cooler (2).
Fit the oil radiator (1) by inserting it first into the pin (F) of the headlamp support.
Insert the spacer (3) and the screw (4).
Tighten the screw (4) to the specified torque (Sec. 3 - 3, Engine torque settings).
2
3
section
9 - 2.2 Engine
Position the pipes (7) in the crankcase half. Position the plate (9).
Tighten the screw (8) to the specified torque (Sec. 3 - 3, Engine torque settings).
9
7
Connect the sensor (12) to the main wiring.
12

Fill the lubrication system D 4, Changing the engine oil and filter car-
tridge
Refit the front half-fairings E 2, Rimontaggio carene
Refitting the side laterali
fairings
1
section
9 - 2.3 Engine
2.3 - Lubrication system: oil breather tank
4
3
2
1
1 Oil breather tank

2 O-ring
3 Clamp
4 Breather hose
5 Clamp

Important
section
9 - 2.3 Engine
Refitting the oil breather tank
Remove the saddles E 3, Removing of the saddles
Remove the side fairings E 3, Removing the fairings
Remove the front half-fairings E 2, Removing of the front half-fairings
Remove the half-fairings E 2, Removing of the half-fairings
Remove the instrument panel internal E 1, Removing of the instrument panel
bulkheads
Remove the fuel tank L2, Removing of the fuel tank
Remove the air filter L 7, Removing of the air filter
Disconnect the throttle cable F 1, Removing of the throttle grip cable
Remove the airbox and the throttle body L6, Removing of the airbox and throttle
body
Loosen the clamp (5) to disconnect the pipe (4) from the blow by.
Slide off the tank (1) with the pipe (4) from the frame.
4 1
To disassemble the tank (1) from the pipe (4) loosen the clamp (3).
3
1
section
9 - 2.3 Engine
Refitting the oil breather tank
Insert the pipe (4) in the tank (1) and tighten the clamp (3).
3
1
House the tank (1) with the pipe (4) into the frame.
4 1
Connect the pipe (4) to the blow by tightening the clamp (5).
section
9 - 2.3 Engine

Refit the airbox and the throttle body L6, Refitting of the airbox and throttle
body
Connect the throttle cable F 1, Refitting of throttle grip cable
Refit the air filter L 7, Refitting of the air filter
Refit the fuel tank L2, Refitting of the fuel tank
Refit the instrument panel internal E 1, Refitting of the instrument panel
bulkheads
Refit the side fairings E 2, Refitting of the half-fairings
Refit the side fairings E 3, Refitting of the fairings
Refit the saddles E 3, Refitting of the saddles
section
9 - 2.3 Engine
Positioning of the blow-by hose
1
section
9 - 3.1 Engine
3.1 - Cooling system: coolant expansion tank
2 1
4
3
5 6
1 Coolant expansion tank

2 Filler cap
3 Screw
4 Breather hose
5 Hose clip
6 Breather hose

1200 ABS COOLING SYSTEM
1200 S ABS COOLING SYSTEM
Important
section
9 - 3.1 Engine
Removal of the expansion tank

Drain the cooling system D 4, Change the coolant
Remove the front half-fairings E 2, Smontaggio carene
Removal of side laterali
fairings
Remove the half-fairings E 2, Removal of the seat
Loosen the clamp (5) and remove the hose (6) from the radiator.
Loosen the screws (3).

Remove the complete tank (1) and the pipes (6) and (7).
Loosen the clamps (5) to remove the hoses (6) and (7) from the tank.
6 7
5
section
9 - 3.1 Engine
Refitting the expansion tank
Locate the hoses (6) and (7) on the tank with the clamps (5).
Position the tank (1) with the pipes (6) and (7).
Insert the screws (3) and tighten them to the specified torque (Sec. 3 - 3, Frame torque settings).
6 7
5
Attach the hose (6) to the radiator with the clamp (5).

Refit the side fairings E 2, Refitting the seat
Refit the front half-fairings E 2, Refitting
Rimontaggio carene
the side laterali
fairings
Fill the cooling system D 4, Change the coolant
section
9 - 3.1 Engine
Positioning the water tank - water radiator pipe
1
section
9 - 3.2 Engine
3.2 - Cooling system: radiator
3
4
7
6 8
5 7
8
3 4
14 21 16
9 19 20
14
11
5 27
13 18 14
5 12
26 22
10 25 2 17
14 1
19 24
23
12
14
14
15
1 Horizontal cylinder coolant outlet union 15 Radiator/thermostat hose

2 Pump/radiator hose 16 Thermostat
3 Screw 17 Clamp
4 Spacer 18 Thermostat/cylinder head hose
5 Rubber pad 19 Sealing washer
6 Radiator cap 20 Vertical cylinder coolant outlet union
7 Clips 21 Thermostat protection ring
8 Screw 22 Thermostat/cylinder head hose
9 RH fan 23 Copper gasket
10 Radiator 24 Temperature sensor
11 LH fan 25 Screw
12 Screw 26 Washer
13 Banjo bolt 27 Support
14 Clamp

1200 ABS RADIATOR
1200 ABS COOLING SYSTEM
1200 S ABS RADIATOR
1200 S ABS COOLING SYSTEM
Important
section
9 - 3.2 Engine
Removal of the radiator
Remove the half-fairings Removal of side
carene laterali
Loosen the clamps (14) on the coolant hoses (15) and (2); disconnect the hoses from the unions on the radiator (10).
14
15
2
10
14
Loosen the clamp (A) and remove the expansion tank-radiator hose (B).
Loosen the screw (3) with the spacer (4) fixing the water radiator on the right side of the frame.
B
A
Loosen the screws (3) with spacer (4) fixing the radiator on the left side.
4 3
section
9 - 3.2 Engine
Disconnect the wiring connectors of the main wiring loom (C) from both fans.
Remove the water radiator (10) from the vehicle, by sliding it from the pin (D).
Radiator inspection
Visually inspect the oil cooler. If it shows signs of damage or leaks, the radiator must be renewed.
Check also that the air flow through the radiator core is not obstructed by leaves, insects, mud, etc.
Important
Excessive cooling temperatures can be caused by a partial obstruction of the radiator core.
Carefully check the condition of the radiator core.
section
9 - 3.2 Engine
Renewal of the cooling fan
Unscrew the three fan retaining screws (8) and remove the fan (11) from the radiator.
Repeat the above operation for the other cooling fan (9).
During refitting, tighten the screws (8) to the specified torque (Sec. 3 - 3, Frame torque settings).
11
9
8 8
Refitting the radiator

Check that there are vibration damper mounts (5) on the radiator brackets (10) and that the support is fitted (27).
5 10
27
5
5
Insert the radiator support (10) into the pin (D).
section
9 - 3.2 Engine
Tighten the screw (3) with spacer (4) on the left and right side.
4 3
Reconnect the fan wiring to the main wiring loom (C).
Insert the cooling system pipes (15) and (2) in the corresponding unions on the radiator and tighten the clamps (14) to the spec-
ified torque (Sec. 3 - 3, Frame torque settings).
14
15
2
10
14
section
9 - 3.2 Engine
Attach the expansion tank-radiator connection hose (B) to the inlet on the radiator cap with the clamp (A).
B
A

Refit the side fairings E 2, Refitting the side
Rimontaggio fairings
carene laterali
section
9 - 3.2 Engine
Removal of the cooling system hoses and unions
Remove the half-fairings Removal of side
carene laterali
Loosen the fixing clamps (14) of the water radiator (10) pipe (2) and the fixing clamps of the radiator/thermostat sleeve (15) to the
thermostat.
14
15
2
10
14
2
14
Loosen the clamps (14) and (17) securing the thermostat assembly (16) – thermostat-cylinder head hose (18) – thermostat-cylin-
der head hose (22).
18 16
17
section
9 - 3.2 Engine
22 14
18
14
Loosen the clamps (14) to disassemble the thermostat unit (16) - thermostat/head sleeve (18) - thermostat/head sleeve (22) -
radiator pump pipe (2).
14 16
14
22
18 2
Unscrew the screws (12) and remove the union (20).

Recover the O-ring gasket (19) located between the retainer and the vertical head.
12
20
section
9 - 3.2 Engine
Unscrew the screws (12) and remove the horizontal cylinder union (1).
Collect the O-ring gasket (19) located between the retainer and the horizontal head.
12
Important
Periodically check the connection hoses for leaks.
Hoses that are cracked, swollen, or hardened should be renewed.
section
9 - 3.2 Engine
Refitting the cooling system hoses and unions
Install a gasket (19) in the seat of the horizontal head retainer (1) and one in retainer seat (20).
Fasten the retainer (1) on the horizontal head with the screws (12) and tighten the screws to the specified torque (Sec. 3 - 3,
Fasten the retainer (20) on the vertical head with the screws (12) and tighten the screws to the specified torque (Sec. 3 - 3, Frame
torque settings).
12
12
20
To assemble the thermostat unit (16) - thermostat/head sleeve (18) - thermostat/head sleeve (22) - radiator pump pipe (2) position
the clamps (14) and tighten the clamps to the specified torque (Sec. 3 - 3, Frame torque settings).
14 16
14
22
18 2
section
9 - 3.2 Engine
Position the thermostat unit (16) - thermostat/head sleeve (18) - thermostat/head sleeve (22) with the clamps (14) and (17) and
tighten the clamps to the specified torque (Sec. 3 - 3, Frame torque settings).
18
14
22 14
18 16
17
section
9 - 3.2 Engine
Position the pump /radiator pipe (2) and the radiator/thermostat sleeve (15) with the clamps (14) and tighten the clamps to the
specified torque (Sec. 3 - 3, Frame torque settings).
14
15
2
10
14
2
14

Refit the side fairings Refitting the side
E 2, Rimontaggio fairings
carene laterali
section
9 - 3.2 Engine
Thermostatic valve sleeves and water radiator sleeves positioning
section
9 - 3.2 Engine
section
9 - 3.2 Engine
1
section
9 - 3.3 Engine
3.3 - Cooling system: water pump
18
13 17
10 12
14
15
16
9 11
8
7
6
5
4
3
2
1
A
A
1 Screw
2 Washer
3 Circlip
4 Washer
5 Outer bearing
6 Inner bearing
7 Spacer
8 Counterface
9 Mechanical seal
10 Water pump impeller
11 Locating dowel
12 Water pump cover assembly
13 Screw
14 Plug
15 Sealing washer
16 Alternator-side crankcase cover
17 Sealing washer
18 screw

1200 ABS WATER PUMP-ALTERNATOR COVER
1200 S ABS WATER PUMP-ALTR-SIDE CRANKCASE COVER
Important
section
9 - 3.3 Engine
Removal of the water pump

Remove the half-fairings E 2, Removal of the half-fairings
Remove the front half-fairings E 2, Removal of the front half-fairings
Remove the cooling system pipes from N 3.2, Removal of the cooling system hos-
the water pump cover es and unions
Remove the front sprocket cover G 8, Removing of the front sprocket
Drain the engine oil D 4, Changing the engine oil and filter car-
tridge
Remove the clutch pushrod F 2, Removal of the clutch transmission
unit
Remove the pump-cylinder hoses N 5, Removal of the cylinder/piston as-
sembly
Remove the alternator-side crankcase N 8, Removal of the alternator-side crank-
cover case cover
Note
For clarity, the figures show the engine removed from the frame.
Unscrew and remove the water pump cover (12) fixing screws (13) and (18) to the alternator cover (16).
Remove the water pump cover (12).
13
18 16
13
13
Clean the pump housing of any scale. Check the bearings wear by turning the impeller shaft (10); in case of excessive clearance,
it is necessary to replace them by operating as follows.
Remove the circlip (3) on the impeller shaft and the washer (4) located below it.
Slide off the rotor (10) with the sealing ring (9) from the outside.
10
section
9 - 3.3 Engine
4 3
Recover the ceramic washer (A) and sealing ring (B) located on the inner side.
Undo and remove the screws (1) with the washer (2).
section
9 - 3.3 Engine
Working from the impeller side, use a suitable drift to press on the inner race of end bearing (5) until it can be extracted from the
cover.
Use the same technique to remove the other bearing (6).
Working from the inside of the cover, remove the counterface (8) of the mechanic seal (9).
Remove the inner spacer (7).
Check the condition of the components of the mechanical seal: there should be no signs of deformation, cracking, or excessive
wear. In the case of damage, both components must be renewed.
Refitting the water pump

Clean the seat in the cover, any parts you intend to reuse, and the impeller shaft. Lubricate with engine oil and refit as follows.
Using pad with code 88713.0869 fit the new mechanic seal (9) on the impeller shaft.
88713.0869
Working from the inside of the cover, fit the inner spacer (7) with its square edge (A) facing outwards.
Using a suitable drift that bears on the outer race, drive home the bearing (6) against the spacer (7) with the shield side (B)
facing the cover.
section
9 - 3.3 Engine
B
A 7
Install the other bearing (5) against the previous one.
Fit the two screws (1), with washer (2), by tightening to the specified torque (Sec. 3 - 3, Engine torque settings).
Turn over the cover and, using the tool code 88713.0870, install the counterface (8), located as shown in figure, until it stops
against the spacer (7).
88713.0870
section
9 - 3.3 Engine
88713.0870
7 8
Fit the sealing ring (B) and the ceramic washer (A).
Insert the impeller shaft (10) with the mechanic seal (9) and turn the cover over.
10
Fit the spacer (4), positioned as shown in the cross-sectional view, and lock the assembly in place with circlip (3).
Rotate the impeller (10) and make sure it turns smoothly without sticking.
Clean the mating surfaces thoroughly on the pump cover and on the alternator-side crankcase cover.
section
9 - 3.3 Engine
10
3
3 10
Apply a bead of liquid gasket to the water pump cover (12) as shown in the figure.
Fit the locating dowels (11) and position the pump cover (12) on the alternator-side crankcase cover.
12 11
Insert the fixing screws (13) and (18) of the cover.

Tighten the screws (13) and (18) to the specified torque (Sec. 3 - 3, Engine torque settings).
Refit the components removed in the procedure.
section
9 - 3.3 Engine
13
18 16
13
13

Install the alternator cover N 8, Refitting the alternator-side crank-
case cover
Refit the pump-cylinder hoses N 5, Refitting the cylinder/piston assembly
Refit the clutch control piston F 2, Refitting the clutch transmission unit
Refill the system with engine oil D 4, Changing the engine oil and filter car-
tridge
Refit the sprocket cover G 8, Refitting the front sprocket
Refit the cooling system hoses to the wa- N 3.2, Refitting the cooling system hoses
ter pump cover and unions
Fit the front half-fairings E 2, Refitting of the front half-fairings
Fit the half-fairings Refitting the side
carene laterali
1
section
9 - 4.1 Engine
4.1 - Cylinder head assemblies: checks and adjustments
2
4
3
5
5
1 Closing shim
2 Intake side camshaft
3 Opening shim
4 Exhaust side camshaft
5 Valve

1200 ABS CYLINDER HEAD: TIMING SYSTEM
1200 ABS VERTICAL CYLINDER HEAD
1200 ABS HORIZONTAL CYLINDER HEAD
1200 S ABS CYLINDER HEAD: TIMING SYSTEM
1200 S ABS VERTICAL CYLINDER HEAD
1200 S ABS HORIZONTAL CYLINDER HEAD
Important
section
9 - 4.1 Engine
Checking and adjusting the valve clearances

Remove the seat E 3, Removal of the seat
Remove the rear right side panel E 3, Removal of the side panels
Remove the tank fairing E 2, Removal of side
Smontaggio fairings
carene laterali
Remove the airbox L 6, Removal the airbox and throttle body
Remove the oil breather expansion tank N 2.3, Removing of the oil breather tank
Loosen the timing belt covers N 4.2, Removal of the timing belt covers
Loosen the water radiator fixing screws N 3.2, Removal of the water radiator
and leave the cooling system connected
Remove the coils M 3, Ignition
coils
Remove the cylinder head cover N 4.4, Removal of the camshafts
Note
Move the piston of the cylinder being checked to TDC of the power stroke: in this condition, all the valves are closed and the
timing shafts come in neutral position and, therefore, free to rotate; check to the valve clearance on the cylinder head on which
it operates.
section
9 - 4.1 Engine
Checking the opening clearance
Using a feeler gauge, check the clearance between the opening rocker arm (A) and the lowest point of the camshaft lobe (B),
taking care not to compress the rocker arm return spring.
The value must be within the specified ones (Sec. C 1.1, Timing system/valves).
If not, remove the opening set screw (3), as described in chapter “Removing the valves” (Sec. N 4.5), and replace it with one of
suitable height to obtain the prescribed clearance.
Note
Opening rocker arm shims measuring 1.80 to 3.45 are available as replacement parts: the size is punched on the shim.
A
3 3
section
9 - 4.1 Engine
Checking the closing clearance
Using a feeler gauge, check the clearance between the closing rocker arm (C) and the highest point of the camshaft lobe (D).
The value must be within the prescribed ones (Sec. C 1.1, Timing system/valves).
If not, remove the closing set screw (1), as described in chapter “Removing the valves” (Sec. N 4.5), and replace it with one of
suitable height to obtain the prescribed clearance.
Note
Closing rocker arm shims measuring from 2.2 to 4.5 are available as replacement parts: the size is punched on the shim.
C D
section
9 - 4.1 Engine
Checking valve lift
Set the engine as the configuration described for the “Checking and adjusting the valve clearances”, previously described.
Position the tool 88765.1518 on the cylinder head: the part marked “A” should be on the intake side and the part marked “S”
should be on the exhaust side.
Seat the plate (A) and tighten the screws (B).
88765.1518
A
88765.1518
Set the opening valve clearance to zero when the camshaft is in its rest position by fitting a feeler gauge between the upper
rocker arm and the opening shim.
Lock the dial gauge into the seat of the stand marked “A” and position the fork probe 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 (Sec. C 1.1, Timing system/valves).
Repeat the same operation for the exhaust valves, using the dial gauge in the support seat 88765.1518 with the marking “S”.
Refit the components by carrying out the same operations indicated in chapter “Checking and adjusting the valve clearances”,
previously described.
Refit the cylinder head cover N 4.4, Refitting the camshafts
Refit the coils M 3, Bobine
Ignitiondicoils
accensione
Fasten the water radiator to the frame N 3.2, Refitting the radiator
Fasten the timing belt covers N 4.2, Refitting the timing covers
Refit the oil breather expansion tank N 2.3, Refitting oil breather tank
Refit the airbox L 6, Refitting the airbox and throttle body
Refit the tank fairing Refitting the side
carene laterali
Refit the rear right half-fairing E 3, Refitting the side panels
Refit the seat E 3, Refitting the seat
section
9 - 4.1 Engine
Checking the engine timing

Remove the tank fairing E 2, Smontaggio carene
Removal of side laterali
fairings
Remove the coils M 3, Bobine
Ignition di accensione
coils
Set the engine to the configuration described for the “Checking and adjusting the valve clearances”, previously indicated.
Install tool 88765.1188 (G) in the spark plug bore to determine the piston TDC, the gauges (H) on the tool 88765.1518 and the
timing check tool (degree wheel (L) 88713.0123 with graduated disk).
88765.1188
88765.1518
88713.0123
section
9 - 4.1 Engine
Set the opening valve clearance to zero when the camshaft is in its rest position by fitting a feeler gauge 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 (G), set the gauges (H) to zero.
Set the tension value of the belts as described at Sec. D 5, Checking and adjusting timing belt tension.
Turn the degree wheel (L) anticlockwise until the gauge dial (H), on the exhaust side, shows a lift of 1 mm. Check that the value
of the angular displacement read on the degree wheel (L) is as specified in (Sec. C 1.1, Timing system/valves).
Continue to rotate in the same direction until you obtain a lift of 1 mm 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 on the gauge (H), during closure of the valve for the compression
stroke. Check the angular value with the prescribed one (Sec. C 1.1, Timing system/valves).
Continue to rotate the degree wheel (L) anticlockwise until you obtain a lift of 1 mm of the exhaust valve, when opening or closing
the valve.
Check the angular displacement value against the specified value.
Repeat the procedure for the vertical cylinder.
A tolerance of ±3° is allowed in the values detected with the described procedure regarding the prescribed ones (Sec. C 1.1, Tim-
ing system/valves).
88765.1188
88765.1518
88713.0123
section
9 - 4.1 Engine
Remove the installed tools to check timing. Then tension the belts to the value of the prescribed operation, as described at
Sec. D 5, Measuring the timing belt tension values.
In case of values different from the described ones (Sec. C 1.1, Timing system/valves), loosen the fixing screws (M) of the timing
pulley and correct the value detected by turning the ring nut of the timing shaft with the supplied wrench with code 88713.1806.
Lock the three fixing screws (M) of the timing pulley to the specified torque (Sec. 3 - 3, Engine torque settings) and mark the new
position of the components.
88713.1806

Refit the coils M 3, Ignition
coils
Fasten the timing belt covers N 4.2, Removal of the timing belt covers
Refit the oil breather expansion tank N 2.3, Refitting the oil breather tank
carene laterali
1
section
9 - 4.2 Engine
4.2 - Cylinder head assemblies: timing system
24
11
23
21
25 22 12
10
13 16
1 7
8 16
9 17
14 18
19 7
20 18 8
15 12
13
4 8 7
12
8 7 9 14
3 2 5 6
4
1 Lower vertical cylinder timing belt cover 14 Timing belt
2 Air filter 15 Nut
3 Horizontal cylinder timing belt cover 16 Key
4 Screw 17 Spacer
5 Filter cover 18 Camshaft pulley
6 Screw 19 Driveshaft pulley spacer
7 Washer 20 Spacer
8 Nut 21 Nut
9 Tensioner pulley assembly 22 Screw
10 Circlip 23 Washer
11 Camshaft pulley 24 Spacer flange
12 Tensioner pin 25 Upper vertical cylinder timing belt cover
13 Idler pulley assembly

1200 ABS TIMING SYSTEM
1200 S ABS TIMING SYSTEM
Important
section
9 - 4.2 Engine
Note
To work with the engine installed, first proceed as follows:

Remove the tank fairing Removal of side
carene laterali
Note
Remove also any parts which may impede the procedure in any way.
Removal of the timing belt covers

Undo the fixing screws (4) of the external covers (1) and (25) and remove it from the vertical thermal unit.
Undo the fixing screws (4) of the external cover (3) and remove it from the horizontal thermal unit.
4
25
4
4
section
9 - 4.2 Engine
Removal of the movable tensioner/timing belt
Loosen the nut (8) and remove the washer (7) and the tensioner pulley (9) from the pin (12) on the cylinder head.
Remove the timing belt (14) from the horizontal cylinder assembly.
Important
If the belts are to be re-used, mark the direction of rotation with an arrow and also mark the cylinder they belong to.
Repeat the procedure for the other cylinder.
14
Removing of the cylinder head pulley/fixed tensioner

Insert the tool code 88713.1806 in the pulleys to lock their rotation and use the bush supplied to loosen the fixing nuts (21) of
the pulleys.
Important
On reassembly, always use new nuts.
Remove the nuts (21) and the pulleys (11) from the camshafts.
88713.1806
21
11
Loosen the nut (8), and remove the washer (7) and the fixed tensioner (13).
Repeat the same procedure to remove the other pulley.
8 13
section
9 - 4.2 Engine
Removal of the tensioner and idler pulley mounting studs
Using the tool code 88713.1821, remove the tensioner pins (12) from the cylinder heads.
88713.1821 12
Disassembly of the camshaft pulleys

Unscrew and remove the screws (22).
Slide off the washer (23).
Withdraw the camshaft pulley (11) from the spacer flange (24).
22
23
11
24
section
9 - 4.2 Engine
Removing the timing belt driveshaft pulleys
Use the tool code 88713.1805 to hold the driving pulley on the engine crankcase against rotation.
Important
If this operation is carried out with the engine installed in the frame, hold the driveshaft pulleys against rotation using the tool
code 88713.2011 mounted on the alternator cover.
Loosen the nut (15) using the socket supplied with the service tool.
88713.1805 15
Remove the nut (15), the spacer (20) and the outer pulley (18).
18
20
Remove the first Woodruff key (16) from the timing belt driveshaft.
Remove the intermediate spacer (19) and the inner pulley (18).
16
19
18
section
9 - 4.2 Engine
Remove the inner spacer (17) and second Woodruff key (16) on the timing belt driveshaft.
16
17
It is now possible to remove the circlip (10) on the driveshaft.
10
Refitting the timing belt driveshaft pulleys

To fit the circlip (10) in the driveshaft seat, use the tool code 88713.2834.
10
Install the inner spacer (17) on the driveshaft, taking care to align the notch in the spacer with the slot for the Woodruff key.
17
section
9 - 4.2 Engine
Fit the first Woodruff key (16) on the timing belt driveshaft.
16
Locate the inner pulley (18).
18
Refit the second tongue (16) and the washer (19).
16
19
Locate the outer pulley (18) and the spacer (20).

Apply the recommended grease to the threads on the end of the driveshaft.
A
18
20
section
9 - 4.2 Engine
Fit the nut (15).
Important
To prevent the nuts working loose and consequent serious engine damage, always use new self-locking nuts on all the timing
belt pulleys on reassembly.
Lock rotation of the pulleys with tool with code 88713.1805 and, using the insert supplied with the wrench in conjunction with a
torque wrench, tighten the self-locking nut to the specified torque (Sec. 3 - 3, Engine torque settings).
88713.1805 15
Refitting the idler and tensioner pulley mounting studs

Apply the recommended threadlocker to the threads of the studs.
Insert the tensioner pins (12) on the cylinder heads, and tighten them using the tool code 88713.1821.
Tighten the tensioner screws to the specified torque (Sec. 3 - 3, Engine torque settings).
88713.1821 12
2
LOCK
section
9 - 4.2 Engine
Reassembly of the timing pulleys
Fit the pulley (11) on the flange (24), aligning the timing mark (D) on the pulley with the timing mark on the (E) on the flange.
Install the washer (23) up against the pulley, aligning the timing notch (F) with the timing marks on the pulley and the flange.
Insert the three screws (22) in the threaded holes (G) of the flange.
Tighten the screws (22) to the specified torque (Sec. 3 - 3, Engine torque settings).
22
23
11
E 24
section
9 - 4.2 Engine
Refitting the cylinder heads pulleys/fixed tensioners
Check that the keyway on the end of the camshaft is in good condition and without burrs.
Fit a Woodruff key (B) in the keyway of each camshaft.
Fit the pulley (11) on the camshaft, inserting the Woodruff key in the in the slot (C) in the pulley.
Apply the recommended grease to the threads on the end of the camshaft.
Repeat the procedure on the other camshaft.
C
11
11
section
9 - 4.2 Engine
Insert the tool code 88713.1806 into the pulleys to prevent rotation.
Apply the recommended grease to the mating face of the nut (21).
Fit the nut (21).
Carry out the same operations on the other camshaft.
Important
Always fit new nuts on reassembly.
21 A
88713.1806
Using the bush supplied with tool with code 88713.1806 and a torque wrench, tighten the nuts (21) to the specified torque (Sec. 3
- 3, Engine torque settings).
88713.1806
21
Insert the fixed tensioners (13), with bearings and washers (7), into the cylinder head pins and tighten the nuts (8) to the specified
torque (Sec. 3 - 3, Engine torque settings).
8 13
section
9 - 4.2 Engine
Undo the locking screws (22) of the pulleys, turning them anti-clockwise through 90° ±5°.
Check that the pulleys have no endfloat and can rotate freely at all points along the full length of the slots.
22
22
Refitting the timing belts

Rotate the pulleys on the timing belt driveshaft until the timing mark on the outer roller is aligned with the mark on the clutch-
side crankcase cover.
In this condition, the horizontal cylinder piston will be at top dead centre.
Install in the alternator cover seat the tool code 88713.2011 to prevent crankshaft rotation and lock it with the corresponding pin,
tighten the M8 screw of the tool to the torque of 20 Nm.
88713.2011
Important
To achieve correct timing, the screws (22) securing the pulleys to the hubs must be loose and positioned in the centres of their
slots.
section
9 - 4.2 Engine
First carry out timing on the vertical cylinder head.
Approach the tool code 88765.1609 to insert the pins (F) in the timing shaft seats (G).
88765.1609
22 G 22
G 22 G
Position the tool code 88765.1609 with legend “UP” and the arrow facing the cylinder head cover.
First place the pins (F) of the tool code 88765.1609 in the intake side pulley with the tool code 88713.3219.
88765.1609 88713.3219
88765.1609
F
88713.3219
section
9 - 4.2 Engine
Place the pins (F) of tool code 88765.1609 in the exhaust side pulley manually.
88765.1609
F
Tighten manually the knobs with tool code 88765.1609 until they stop.
88765.1609
With a torque screwdriver (H) tighten the knob nuts of the tool code 88765.1609 to the torque of 2 Nm ±10%.
88765.1609
Fit the vertical cylinder timing belt around the camshaft pulleys and pass it behind the idler pulley.
Note
If the used belts are to be refitted, position them in their original direction of rotation and on their original cylinder.
section
9 - 4.2 Engine
Fit the tensioner pulley (9) and the washer (7) on the pin of the cylinder head.
Apply grease to the tensioner pulley pin threads and to the contact face of the nut (8).
Start the nut (8).
Check the timing belt tension and adjust if necessary as described in the paragraph Measuring the timing belt tension values
(Sec. D 5) of the vertical cylinder head belt.
Warning
Check the tension on the belt sections (D) and (E) shown in the figure.
Vertical
Steady Movable
Horizontal
E Steady
Transm.
gear
D Movable
Once the belts are correctly tensioned, ensure that the fixing nut (8) of the tensioner pulley (9) and the screws (22) of the vertical
cylinder head are tightened to the specified torque (Sect. 3 - 3, Engine torque settings).
22
22
9 8
Remove the timing shaft locking tool code 88765.1609 of the vertical cylinder head.
section
9 - 4.2 Engine
Carry out timing on the horizontal cylinder head.
Approach the tool 88765.1609 to insert the pins (F) in the timing shafts seats (G).
88765.1609
Position the tool code 88765.1609 with legend “UP” and the arrow facing the cylinder head cover.
Place the pins of tool 88765.1609 in the exhaust side pulley seat (G) manually.
Manually tighten the knobs with tool code 88765.1609 until they stop.
With a torque screwdriver (H) tighten the knob nuts of the tool code 88765.1609 to the torque of 2 Nm ±10%.
88765.1609
G
H G
section
9 - 4.2 Engine
Fit the horizontal cylinder timing belt around the camshaft pulleys and pass it behind the idler pulley.
Note
If the used belts are to be refitted, position them in their original direction of rotation and on their original cylinder.
Fit the tensioner pulley (9) and the washer (7) on the pin of the cylinder head.
Apply grease to the tensioner pulley pin threads and to the contact face of the nut (8).
Start the nut (8).
8 C
Check the timing belt tension and adjust if necessary as described in the paragraph Measuring the timing belt tension values
(Sec. D 5) of the horizontal cylinder head belt.
Once the belts are correctly tensioned, ensure that the fixing nut (8) of the tensioner pulley (9) and the screws (22) of the hori-
zontal cylinder head are tightened to the specified torque (Sect. 3 - 3, Engine torque settings).
22
22
22
Remove the timing shaft locking tool 88765.1609 of the horizontal cylinder head.
section
9 - 4.2 Engine
Refitting the timing covers
Locate the horizontal cylinder timing belt cover (3) and secure it in place with screws (4).
Carry out the same procedure for vertical cylinder external covers (1) and (25).
Tighten the screws (4) to the specified torque (Sec. 3 - 3, Engine torque settings) following the sequence indicated in figure.
2 6 4
8
4
4
1
7
3 5
4
25 13
1
12 11
10
Note
If the above operations have been carried out with the engine installed in the frame, refit the previously removed parts.

coils
Refit the tank fairing E 2, Rimontaggio carene
Refitting the side laterali
fairings
1
section
9 - 4.4 Engine
4.4 - Cylinder head assemblies: camshafts
7 7
8 8
6
4
9
21
3 13
11
23
22 26 27
13
2
11
16 26 27
19 18
25
19
25
10 12 24
16 1 21 4 9 8 7
17 20 16
15
19
1 17 11
16
14
19
17
3
11 2 22 23 5 8 7
1 Head
2 Stud bolt
3 Banjo bolt
4 Sealing washer
5 Horizontal cylinder head cover
6 Vertical cylinder head cover
7 Banjo bolt
8 O-ring
9 Cylinder head gasket
10 Grub screw
11 Pin
12 Union
13 Clamp
14 Horizontal cylinder exhaust camshaft
15 Horizontal cylinder intake camshaft
16 Plug
17 Sealing ring
18 Vertical cylinder exhaust camshaft
19 Key
20 Vertical cylinder intake camshaft
21 Screw
22 Timing side support
23 Opposite side support
24 Sealing washer
25 Intake manifold
26 Screw
27 Sealing washer
section
9 - 4.4 Engine
1200 ABS THROTTLE BODY
1200 S ABS THROTTLE BODY
Important
section
9 - 4.4 Engine
Removal of the camshafts

Remove the tank fairing E 2, Removal of side
Smontaggio fairings
carene laterali
coils
Unscrew and remove the screws (7) and the O-rings (8) from the cylinder head covers.
Remove the cylinder head cover (6).
7
7
Remove the gaskets (4) and (9).
section
9 - 4.4 Engine
Repeat the same procedure for the other cylinder head cover. Unscrew the screws (3) securing the camshaft supports.
Withdraw the camshaft supports (22) and (23) straight out from the cylinder head, taking care not to damage the machined faces
and locating dowels (11).
3 3
23 22
11
11
Remove the exhaust camshaft (14) and the intake camshaft (15), and slide off the sealing rings (17) on their ends. Repeat the
same procedure for the other cylinder head.
17 15 17 14
If necessary, unscrew the stud bolts (2) from the cylinder heads.
section
9 - 4.4 Engine
Checking the camshafts and supports
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 centres and check the runout on the areas indicated using two dial gauges.
Service limit: 0.1 mm.
Visually inspect the camshaft tracks for scoring and abnormal wear. If any of the above defects are found, the camshaft should
be renewed.
If you find scoring or excessive wear, check the operation of the engine lubrication circuit.
section
9 - 4.4 Engine
Refitting the camshafts
If the stud bolts (2) were removed, apply the recommended threadlocker to the short end of the stud bolts (2), i.e. the end that
is to be screwed into the cylinder head. Fasten the stud bolts (2) to the specified torque (Sec. 3 - 3, Engine torque settings).
2
LOCK
Check that the camshafts (marked “VA” and “VS” for the vertical cylinder head and “OS” and “OA” for the horizontal cylinder
head) are clean and in good condition. If the camshafts are not new, use emery cloth to remove signs of wear on the cam and
support surfaces, working on a flat surface.
Lubricate with the specified lubricant (Molycote M55 Plus), the camshaft seats on both the cylinder head and the supports (22)
and (23) (green zone).
Fill the reservoirs (A) with the recommended lubricant (Molycote M55 Plus).
A 22
23
section
9 - 4.4 Engine
Apply sealant (Three Bond 1215 liquid gasket) at the four points of the support (22) shown in red in the photo.
Clean off any excess sealant.
Note
Only apply sealant to the timing side support (22): do not apply to support (23).
22
Install the camshafts (14) and (15) in the cylinder head, and rotate them to distribute the lubricant evenly.
Check that the locating dowels (11) are present.
11 14
15 11
Fit the supports (22) and (23) so 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 zone (C) of the support.
Important
The support (22) must be installed on the timing side.
Bed down the supports.

Apply engine oil to the threads and undersides of the heads of the screws (3).
Insert the screws (3).
3 3
C C
23 22
section
9 - 4.4 Engine
Pre-tighten the screws (3) to the specified torque (Sec. 3 - 3, Engine torque settings).
Pre-tighten one support at a time, working in the sequence 1-2-3-4-5-6-7-8.
Tighten the screws to the specified torque (Sec. 3 - 3, Engine torque settings).
Tighten one support at a time, working in the sequence 1-2-3-4-5-6-7-8.
Remove any excess sealant from between the cylinder head and the support.
Turn the camshafts by hand to check that they rotate freely.
Note
The screw (3) in position 1 must always be installed on the intake and timing side.
3 8 3
6
5
4
7
2
Important
Check lifted valve as explained (Sec. N 4.1, Checking valve lift).
section
9 - 4.4 Engine
Sealing rings
Lubricate the sealing rings (17) with denatured alcohol.
Fit the installation tool code 88713.2861 on the camshaft and install the sealing ring on the cylinder head with the spring side.
Important
Always fit new sealing rings on reassembly.
Use the drift provided with the tool and a mallet to seat the sealing rings.
17 88713.2861
88713.2861
When correctly installed, the sealing ring should be flush with the bevel of the cylinder head bore.
section
9 - 4.4 Engine
Cylinder head cover
Apply sealant (Three Bond 1215 liquid gasket) at the four points of the cylinder head cover shown in red in the photo.
Fit the gaskets (4) and (9) on the cylinder head cover, as shown in the figure.
Apply in the two areas of the cylinder heads surface a strip of about 2 mm (MAX about 4 mm) of sealant (liquid sealant Three
Bond 1215), observing the heights and position indicated in figure.
25 ±1 mm
25 ±1 mm
MIN. 2 mm
MAX.approx.
circa 4 mm
section
9 - 4.4 Engine
Cylinder head cover identification: The vertical head rocker cover (6) has a nib (A) on the left-hand side (exhaust side),
whereas rocker cover (5) has a nib (B) on the right-hand side (exhaust side).
6
5
Locate the cover (6) on the cylinder head, aligning the four fixing holes.
Start the screws (7) with the O-rings (8).
Tighten the screws (7) to the specified torque (Sec. 3 - 3, Engine torque settings), observing the indicated sequence.
1
7
7 4
8
3
Remove excess sealant from the area of application.

Repeat the same procedure for the other cylinder head.
If the dowel (10) has been removed, during refitting apply threadlocker and tighten to the specified torque (Sec. 3 - 3, Engine
torque settings).
10
LOCK
6
section
9 - 4.4 Engine
Refit all the components removed in the procedure.
coils
Refit the tank fairing E 2, Refitting of the tank fairing
section
9 - 4.4 Engine
Removal of the intake manifold and coolant union
Remove the tank fairing Removal of side
carene laterali
Remove the injectors unit L 6, Removal of the injectors
Loosen the clamp (F) and remove the pipe (T).
T
F
Remove the manifolds (25) undoing the screws (21).
21 21
21
21
25
25
21 21
Loosen the clamp (A) and remove the hose (B). Remove the union (12) and recover the seal (24).
section
9 - 4.4 Engine
24
12
Refitting the intake manifold and coolant union

Apply prescribed threadlocker to the retainer (12), insert it with the gasket (24) and tighten the retainer to the specified torque
(Sec. 3 - 3, Engine torque settings).
Install the pipe (B) and tighten the clamp (A) to the specified torque (Sec. 3 - 3, Engine torque settings).
2
LOCK
24
12
section
9 - 4.4 Engine
Check that the mating surfaces of the cylinder head and manifold are perfectly flat and clean and install the intake manifold (25)
on the cylinder head.
Lock the fixing screws (21) to the specified torque (Sec. 3 - 3, Engine torque settings) in a crosswise pattern (1-2-3-4).
21
2 3
25
4 1
1

coils
carene laterali
1
section
9 - 4.5 Engine
4.5 - Cylinder head assemblies: valves - rocker arms
2 15 12 1 16 4 19 17 1
12
3
23 15 12
2 25
15
16
1
23 24 15
12
1 4 2
18
21 17 3
22 20 2
5
12 15
12 15 6
5
7 8
10 9 10 13 9 13
11 14
1 Closing rocker arm shaft 14 Intake valve
2 Opening rocker arm shaft 15 Aluminium gasket
3 Opening rocker arm 16 Closing rocker arm (right)
4 Closing rocker arm (left) 17 Spacer
5 Valve opening shim 18 Valve return spring (right)
6 Half rings 19 Valve return spring (left)
7 Valve closing shim 20 Head
8 Sealing ring 21 Cylinder head nut
9 Valve guide 22 Washer
10 Exhaust valve seat 23 Spacer
11 Exhaust valve 24 Valve return spring (right)
12 Plug 25 Valve return spring (left)
13 Intake valve seat

1200 ABS CRANKCASE HALVES
1200 S ABS CRANKCASE HALVES
Important
section
9 - 4.5 Engine
Removal of the cylinder heads

Remove the engine from the frame N 1, Removal of the engine
Remove the coolant hoses N 3.2, Removal of the cooling system hos-
es and unions
Remove the timing belt covers and the N 4.2, Removal of the timing belt covers
timing belts
Refit the intake manifolds N 4.4, Removing of the intake manifolds
Using the tool code 88713.2676, undo the nuts (21) on the cylinder head stud bolts.
Remove the cylinder head nuts (21) and special washers (22).
21
22
Remove the cylinder head assembly by lifting it off the engine studs.
section
9 - 4.5 Engine
Removing the valves

Remove the cylinder head assembly from N 4.5, Removal of the cylinder heads
the engine
Remove the timing belt pulleys N 4.2, Removing of the cylinder head
pulley/fixed tensioner
Bobine dicoils
accensione
Remove the cylinder head covers, the timing N 4.4, Removal of the camshafts
shaft supports and the timing shafts
Raise the rocker arm (3) and remove the opening shim (5) from the valves with a pair of pliers.
Push down the closing rocker arms (16) and (4) and the closing shim (7).
Remove the half rings (6) from the valves with a magnetic screwdriver. Extract the closing shims (7) from the valve using a pair
of pliers.
16
7
4
6
6
7
Withdraw the valves (14) and (11) from underside of the cylinder head.
11
14
section
9 - 4.5 Engine
Removing the valve rocker arms
With the cylinder head in the condition described in the previous paragraph, remove the rocker arms.
Unscrew the eight plugs (12) and recover the seals (15).
12
15
12
Using an M6 screw, withdraw the shafts (2) of the opening rocker arms (3) on the exhaust and intake sides.
Remove the opening rocker arms (3).
section
9 - 4.5 Engine
Using the claw of the rocker arm spring tensioning kit 88713.2069 installed between the spring and the inner wall of the cylinder
head, move the straight end of the rocker arm return spring (19) and (18) and insert it in the drilled shaft.
18
19
Use the shaft to slide the end of the spring into its final position.
Using an M6 screw, withdraw the shafts (1) of the closing rocker arms on the exhaust and intake sides.
section
9 - 4.5 Engine
Remove the closing rocker arms (4) and (16), the springs (18) and (19) with the spacers (17).
16
18 17
17
19
Carry out the same operation to remove the closing rocker arms (4) and (16), the springs (24) and (25) with the spacers (23).
Remove the sealing rings (8) from the ends of the valve guides.
section
9 - 4.5 Engine
Overhaul of 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, ridges or other damage.
Check that the cylinder barrel mating surfaces of the cylinder head are free of carbon deposits and scale. If this is not the case,
spread diamond dressing compound (6 to 12 micron thickness) on a reference surface and slide the cylinder head on the surface
as shown in the figure until a flat finish is obtained.
section
9 - 4.5 Engine
Valve seats
Visually inspect the valve seats: for cracking or pitting.
Minor damage can be repaired by grinding with special 45° and 60° single-blade grinders. Grind the valves and check the seal.
60 45
If the valve seats are excessively damaged, fit oversize seats. Replacement seats are available with 0.03 and 0.06 mm oversized
outside diameters.
Important
When you change the valve seats, change the valve guides as well.
Proceed as follows:
Remove the worn seats, grinding carefully to avoid any damage to cylinder head bores.
Check the diameter of head bores and choose the oversized valve seat that will give an interference fit of 0.04 to 0.10 mm.
24±0.02 16±0.02
section
9 - 4.5 Engine
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 the head bores using the appropriate valve guide seat installer 88713.2846 and 88713.2847.
Allow the cylinder head to cool down and grind the seats to the following dimensions:
CA = Ø 41.6±0.025 mm.
CS = Ø 33.6±0.025 mm.
S = 1.2 mm.
D = 0.2 to 0.4 mm.
Important
Do not use any lapping compound after final grinding.
A A B
5:1 B
5:1
S
S
D
CS CA
It is advisable to smooth the joint between the intake valves seats and the intake ducts (F = before; G = after).
section
9 - 4.5 Engine
Valve guides
Check internal surface of the valve guides: for cracking or distortion.
Thoroughly check the dimensions of the inner surface of the valve guide. Measure the inside diameter with a bore diameter
gauge.
Measure the diameter at different positions of the valve guide.
The assembly clearance must be:

highest measured value – lowest measured value = 0.03 to 0.045 mm;
the maximum permissible wear limit is 0.08 mm.
change the valve guides when the ovality exceeds permissible limit or the clearance to the valve stem is outside the tolerance
range;
When you change the valve guide, you must also change the valve.
Valve guides as spare parts are available with outside diameter oversized by 0.03, 0.06 and 0.09 mm.
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 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 to 0.051 mm;
- heat up the cylinder head again and chill the new valve guides in dry ice;
- lubricate the bores in the cylinder head and install the valve guides using the appropriate service tools and in reference to the
dimensions given in the figure;
A= 22.4±0.15 mm.
B= 28.45±0.15 mm.
Hone the mating surface with a reamer.
B A
section
9 - 4.5 Engine
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” block and measure deformation with a dial gauge.
Service limit: 0.053 mm.
Check the valve stem for buckling. Place valve on a "V" block, set a dial gauge perpendicular to head and measure run-out of valve
face at 45°.
- nominal concentricity: 0.01 mm;
- service limit: 0.03 mm.
section
9 - 4.5 Engine
Use Prussian blue or a mixture of minimum and oil to check that the contact surface (W) between the valve and seat is 1.4 to
1.6 mm (1.05 to 1.35 mm when new). Grind the seat if the dimension measured is greater than the above limit.
W
45
W
45˚
30
Checking the valve seal

After grinding the seats it is important to check the seal between the valve face and the seat: if the seat contact area (S) on the
valve is wider than the 45° band (W) this could lead to poor sealing.
S
45
W
section
9 - 4.5 Engine
Checking the rocker arms
Check for signs of wear, grooves or chrome flaking off.
Check the condition of rocker arm bore and shaft.
Assembly clearance: 0.025 to 0.049 mm.
Wear limit: 0.08 mm.
Opening and closing shims - Springs

Check the condition of the contact surfaces of the valve opening and closing shims: there must be no signs of wear.
Check the condition of the closing rocker arm return springs: check for cracking, distortion, or loss of elasticity.
section
9 - 4.5 Engine
Reassembly of the cylinder head
The exhaust side can be identified by the three threaded holes on the flange.
The intake side can be identified by the presence of four threaded holes on the flange.
All the photos in this chapter refer to a vertical cylinder head.
Valve guide sealing rings

Position the cylinder head on the appropriate support 88713.2103.
Use engine oil to lubricate the valve guides sealing rings (8) and insert them from the spring side onto tool 88713.2442.
Fit the end of the tool into the valve guide and use a mallet to tap the sealing rings (8) home into the valve guides.
8
88713.2442
section
9 - 4.5 Engine
Reassembly of the closing rocker arms
Check that the rocker arms are not scored or show signs of breakage in the area of contact with the camshaft and shim.
The closing rocker arm shafts are 10 mm in diameter, whereas the opening rocker arm shafts are 9 mm in diameter.
Using an M6 screw, position the closing rocker shaft (1) towards the exhaust side of the cylinder head.
Locate the spacer (17) on the shaft.
17
Locate the spring (18) on the spacer (17).
18
17
section
9 - 4.5 Engine
Locate the closing rocker arm (16) and drive the shaft home.
16
Proceed in a similar manner to install the closing rocker arm (4) with the spring (19).
4
19
Load the springs (18) and (19) on the closing rocker arms (16) and (4) respectively using the tool 88713.2069.
19
16
18
section
9 - 4.5 Engine
Proceed to install the closing rocker arms (4) and (16), the springs (24) and (25), the relative pins on the exhaust side in the same
manner as described for the intake side.
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.
16 4
16
Refitting the valves, closing shims and half rings

Carefully clean the two intake valve seats (A) and the two exhaust valve seats (B).
Lubricate the stems of the two intake valves (14) and the two exhaust valves (11) with engine oil.
Install the valves in respective seats in the cylinder head.
11
14 B
A
11
14
Hold the closing rocker arm (16) pushed downwards and fit the closing shim (7) on the valve stem up to reach the rocker arm. If
using the old cylinder head, start by fitting the original shim.
16
section
9 - 4.5 Engine
Insert the new half rings (6) in the valve groove (T) and release the rocker arm to obtain shim (7) internal position. Turn the closing
rocker arm (16), and compress the spring as much as possible while holding the valve, the shim and the half rings in the valve
closed position. Release the rocker arm with a rapid motion, so that the half rings seat in the shim.
6 16
6
7
16
section
9 - 4.5 Engine
Repeat the procedure with the opposite valve and check that the top of the valve stem is aligned with the surface of the shim (7);
if it is not, repeat the half ring installation procedure.
Install the closing shims on the intake valves (14) using the method described above for the exhaust valves.
Refit the timing shafts (Sec. N 4.4, Refitting the camshafts) to check the valve clearance when closed (Sec. N 4.1, Checking and
adjusting the valve clearances).
Refitting the opening shims and opening rocker arms

Using an M6 screw, position the opening rocker arm shaft (2) (diameter 9 mm).
Locate the opening rocker arm (3) and drive the shaft home.
section
9 - 4.5 Engine
Install the four rocker arms (3) in the manner described above.
Raise the opening rocker arm (3) and install the opening shim (5) so it seats against the valve stem.
Release the rocker arm so that it rests against the shim.

Ensure the shim is correctly seated by lightly tapping the rocker arm shoe (A) with plastic mallet.
Refit the timing shafts (Sec. N 4.4, Refitting the camshafts) to check the valve clearance when open (Sec. N 4.1, Checking and
adjusting the valve clearances).
section
9 - 4.5 Engine
Insert the gaskets (15) on the plugs (12), orienting them (preferably) with the sharp edge side (T) facing the cylinder head.
Apply prescribed threadlocker on the plug threads (12): apply the product on the first two plug threads, spreading it for the half
circumference (about 180°).
Tighten the plugs to the specified torque (Sec. 3 - 3, Frame torque settings).
Note
After tightening, remove any excess of product.
12 15
2
LOCK
12
2
LOCK
12

Refit the camshaft supports N 4.4, Refitting the camshafts
Refit the timing belt pulleys N 4.2, Refitting the cylinder heads pulleys/
fixed tensioners
Refit the cylinder head covers N 4.4, Refitting the camshafts
Bobine coils
di accensione
Refit the cylinder head assembly N 4.5, Refitting the cylinder head assem-
blies
section
9 - 4.5 Engine
Refitting the cylinder head assemblies
Warning
To prevent oil leaks past 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 spoiled gaskets and O-rings and
apply again liquid sealant (Sec. N 5, Refitting the cylinder/piston assembly).
Before fitting the head, check that gasket is installed on the mating surface between head and cylinder (Sec. N 5, Refitting the
cylinder/piston assembly).
Note
When fitting the gasket, side (E) with the stamped code must be in contact with the cylinder head.
Lower the cylinder head carefully over the studs. Take care not to damage the threads.
Fit the special washers (22) and nuts (21) onto the cylinder head studs.
Tighten the nuts (21) on the stud bolts evenly and gradually in a crosswise pattern using tool 88713.2676 in conjunction with a
torque wrench.
Pre-tighten and tighten the nuts (21) to the specified torque (Sec. 3 - 3, Engine torque settings).
21
22

Refit the coolant hoses N 3.2, Refitting the cooling system hoses
and unions
Refit the intake manifolds N 4.4, Refitting the intake manifolds
Refit the timing belts and covers N 4.2, Refitting the cylinder heads pulleys/
fixed tensioners
Refit the engine to the frame N 1, Refitting the engine
1
section
9-5 Engine
5 - Cylinder/piston assemblies
12 11 7 9
7
6
10
1
7 8
4 32
2 3 2 4
1
10 6 11 12
1 Piston
2 Gudgeon pin circlip
3 Gudgeon pin
4 Set of piston rings
5 Cylinder-crankcase gasket
6 Water pump outlet union
7 Hose clip
8 Horizontal cylinder coolant inlet hose
9 Vertical cylinder coolant inlet hose
10 Cylinder barrel
11 Cylinder head gasket
12 Bush

1200 ABS CYLINDERS - PISTONS
1200 S ABS CYLINDERS - PISTONS
Important
section
9-5 Engine
Removal of the cylinder/piston assembly

Remove the engine from the frame N 1, Removal of the engine
Remove the coolant hoses N 3.2, Removal of the cooling system hos-
es and unions
Remove the timing belt covers and the N 4.2, Removal of the timing belt covers
timing belts
Remove the heads from the engine block N 4.5, Removal of the cylinder heads
Loosen the clamps (7) and remove the hoses (8) and (9) from the cylinder barrels (10) and from the alternator-side crankcase
cover.
10
7
8
10
7
9
If damaged, unscrew the unions (6).
Note
The following procedure is described with the engine removed from the frame and the cylinder head removed from the engine
(Sec. N 4.5, Removal of the cylinder heads).
section
9-5 Engine
Remove the cylinder head gasket (11) from the cylinder barrel.
11
Remove the bushes (12).
12
12
Use the tool 88765.1523 to bring the piston of the horizontal cylinder near the TDC.
88765.1523
Carefully lift the cylinder barrel (10) 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 (3).
Note
For better sealing the piston ring gaps should be positioned at 180° intervals.
section
9-5 Engine
Since insertion of piston in the barrel is a difficult operation to perform at the time of reassembly, remove the piston together
with the barrel as described below.
Stuff the crankcase opening with a rag or soft paper to prevent foreign material from falling in.
10
Remove the circlip (2) from the gudgeon pin (3) on the clutch side.
2 3
Working from the opposite side, drive out the gudgeon pin sufficiently to release the connecting rod.
Lift the barrel-piston assembly clear of the crankcase studs. If work is to be carried out on the piston, carefully withdraw it from
the cylinder.
Remove the four O-rings (A) located on the crankcase studs between the barrel and the base gasket (5).
A 5
section
9-5 Engine
To remove the vertical barrel-piston assembly, bring the vertical piston to TDC and proceed as for removal of the horizontal
cylinder barrel.
Important
Mark the pistons to show from which cylinder they were removed:
V= Vertical - H= Horizontal.
Overhaul of the cylinder barrel/piston components
Overhauling the cylinder

Check that the walls of the cylinder bore are perfectly smooth. Measure the cylinder bore diameter at 50 mm from the top
face and determine the size class to which it belongs in accordance with the values specified in Sec. C 1.1, Cylinder/Piston.
Repeat measurement of the diameter at three heights A (10 mm from the upper surface), B (50 mm from the upper surface) and
C (100 mm from the upper surface) and in two direction at 90° between them; check that the measurements of taper and ovality
in the bore fall within the range specified in Sec. C 1.1, Cylinder/Piston.
In the event of damage or excessive wear the barrel must be renewed as it has a silicon carbide coating (which provides the
cylinder walls with excellent anti-friction and anti-wear properties) and therefore cannot be rebored.
The cylinder barrels are marked with letters (stamped between two oil return ways) indicating their size class.
Always match cylinders with pistons from the same size class.
50
B
C
Ø
section
9-5 Engine
Overhaul of the piston
Clean the piston crown and piston ring grooves, removing any carbon deposits.
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 up from the bottom of the skirt and in perpendicular direction to the pin axis.
The pistons must always be renewed as a pair.
7,5 mm
Checking the piston-cylinder clearance

The pistons are marked with a letter (punched into the piston crown) that indicates the size class to which they belong.
Always match cylinders with pistons from the same size class.
The prescribed values are given in Sec. C 1.1, Cylinder/Piston.
section
9-5 Engine
Overhauling the gudgeon pins
Gudgeon pins must be perfectly smooth without signs of scoring, steps, or blueing due to overheating. The well-lubricated gudg-
eon pin must slide smoothly inside the piston without stiffness.
Coupling clearance values with the piston and the connecting rod, see Sec. C 1.1, 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. Replacement pistons are supplied complete with piston rings
and gudgeon pin.
section
9-5 Engine
Checking the piston ring-grooves clearance
The maximum permissible wear limit is 0.15 mm for the top segment (1st) and 0.10 mm for the others (2nd and oil scraper ring).
The piston rings must always be installed with markings facing upwards.
1st segment
2nd segment
oil scraper ring
1st segment
MARK
2nd segment
MARK
oil scraper ring
section
9-5 Engine
Checking the piston ring/cylinder clearance
Insert the ring in the cylinder bore so that it is positioned 50 mm from the top face of the cylinder barrel; make sure that the ring
is positioned perfectly square to the cylinder walls by checking with a gauge at several points around the ring that the top surface
of the ring is exactly 50 mm from the top face of the cylinder barrel.
Measure the piston ring gap (A):
Distance (A) mm Wear limit

Top compression ring 0.2 to 0.4 0.8
Second compression ring 0.3 to 0.5 0.8
Oil control ring 0.2 to 0.7 1.0
50
A
section
9-5 Engine
Refitting the cylinder/piston assembly
If new units are used, it is necessary to couple the cylinders and pistons of the same selection (see paragraph “Overhaul of the
cylinder barrel/piston components” of this section).
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).
Note
For better sealing the piston ring gaps should be positioned at 180° intervals.
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 port.
Remove any deposits and degrease the contact surfaces of the crankcase half and the cylinders.
Check that the cylinder barrel locating bushes (B) are fitted on the crankcase.
section
9-5 Engine
Apply sealant to the gasket (5) then locate the gasket on the crankcase.
Using the cap 88713.1920, fit the O-rings (A) on each stud bolt and guide them into their seats in the crankcase.
88713.1920
Bring the connecting rod small end close to TDC and slide the barrel-piston assembly (1-10) onto the crankcase studs.
Push the connecting rod small end into the piston close to the gudgeon pin (3) bore. Lubricate and insert the gudgeon pin.
10
section
9-5 Engine
The gudgeon pin (3) must slide smoothly in the connecting rod small end bush and in the piston (1).
Close the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the retainer ring (2) as shown
in the figure.
Important
Always fit new circlips (2) on reassembly.
1
2 3
Push the cylinder barrel (10) down until it seats against the crankcase.
10
Refit the bushes (12).
12
12
section
9-5 Engine
Fit the cylinder head gasket (11) over the studs. The side marked with the part number must be facing the cylinder head.
Note
The shape of the gasket prevents incorrect fitting, provided that the coolant flow holes are aligned with those on the cylinder.
11
Repeat the procedure for the other cylinder and refit the cylinder heads (Sec. N 4.5, Refitting the cylinder head assemblies).
If fillers have been removed, apply prescribed threadlocker on them (6), and tighten to the specified torque (Sec. 3 - 3, Engine
torque settings).
LOCK
5
Fix the pipes (8) and (9) and tighten the clamps (7) to the specified torque (Sec. 3 - 3, Engine torque settings).
10
7
9
10
7
8
section
9-5 Engine

Refit heads on the engine block N 4.5, Refitting the cylinder head assem-
blies
Refit the timing belt external covers and N 4.2, Refitting the timing covers
the timing belts
Refit the coolant hoses N 3.2, Refitting the cooling system hoses
and unions
Refit the engine to the frame N 1, Refitting the engine
1
section
9 - 6.1 Engine
6.1 - Clutch assembly: clutch
2 3 6
1 10 11
9
14 7 8
4 5
13
12
1 Screw
2 Ring
3 Clutch spring
4 Pressure plate
5 Bearing
6 Circlips
7 Nut
8 Belleville washer
9 Clutch plates
10 Belleville washer
11 Flat ring
12 Clutch centre
13 Spacer
14 Clutch lifter

1200 ABS CLUTCH
1200 S ABS CLUTCH
Important
section
9 - 6.1 Engine
Description of the clutch assembly
The clutch is disengaged by a drive unit consisting of a thrust piston (C) accommodated inside a small cap mounted to the gen-
erator cover. This piston (C) pushes a pushrod (B), which runs through gearbox primary shaft and operates the pressure plate (4)
located on top of the clutch plate pack (9).
Drive is transmitted from the crankshaft to the gearbox primary shaft by a gear integrated with the clutch housing/primary drive
gear pair (A).
Accommodated in the clutch housing is a set of drive and driven plates (9). When the clutch is operated, the driven plates push
away a drum (12) which is splined onto the gearbox primary shaft.
Before working on the internal clutch parts, check that the clutch operates correctly. Then deal with the problem in a systematic
manner.
C
B
A
12
The following is a list of possible causes of clutch malfunctions.
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 drum.
A clutch which slips may be caused by:

- insufficient play of the control lever;
- worn clutch plates;
- weakened springs;
- faulty clutch release mechanism;
- excessive wear of the hub or clutch drum.
A noisy clutch may be caused by:

- excessive backlash between the primary drive gears;
- damaged primary drive gear teeth;
- excessive play between friction plate tabs and the clutch drum;
- worn gear/clutch drum bearings;
- the presence of metal particles (filings) on the gear teeth.
section
9 - 6.1 Engine
Removal of the clutch
Remove the oil sump guard unit E 2, Removing of the oil sump guard unit
tridge
Remove the clutch cover N 6.2, Removal of the clutch-side crank-
case cover
Note
Undo the fixing screws (1) and remove the ring (2) and the springs (3) from the pressure plate (4).
1
1
section
9 - 6.1 Engine
Slide the pressure plate (4) paying attention to the circlips (6).
Remove the clutch control pin (14) and the bearing (5).
`
14
5
Lock the clutch drum (12) using the appropriate tool, undo the fixing nut (7).
7
12
Remove the Belleville spring (8), slide the clutch drum (12) and remove the series of discs (9) from the clutch bell.
9
12
section
9 - 6.1 Engine
When removing the discs (9), keep them paired in the assembly order and set them aside tied together, if necessary.
Slide the spacer (13).
13
Withdraw the Belleville washer (10) and flat ring (11) from the clutch centre (12).
12
10
11
section
9 - 6.1 Engine
Checking and overhauling the components
Clearance between the clutch drum and friction plates

Insert a friction plate (E) in the clutch drum (F) and measure the clearance (S) with a feeler gauge.
Clearance “S” must not exceed 0.6 mm.
If it does, renew the plates and, if necessary, the clutch drum.
F
S
Overhaul of 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.
Important
The total thickness of the discs pack must not be less than 46.1 mm.
Place the plate on a flat surface and check the amount of deformation with a feeler gauge.
Max flatness error: 0.2 mm.
section
9 - 6.1 Engine
Overhaul of the pressure plate
Check bearing (5) condition. renew the bearing if the play is excessive.
Check the contact surfaces of the last friction plate; if extremely scored, polish it in the same manner as described previously for
the cylinder head surface (Sec. N 4.5, Overhaul
Revisioneofcomponenti testa).
cylinder head components).
Check conditions of the spring guide bucket tappet (G) of the pressure plate (4) and of the circlips (6).
4 6
Overhauling the pressure plate springs

Measure the length “L” of each spring (3).
Minimum length: 41 mm.
Renew any springs that are shorter than the above limit value.
section
9 - 6.1 Engine
Reassembling the clutch
Position the spacer (13).
13
Fit the flat ring (11) and the Belleville washer (10) on the clutch drum (12), so that the convex side faces the clutch drum.
12
10
11
Locate the Belleville washer (8).
section
9 - 6.1 Engine
Install the clutch plates (9) in the following order:
on the drum (12):
- a series of ten driving discs (L) alternately to new driven discs (I) thickness 2 mm;
on the pressure plate (4):
- one driven disc (H), 2 mm thick;
- a driving disc (L).
12
12
H
L
Apply the prescribed grease to the thread of the gearbox primary shaft and the mating surface of nut (7), and fit it over Belleville
washer (8).
Lock the clutch drum using the appropriate tool and tighten the fixing nut (7) to the specified torque (Sec. 3 - 3, Engine torque
settings).
section
9 - 6.1 Engine
Insert the control pin (14) in the bearing (5) and the latter in the gearbox primary shaft.
14
5
Place the pressure plate (4) with two discs on the corresponding centring tool (T).
Fit the pressure plate (4).
T
4
Insert a spring (3) in each slot.

Position the O-ring (2).
Lubricate the thread of the screws (1) with oil.
Insert the screws (1).
section
9 - 6.1 Engine
1
1

Refit the clutch-side crankcase cover N 6.2, Refitting the clutch-side crankcase
cover
Top up the engine oil D 4, Changing the engine oil and filter car-
tridge
Refit the oil sump guard unit E 2, Refitting of the oil sump guard unit
1
section
9 - 6.2 Engine
6.2 - Clutch assembly: clutch-side crankcase cover
14 18 19 16
17 12
13 15
1
7 8 9 10 11
1
15
6
4
1 Clutch-side crankcase cover

2 Screw
3 Screw
4 Oil level sight glass
5 Screw
6 Plug
7 Bush
8 Sealing ring
9 Shim
10 Circlip
11 O-ring
12 Locating bush
13 O-ring
14 Plug
15 Sealing washer
16 Screw
17 Plug
18 Panel
19 Plate

1200 ABS CLUTCH-SIDE CRANKCASE COVER
1200 S ABS CLUTCH-SIDE CRANKCASE COVER
Important
section
9 - 6.2 Engine
Removal of the clutch-side crankcase cover
Drain the engine oil D 4, Changing the engine oil and filter cartridge
Unscrew the screw (7) placed at the bottom end of the clutch cover.
Unscrew the screws (2), (3) and (5) securing the clutch-side crankcase cover (1).
1
5
3
5
2
Tap around the edge of the cover with a plastic mallet to detach it from the crankcase half.
Remove the clutch cover (1) paying attention to the centring bushing (12).
Check the condition of the centring bushing (12) and replace if deformed.
12
section
9 - 6.2 Engine
Disassembly of the clutch-side crankcase cover
Remove the plug (14) and its O-ring (13), the plug (17) and its O-ring (15) from the cover.
13
17
15
14
Undo the fixing screw (16) of the inner cover (19).

Remove the inner cover (19) and sound-proofing panel (18).
Remove the circlip (10) and withdraw the shim (9) and the sealing ring (8).
The drilled bush (7) is mounted to the cover by a forced interference fit. Remove it using a suitable puller.
Inspect the sealing ring (8) and renew it if necessary.
16
18
10 8
9
19
section
9 - 6.2 Engine
Reassembly of the clutch-side crankcase cover
Fit the plug (14) and the gasket (13). Fit the plug (17) and the gasket (15).
13
17
15
14
If the bush has been replaced, fully seat the new bush (7) in the slot in the cover using a suitable drift and a press.
If the sealing ring (8) needs to be renewed, fit the new seal into the crankcase cover, positioning it so the side without a spring
is facing the circlip (10).
Before fitting, check that the edges of the circlip groove show no sign of burrs which might otherwise damage the sealing ring.
Then fit the shim (9) and the circlip (10).
Important
In order for the sealing ring (8) to function correctly, it must have an assembly clearance that allows the circlip (10) to rotate.
Position the sound-proofing panel (18) inside the clutch-side crankcase cover (1), aligning it with the pin (D) as shown in the figure.
Position the inner cover (19) on the panel (18), aligning it with the pin (D).
Position and tighten the fixing screw (16) to the specified torque (Sec. 3 - 3, Engine torque settings).
D
16
18
10 8
9
19
section
9 - 6.2 Engine
Refitting the clutch-side crankcase cover
Clean and degrease mating surfaces on the clutch-side crankcase half cover and crankcase and ensure that locating bush (12)
and the O-ring (11), located in correspondence with the oil way, are installed in the crankcase.
11
12
Apply an even, regular bead of DUCATI liquid gasket (A) on the mating surface of the crankcase half and around all holes.
Fit the cover assembly (1) to the crankcase half and insert the retaining screws. Lock the screws (2), (3) and (5) to the specified
torque (Sec. 3 - 3, Engine torque settings) in a crosswise pattern.
1
5
3
5
2

tridge
1
section
9 - 6.3 Engine
6.3 - Clutch assembly: primary drive gears
4
3
1 Clutch drum/Primary drive gears

2 Spacer
3 Threaded ringnut
4 Lock washer

1200 ABS CLUTCH
1200 ABS CONNECTING RODS
1200 S ABS CLUTCH
1200 S ABS CONNECTING RODS
Important
section
9 - 6.3 Engine
Removal of the primary drive gear
tridge
Remove the clutch-side crankcase cover N 6.2, Removal of the clutch-side crank-
case cover
Remove the clutch assembly N 6.1, Removal of the clutch
Withdraw the clutch housing (1) complete with driven gear of the primary pair (A).
Remove the inner spacer (2).

Remove the oil pump (C) (Sec. N 2.1, Removal of the oil pump).
Lock the primary pinion (B) with the holding tool 88713.2423 and unscrew the threaded ring nut (3) using the bushing
88713.2422.
88713.2423
88713.2422
section
9 - 6.3 Engine
Remove the nut (3) and lockwasher (4).
Remove the complete primary drive gear (B) using a commercial puller and placing a brass or aluminium pad between the end of
the crankshaft and the puller screw.
Remove the spacer (D).
section
9 - 6.3 Engine
Refitting the primary drive gears and checking backlash
Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear.
Position the spacer (D) onto the crankshaft.
Fit the driving gear (B) onto the crankshaft with the oil pump drive sprocket facing the crankcase.
Temporarily secure the gear with the washer (4) and nut (3).
Important
If fitting a new primary driving gear (B), check the backlash.
section
9 - 6.3 Engine
To check the clearance, temporarily fit the clutch bell (1) complete with the primary driven gear (A) on the gearbox primary shaft.
Fix a dial gauge to the engine crankcase, positioning the stylus against a gear tooth.
Turn the driven gear (A) to mesh the teeth and check that clearance ranges between 0.05 and 0.07 mm.
Repeat the check at 16 different points of the driven gear.
If the measured values are outside the permissible tolerance limits, try changing the position of driven gear (A) on the primary
shaft, leaving the driving gear (B) on the crankshaft. If the clearance is still outside the tolerance limits, replace the primary drive
gear pair (1).
A
After checking backlash, fit the bushing 88713.2422 on a torque wrench, lock the pinion (B) with the holding tool 88713.2423.
88713.2423
88713.2422
Position the washer (4) and the ring nut (3). With the appropriate tool (U), tighten the ring nut (3) to the specified torque (Sec. 3
- 3, Engine torque settings).
section
9 - 6.3 Engine
Refit the oil pump (C) and check the clearance between the oil pump gear and primary drive gear on the crankshaft (Sec. N 2.1,
Refitting the oil pump).
Thoroughly degrease the mating surfaces of the clutch bell (1).
Fit the spacer (2) onto the primary shaft. Fit the clutch housing (1) along with the driven gear (A).
2
C
section
9 - 6.3 Engine

Refit the complete clutch assembly N 6.1, Reassembling the clutch
Refit the clutch-side crankcase cover N 6.2, Removal of the clutch-side crank-
case cover
Refill the engine with oil D 4, Changing the engine oil and filter car-
tridge
1
section
9 - 7.1 Engine
7.1 - Gearbox assembly: gearchange mechanism
12 13 16 23 19 18
11
10
14 15 17 24
9 22 20
5
6
7
8
1
2
4
3
1 Return spring 13 Nut

2 Washer 14 Selector drum control fork
3 Banjo bolt 15 Gearchange lever pin
4 Gear pawl assembly 16 Shaft with gearchange lever arm
5 Interlock plunger holder 17 Gearchange lever arm return spring
7 Detent ball spring 19 Spacer
8 Ball 20 Screw
9 Circlip 21 Gearchange mechanism
10 Selector claw return spring 22 Locating ring
11 Shim 23 Stop plate
12 Ring 24 Shim

1200 ABS GEARCHANGE MECHANISM
1200 S ABS GEARCHANGE MECHANISM
Important
section
9 - 7.1 Engine
Removal of the gear selector lever

tridge
unit
Empty the coolant out of the cooling sys- D 4, Change the coolant
tem
sembly
Remove the water pump-radiator hose N 3.2, Removal of the cooling system hos-
es and unions
cover and flywheel-alternator assembly case cover
Unscrew and remove the fixing screws (18) and (20) of the complete gear selector lever (21) and collect the spacer (19).
Remove the gearchange mechanism complete with the shaft, spring, and stop plate.
21
18
20
19
21
section
9 - 7.1 Engine
Important
Visually inspect the gear selector claw (14) for wear, particularly around the area where it contacts the selector drum.
If it proves necessary to change components, disassemble the gear selector lever as shown in the exploded view.
Reassemble the gear selector lever orienting the eccentric pin (15), suitably lubricated, in such a way that the lever arm (16) is
positioned centrally with respect to the shoulders of the stop plate (23).
16
= =
23
Check that the spring (10) is installed correctly as shown in the figure.
Incorrect fitting Correct fitting
10 10
Tighten the nut (13) to the specified torque (Sec. 3 - 3, Engine torque settings).
A
13
16
14 15
23
section
9 - 7.1 Engine
Disassembly of gear interlock plunger and pawl assembly

tridge
Remove the clutch-side crankcase cov- 9 - 6.2, Removal of the clutch-side crankcase
er cover
Remove the clutch assembly 9 - 6.1, Removal of the clutch
Remove the primary gear 9 - 6.3, Removal of the primary drive gear
Unscrew the interlock plunger screw (5) and remove the seal (6), spring (7) and the detent ball (8).
Unscrew the clutch-side crankcase half screw (3) and remove the pawl (4), washer (2) and spring (1).
4 3
1
3
2
4
section
9 - 7.1 Engine
Refitting the gear interlock plunger and pawl assembly
On the special screw (3), fit the gear pawl lever (4), orienting it as shown in the figure, the washer (2) with the square edge side
(D) facing the clutch-side crankcase half, and the spring (1), positioning it so that the hook end (A) is facing the gear pawl lever.
Locate the hook end (A) of the spring on the gear pawl lever as shown in the figure.
Apply threadlocker to the screw thread. Start the screw in the crankcase half. Position end (B) of the spring so that it rests against
rib (C) of the crankcase half, as shown in the figure. Tighten the screw (3) to the specified torque (Sec. 3 - 3, Engine torque set-
tings). Manually move the gear stopper to check for proper spring operation.
2
LOCK
3
1
4
2
2
LOCK
1
D B
A
B
C
section
9 - 7.1 Engine
Grease and then fit the ball (8), spring (7), and seal (6) to the gear interlock plunger (5).
Tighten the pin to the specified torque (Sec. 3 - 3, Engine torque settings).
A
8

Refit the primary gear 9 - 6.3, Refitting the primary drive gears and
checking backlash
Refit the complete clutch assembly 9 - 6.1, Reassembling the clutch
cover
tridge
section
9 - 7.1 Engine
Refitting the gear selector lever
Position the gearbox drum selector fork in the centre of the gear rollers.
Position the gear selector lever (21) together with control shaft, spring and plate into the chain-side crankcase half.
21
Insert the screws (18) and (20) with the spacer (19).
Temporarily fit gear change lever (or a service lever) and engine pinion and shift to neutral gear.
21
18
20
19
Place the tool 88713.3334 on the gear claw.
88713.3334
section
9 - 7.1 Engine
Place the tool 88713.3334 inserting the clutch rod (E) into the tool hole, block the pin (F) of the tool in the gear claw pressing with
the hand in the point (G) (claw stroke lock plate) towards the right, as shown in photo.
G F
Then tighten the gear selector lever fixing screw (18) and (20) (Sec. 3 - 3, Engine torque settings).
Warning
Make sure that the gear selector lever fixing screws (18) and (20) are those indicated in our spare parts catalogue. They must be
screws of class 12.9 in order to respect the tightening torque indicated in Sec. 3 - 3, Engine torque settings.
Start tightening the first screw (18), and continue with screw (20).
18
20
section
9 - 7.1 Engine
18
20
Remove service tool no.

Check that the pin (H) placed on the gear drum is axially to the notch (L) on the gear claw (with gear in neutral).
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 the flywheel/alternator assembly. N 8, Refitting the flywheel-alternator as-
and alternator side crankcase cover sembly
Refit the water pump-radiator hose N 3.2, Refitting the cooling system hoses
and unions
tridge
Refit the oil sump guard unit E 2, Refitting the of oil sump guard unit
1
section
9 - 7.2 Engine
7.2 - Gearbox assembly: gearbox shafts
Primary shaft
Secondary shaft 2
7
6
5
4
3
23
11 7
10 6
7 22
1 6 4
4 12
9 4
30 27 6 21
7 6
28 8 7 26
13 20
32 19 25
30 18 3
14 15 17 4
29
31 24
6
7
1 Shim, thickness 1
2 Gearbox primary shaft
3 Shim, thickness 0.5
4 Needle roller bearing
5 5th speed driving gear
6 Splined washer, thickness 0.5
7 Circlip
8 3rd- 4th speed driving gear
9 6th speed driving gear
10 2nd speed driving gear
11 Shim, thickness 1.8
12 Splined washer, thickness 0.5
13 Special needle roller (square cross-section)
14 Selector drum
15 Shim
16 Selector drum assembly
18 1st speed driven gear
19 Shim, thickness 1
20 5th speed driven gear
22 3rd speed driven gear
24 2nd speed driven gear
25 Gearbox secondary shaft
26 Shim
section
9 - 7.2 Engine
28 1st, 4th- 2nd, 3rd speed selector fork
29 5th, 6th speed selector fork
30 Selector fork shaft
32 Needle roller retaining circlip (square cross-section)

1200 ABS GEARCHANGE MECHANISM
1200 ABS GEARBOX
1200 S ABS GEARCHANGE MECHANISM
1200 S ABS GEARBOX
Important
section
9 - 7.2 Engine
Removal of the gearbox assembly

Remove the engine from the frame 9 - 1, Removal of the engine
Remove the timing components 9 - 4.2, Removal of the timing belt covers
Remove the timing shaft unit 9 - 4.4, Removal of the camshafts
Remove the complete cylinder head unit 9 - 4.5, Removal of the cylinder heads
Remove the cylinder barrel/piston assem- 9 - 5, Removal of the cylinder/piston as-
blies sembly
Remove the alternator-side crankcase 9 - 8, Removal of the alternator-side crank-
cover and the alternator assembly case cover
Remove the oil pump 9 - 2.1, Removal of the oil pump
Remove the starter motor P 3, Starter motor
Remove the clutch cover, drum and bell 9 - 6.1, Removal of the clutch
case cover
Separate the crankcase halves 9 - 9.2, Separation of the crankcase halves
Withdraw the selector fork shafts (30).

Move the forks (28) and (29) to disengage them from the slots in the selector drum (34).
30
28
29
Withdraw the selector drum (16) taking care not to lose shims (31) and (27) mounted on the shaft. Note that the positions of the
shims must not be inverted.
31
16 27
29
section
9 - 7.2 Engine
Once removed, it is possible to replace the special rollers (13).
13
Remove gear selector forks (29) and (28).
29
28
section
9 - 7.2 Engine
Remove the gearbox primary (2) and secondary (25) shafts complete with gears, taking care to recover the spacers 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 (2) and secondary (25) shafts
(Sec. N 9.2, Separation of the crankcase halves).
25
2
A
A
25
section
9 - 7.2 Engine
Disassembly of the gearbox shafts
Place the shaft in a vice in such a way as to facilitate the disassembly operations.
Important
Take care not to invert the positions of the shims on reassembly:
this would potentially lead to jamming when using the gear selector control, making it necessary to reopen the engine crankcase.
Disassembly of the gearbox secondary shaft

Remove the chain-side shim washer (26) and clutch-side shim washer (15) from the secondary shaft.
15
Withdraw the first speed driven gear (18) with the roller cage (17) and the shim (19).
18
17
section
9 - 7.2 Engine
19
Remove the fifth speed driven gear (20).
20
Use two flat blade screwdrivers to remove the circlip (7) taking care not to damage the shaft surface.
Remove the circlip (7) and the splined washer (6).
section
9 - 7.2 Engine
Withdraw the fourth speed driven gear (21) with the roller cage (4) and splined washer (12).
4
21
12
Remove the third speed driven gear (22) with the roller cage (4) and the splined washer (6).
4
22
section
9 - 7.2 Engine
Remove the circlip (7) and remove the sixth speed driven gear (23).
23
Remove the circlip (7) and withdraw the splined washer (6) and the second speed driven gear (24).
section
9 - 7.2 Engine
24
Withdraw the roller cage (4) and the shim (3). All the components have thus been removed from gearbox secondary shaft (25).
25 3 4
25
Disassembly of the gearbox primary shaft

Remove the chain-side shim washer (11) and the clutch-side shim washer (1) from the primary shaft.
11
section
9 - 7.2 Engine
Remove the second speed driving gear (10). Use two screwdrivers to prise out the circlip (7) and the splined washer (6).
Important
Take care to avoid damaging the surface of the shaft while removing circlip (7).
10
section
9 - 7.2 Engine
Remove the sixth speed driving gear (9) with its roller cage (4). Remove the splined washer (6) and the circlip (7).
9
4
Withdraw the third and fourth speed driving gear (8).
section
9 - 7.2 Engine
Remove the circlip (7) and the splined washer (6).
Remove the fifth speed driving gear (5) with the roller cage (4).
section
9 - 7.2 Engine
Slide the shim (3) off the primary shaft (2).
2
3
section
9 - 7.2 Engine
Overhaul of 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 - desmo-
dromic drum groove) due to incorrect end float. Restore the correct endfloat by shimming the gearbox shafts and the selector
drum with suitable shims.
For the total gearbox shaft and selector drum end clearance values, refer to Sec. C 1.1, Gearbox.
section
9 - 7.2 Engine
Inspection of the gear selector forks
Visually inspect the gear selector forks. Bent forks must be renewed 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 (Sec. C 1.1Gearbox).
section
9 - 7.2 Engine
Inspection of the gear selector drum
Use a gauge to measure the clearance between fork pin and the slot on the selector drum.
If the service limit is exceeded, determine which part must be replaced by comparing these dimensions with those of new com-
ponents (Sec. C 1.1, Gearbox).
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.
section
9 - 7.2 Engine
Reassembly of the gearbox shafts
Figure 1 shows all the parts to be reassembled on the gearbox primary shaft (2), with the calculated end shims (1) and (11)
(Sec. N 9.2, Reassembly of the crankcase halves).
Fig. 1
11
Figure 2 shows all the parts to be installed on the gearbox secondary shaft (25), with calculated end shims (15) and (26)
(Sec. N 9.2, Reassembly of the crankcase halves).
Fig. 2
15
25
26
section
9 - 7.2 Engine
Reassemble the gears on the gearbox shafts by reversing the disassembly procedure.
Take particular care when installing the idler gears. The assembly of the 3rd and 4th speed gears and the relative fixing compo-
nents on the secondary shaft is given as an example.
Fit the circlip (7), checking that it is fully inserted into its groove on the shaft. Push the circlip into position with a suitable size
tubular drift.
Slide the washer with three internal points (6) over the shaft until it locates against the circlip you have just fitted.
To fit the needle roller cage (4) onto the shaft, first lubricate it with plenty of grease (of recommended type) and then open it
slightly to make it easier to slide on to the shaft.
Fit the 3rd speed gear (22).
4
22
section
9 - 7.2 Engine
Fit on the gear the three-pointed washer (12), which can be distinguished from its counterpart (6) by its bigger outside diameter.
12
Fit another needle roller cage (4) using the method already described.
Fit the 4th speed gear (21).
4
21
section
9 - 7.2 Engine
Fit another safety washer (6) and another circlip (7) into the shaft. Push it inside its seat using the previously used pad.
section
9 - 7.2 Engine
Reassembly of the gearbox
To refit the gearbox components follow the procedure under Sec. N 9.2, Reassembly of the crankcase halves, relating to reas-
sembly of the engine 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.
C D B C
A A
= =

Reassemble the engine crankcase 9 - 9.2, Reassembly of the crankcase halves
halves
checking backlash
cover
Refit the clutch cover, drum and bell 9 - 6.1, Reassembling the clutch
Refit the starter motor P 3, Starter motor
Refit the oil pump 9 - 2.1, Refitting the oil pump
Refit the alternator-side crankcase cover 9 - 8, Refitting the flywheel-alternator as-
and alternator assembly sembly
Refit the cylinder barrel/piston assem- 9 - 5, Refitting the cylinder/piston assembly
blies
Refit the complete cylinder head unit 9 - 4.5, Reassembly of the cylinder head
Refit the timing shaft unit 9 - 4.4, Refitting the camshafts
Refit the timing components 9 - 4.2, Refitting the cylinder heads pulleys/
fixed tensioners
Refit the engine to the frame 9 - 1, Refitting the engine
1
section
9-8 Engine
8 - Flywheel - alternator
18 20 21 19 23
22 14 17
16 15
10 9
3
8
2
12 1
6 7
30
5
29
23 28 27 4
25 33 11
24
2
26 32 31 30 34 13
1 Screw
2 Cylinder coolant inlet union
3 Ignition inspection plug
4 Sealing ring
5 O-ring
6 Cover
7 Screw
8 Aluminium gasket
9 Plug
10 Aluminium gasket
11 Screw
12 Screw
13 Screw
14 Flange
15 Flanged nut
16 Belleville washer
17 Flywheel
18 Washer
19 Inner ring
21 Electric starter driven gear
22 Starter clutch
23 Flywheel-starter clutch assembly
24 Alternator rotor
25 Screw
26 Screw
27 Bearing
28 Circlip
29 Alternator-side crankcase cover
30 Locating bush
section
9-8 Engine
31 Bracket
32 Screw
33 Alternator stator
34 Screw

1200 ABS WATER PUMP-ALTR-SIDE CRANKCASE COVER
1200 ABS ELECTRIC STARTING AND IGNITION
1200 S ABS WATER PUMP-ALTR-SIDE CRANKCASE COVER
1200 S ABS ELECTRIC STARTING AND IGNITION
Important
section
9-8 Engine
Removal of the alternator-side crankcase cover

tridge
unit
sembly
Remove the water pump-radiator hose N 3.3, Removal of the water pump
Note
This operation is described for an engine removed from the frame since all reassembly procedures are easier with the engine on
the bench.
Disconnect the alternator cable connector from the main wiring (A).
Unscrew the two retaining screws (7) of the centre cap (6) over the end of the crankshaft.
section
9-8 Engine
Unscrew the screws (1), (11), (12) and (13) securing the alternator-side crankcase cover (29).
11
11 1
13
12
11
29 11 34
11
11
Fit the tool 88713.1749 to the holes of the screws (7) that have just been removed.
Turn the tool shaft slowly to separate the cover (29) from the LH crankcase half.
88713.1749
29
There is a sealing ring (4) on the cover (29) in correspondence with the gearchange shaft that may be damaged when removing
the alternator cover.
Always check the condition of this sealing ring and renew it if damaged.
29 4
section
9-8 Engine
Disassembly of the alternator-side crankcase cover
Undo the three stator retaining screws (25) and the retaining screws (32) of the two cable guide brackets (31) from inside the
crankcase cover.
Remove the stator (33) and the cable guide (31).
25
32
31
33
The alternator-side crankcase cover is fitted with a bearing (27), held in place by circlip (28), which locates on the end of the crank-
shaft.
Remove the circlip (28) with circlip pliers.
Remove the bearing (27) using a universal puller.
Be careful when fitting the new bearing (27) to ensure it is positioned with the shielded side facing away from the cover.
Secure the bearing with the circlip (28), ensuring that it is correctly fitted in its seat in the crankcase cover (29).
29 28 27
Unscrew the horizontal and vertical cylinder coolant inlet unions (2).
When fitting the new components, apply prescribe threadlocker and tighten to the specified torque (Sec. 3 - 3, Engine torque
settings).
Important
The unions (2) may also be removed without removing the alternator-side crankcase cover (29) from the engine.
Refit the water pump components (B) as described in Sec. N 3.3, Removal of the water pump).
2 B
29
6
LOCK
section
9-8 Engine
Removing the flywheel - generator assembly
Use the tool 88713.2874 fixed to the M10 sidestand fixing holes (D).
Secure the tool to the flywheel with the screw (E).
Unscrew the alternator-flywheel retaining nut (15).
Warning
While unscrewing the nut, apply axial pressure to the socket to avoid damage or injury in the event of the wrench suddenly slip-
ping off the nut.
15
E
88713.2874
Remove the nut (15), the Belleville washer (16) and the flywheel assembly (23) with the driven gear (21) from the crankshaft.
15
16
23 21
section
9-8 Engine
Remove the inner race (19), the needle roller bearing (20) and the washer (18).
Important
Check the race (19), the needle roller bearing (20) and the inner washer (18) for wear. Renew if worn.
18
19 20
section
9-8 Engine
Overhaul of the flywheel-alternator assembly
Examine the inner part of alternator rotor (24) for signs of damage.
Check that the starter clutch is working properly and that the needle races do not show signs of wear or damage of any kind.
If there is any malfunction, remove the whole assembly.
24
Disassembling the generator flywheel

Unscrew the 8 screws (26) and remove the rotor (24) from the flywheel.
26
24
Insert two of the screws (26) just removed from the flywheel rotor-side in their holes in order to remove the flange (14) and the
starter clutch (22) from the flywheel (17). The starter clutch is a slight interference fit on the flange. To remove it, use a suitable
drift.
26
26
17
22
17 14
section
9-8 Engine
Reassembling the flywheel - generator assembly
Install the starter clutch (22) in the flange (14) to bring the edge (A) of the clutch up against the flange.
Important
Assemble the components (starter clutch and flange) so that the edge (A) of the starter clutch is positioned on side of the flange
with the bevelled edge (B).
22
14
14 22
B A
section
9-8 Engine
Seat the flange (14) with the starter clutch (22) in the flywheel (17), aligning the flange locating hole (C) with the flywheel locating
hole (D).
Note
The flange locating hole (C) is the hole with the countersunk lead-in (E).
Note
The locating hole (D) of the flywheel can be either one of the two holes (F).
Note
Use suitable tools to align the locating holes.
C
22
14
D
17
section
9-8 Engine
Important
Assemble the components (flange and flywheel) so that edge (A) of the starter clutch (22) is enclosed between the flange and
flywheel.
22
Install the rotor (24) on the flywheel (17), aligning one of the flywheel locating holes (D) with the rotor locating hole (G).
Note
The rotor locating hole (G) is the hole positioned on the same diameter as the fixing holes (H).
Note
Use suitable tools to align the locating holes.
Apply threadlocker to the rotor-flywheel fixing screws (26) and start them in their threads.
section
9-8 Engine
26
24
5
LOCK
17
Tighten the screws (26) to the specified torque (Sec. 3 - 3, Engine torque settings), observing the indicated sequence.
26
1
5 8
26 3 4
7 6
2
26
Lubricate the surface (L) of the driven gear (21) with engine oil.
Install the driven gear on the starter clutch, ensuring it is properly seated.
Note
To facilitate installation, rotate the driven gear in the direction of the green arrow.
section
9-8 Engine
Hold the flywheel (17) with one hand and check that the driven gear 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 has not been installed correctly.
21
17
17
section
9-8 Engine
Refitting the flywheel-alternator assembly
Fit the roller cage unit (20) with washer (18) and internal ring (19), applying prescribed grease on the washer (18).
18
20
19
Install the roller cage assembly (20) with the washer (18) and inner race (19).
18
19 20
Install the flywheel assembly (23) with the gear (21), aligning the notches as shown in the photo.
21
23
Fit the Belleville washer (16) on the end of the crankshaft.
Warning
The Belleville washer is tapered: position it as shown in the photo.
16
section
9-8 Engine
Apply the recommended threadlocker to the thread on the end of the crankshaft and the nut (15).
Start the nut (15) on the crankshaft.
Hold the flywheel with the tool 88713.2874 to prevent rotation, and tighten the nut (15) to the specified torque (Sec. 3 - 3, Engine
torque settings).
5
15 LOCK
88713.2874
section
9-8 Engine
Refitting the alternator-side crankcase cover
Make sure that the following parts are installed in the alternator-side crankcase cover (29) before refitting it:
- crankshaft end bearing (27) with its circlip;
- the alternator stator (33) with the cable clamp (31).
Install the water pump unit (Sec. N 3.3, Refitting the water pump).
27 29
31
33
Remove any scale and grease from the mating surfaces of the left-hand crankcase half and the crankcase half cover.
Fit the two locating bushes (30).
Spread a continuous uniform bead of DUCATI liquid gasket on the cover mating surface, ensuring continuity around the holes for
the retaining screws and bushes.
30
30
Grease the end of the crankshaft and the gearchange shaft to facilitate installation of the cover and to prevent the sealing ring (4)
from being damaged, if already installed in the cover.
While positioning the cover (29) on the crankcase half, slightly turn the timing belt drive shaft pulleys to facilitate insertion of the
pump control shaft.
29 4
section
9-8 Engine
The notch (M) on the alternator cover must be inserted on the starter motor gear pin (P).
Tap the cover at different positions with a rubber mallet to facilitate its location on the shafts and locating bushes.
Note
Should it be necessary to remove the cover again, fit the puller 88713.1749 located in the threaded holes in correspondence with
the crankshaft.
section
9-8 Engine
Insert the fixing screws in their holes following the indications given in the table.
Ref Qty Description

11 8 M6x25 mm screws
1 1 M6x30 mm screws
34 1 M6x25 mm banjo bolt
13 1 M6x30 mm banjo bolt
Tighten the fixing screws to the specified torque (Sec. 3 - 3, Engine torque settings).
11
11 1
13
12
11
29 11 34
11
11
Damp the sealing ring (4) with alcohol and install it in the alternator-side crankcase cover (29), in correspondence with the gearch-
ange shaft.
29 4
section
9-8 Engine
Make sure that the O-ring (5) is installed in the cover (6).
Apply threadlocker to the screws (7).
Tighten the two fixing screws (7) of the cover (6) matching the crankshaft to the specified torque (Sec. 3 - 3, Engine torque set-
tings).
Reconnect the alternator wiring to the main wiring loom (A).

Refit the water pump-radiator hose N 3.3, Refitting the water pump
Fit the clutch pushrod F 2, Refitting the clutch transmission unit
tridge
section
9 - 9.1 Engine
9.1 - Crankcase assembly: external components
A
12 11
27 13
17
22 25 B
16 14
1
5 26
23
C
2
18 21
28 15
20 19
D
6
E
9
10 F
7
6 24 3 8
G
1 Oil breather valve
2 O-ring
3 Sealing washer
4 Neutral switch H
5 Cylinder barrel/head stud
6 Nipple
7 By-pass spring
8 Plug
9 Plug
10 Aluminium gasket L
11 Nut
12 Lock washer
13 Timing gear pair
14 Key
15
16
Key
O-ring
M
17 Screw
18 Locating dowel
19 Starter idler gear
20 Washer
21
22
Gear shaft
O-ring
N
23 Engine sensor
24 Grub screw
25 Screw
26 Washer
27 Locating dowel P
28 O-ring
section
9 - 9.1 Engine
A Spare parts catalogue

1200 ABS GEARCHANGE CONTROL
B 1200 ABS ELECTRIC STARTING AND IGNITION
1200 S ABS GEARCHANGE CONTROL
C 1200 S ABS ELECTRIC STARTING AND IGNITION
Important
D
section
9 - 9.1 Engine
Removing outer components
Operation Section reference A
Remove the complete cylinder head unit 9 - 4.5, Removal of the cylinder heads B
blies sembly
cover and the alternator assembly case cover C
case cover
D
Remove the mesh filter D 4, Changing the engine oil and filter car-
tridge
E
Unscrew the screw (17) and remove the oil breather valve (1) with the O-rings (2). Check the condition of O-rings (2) and renew
them if necessary.
G
17
1
H
2 1
section
9 - 9.1 Engine
Unscrew and remove the oil filter support nipple (6) and remove also by-pass spring (7).
A 6
7
C
Remove the mesh filter (A) from the clutch crankcase half (Sec. D 4, Change the coolant).
E
A
F Remove the drain plug (10) with its seal (9).
10
G
H 9
Remove the neutral switch (4).

L
M
4
section
9 - 9.1 Engine
Remove the cylinder head studs (5) with the aid of the appropriate tool.
5
A
5
5 B
5 C
E
5
To remove the engine sensor (23), unscrew the screw (25) and recover the washer (26).
F
25
G
23
26
H
Check the condition of O-rings (22) and renew them if necessary.
M
22
section
9 - 9.1 Engine
Refitting the external components
A Make sure that the O-rings (22) are fitted on the crankcase.
22
Fit the engine pickup (23) in its seat in the crankcase half.
Insert the screw (25) with the washer (26) and tighten to the specified torque (Sec. 3 - 3, Engine torque settings).
D
23 25
E
26
F
Use a feeler gauge to check the clearance between the engine sensor (23) and the timing gear (13). The value must be between
0.6 and 0.8 mm.
G
23
H
13
section
9 - 9.1 Engine
Check the condition of O-rings (2) and renew if necessary.
Install the oil vapour breather valve (1) in the crankcase along with O-rings (2), previously lubricated.
Tighten the screw (17) to the specified torque (Sec. 3 - 3, Engine torque settings). A
17
C
2
1
E
Position the by-pass spring (7) on the nipple (6) and apply the recommended threadlocker to the end of the nipple to be screwed F
in the crankcase half. Screw oil filter cartridge fitting (6) fully into the crankcase half, positioning the spring in the seat between
the two notches (A). Tighten the nipple to the specified torque (Sec. 3 - 3, Engine torque settings).
6 A
7
G
H
A
2
LOCK
section
9 - 9.1 Engine
Fit the seal (9) on the oil drain plug (10). Position the seal that the side with the square edge (B) is facing the chain side crankcase
half.
A Clean the plug thread, apply a string of THREE BOND TB1215 along the plug thread spreading it by the entire circumference
(360°).
Tighten the exhaust plug (10) with the corresponding gasket (9) to the specified torque (Sec. 3 - 3, Engine torque settings).
Note
B After tightening, remove any excess sealant.
B
10
C
D 9
Refit the neutral switch (4).
F
4
G
Refit the mesh filter (A) (Sec. D 4, Changing the engine oil and filter cartridge).
L
A
section
9 - 9.1 Engine
Check the condition of O-rings (16) of the stud bolts (5) and replace them if necessary.
Fit, using the tool (C), the O-rings (16) in the corresponding seats (D) of the stud bolts (5).
A
D
16 5
88713.1920
B
C
Now fit the stud bolts (5) in the crankcase halves, applying threadlocker on the threads and tightening to the specified torque
E
(Sec. C 3 - 3, Engine torque settings). Use the appropriate commercial tool for this operation.
2
LOCK 5
F
section
9 - 9.1 Engine
If removed, apply prescribed threadlocker on the dowel (24), tighten the dowel to the specified torque (Sec. 3 - 3, Engine torque
settings), insert the gasket (3) on the service plug (8): the seal must be oriented so that the square edge faces the clutch-side
A crankcase half. Apply prescribed threadlocker on the plug thread (8), insert it in the crankcase half and tighten to the specified
torque (Sec. 3 - 3, Engine torque settings).
3
B
C 24 8
5
E LOCK

Refit the mesh filter D 4, Changing the engine oil and filter car-
F tridge
checking backlash
G Refit the complete clutch assembly 9 - 6.1, Reassembling the clutch
cover
Refit the starter motor 9 - 3, Starter motor
H Refit the alternator-side crankcase cover 9 - 8, Refitting the flywheel-alternator as-
blies
L Refit the complete cylinder head unit 9 - 4.5, Reassembly of the cylinder head
fixed tensioners
M Refit the engine to the frame 9 - 1, Refitting the engine
section
9 - 9.1 Engine
Removal of the timing gears
A
Remove the oil sump guard unit E 2, Removal of the oil sump guard unit
tridge B
unit
Empty the coolant out of the cooling sys-
tem
D 4, Change the coolant
C
sembly
es and unions D
cover and flywheel/alternator assembly case cover
Slide out driving gear (A) of timing gear pair (13) and remove the Woodruff key (14).
E
13
A
F
14 H
section
9 - 9.1 Engine
Relieve the staking on the lock washer (12) of the nut (11).
Restrain the driven timing gear by inserting a pin in one of the holes, and unscrew the nut (11).
A Remove the nut (11), washer (12), driven timing gear (B) and Woodruff key (15) from the timing belt driveshaft shaft.
11
B
C 12
B
D
15
section
9 - 9.1 Engine
Refitting the timing gears
Before reassembling the removed parts, check timing gears (13) for wear. Change, if necessary.
A
Important
The timing gears (13) must always be renewed as a pair.

B
Warning
When introducing the driven gear (B) check that the tongue (15) is correctly fitted on the timing system shaft, align the gear slot
with the tongue matching the driving gear timing mark (A) with the gear (B).
C
15 A
13
F
A
Important H
On completion of the refitting operations, check that tab washer (12) is staked against nut (11) in such a way as to prevent the
nut from working loose.
L
11
M
12
B
N
section
9 - 9.1 Engine
A Operation Section reference

Refit the water pump-radiator hose N 3.2, Refitting the cooling system hoses
and unions
B Refit the pump-cylinder hoses N 5, Refitting the cylinder/piston assembly
C
tridge
section
9 - 9.1 Engine
Removal of the starter motor idler gear
A
Remove the oil sump guard unit E 2, Removal of the oil sump guard unit
tridge B
unit
Empty the coolant out of the cooling sys-
tem
D 4, Change the coolant
C
sembly
es and unions D
cover and flywheel/alternator assembly case cover
Slide the gear pin (21) complete with the gear (19) and washer (20).
E
Warning
Pay attention to the washer (20) since it may fall inside the crankcase half.
20
F
G
19
21
H
21
19
20 M
At this point, it is possible to remove the starter motor as described in Sec. P 3, Starter motor.
section
9 - 9.1 Engine
Refitting the starter motor gear
A Position the washer (20) and the gear (19) in the pin (21) and take the pin into contact with the crankcase half.
21
19
C 20
D 19
E 20 21
F
G Refit the water pump-radiator hose N 3.2, Refitting the cooling system hoses
and unions
H Refit the clutch control piston F 2, Refitting the clutch transmission unit
tridge
L Refit the oil sump guard unit E 2, Refitting the of oil sump guard unit
1
section
9 - 9.2 Engine
9.2 - Crankcase assembly: crankcase halves
3 33 34
32
8
9
11 10
6
7
13 4
5
31
22 14 15 39
16 2
26
1
30
34 33 32 29
23 12
22 38
28 25 FLANGED
BEARING
21 20
24
FLANGED 19
BEARING 35
17 37
36
18 12 27
1 Bearing
2 Bearing holder bushing
3 Alternator-side crankcase half
4 Bearing
5 Circlip
6 Washer
7 Bearing
8 Sealing ring
9 Bearing
10 Retaining plate
11 Screw
12 Screw
13 Clutch-side crankcase half
14 Sealing ring
15 Bearing
16 Circlip
17 Bearing holder bushing
18 Bearing
19 Plug
20 Screw
21 Spacer
22 Bush
23 Bearing
24 Screw
25 Screw
26 Grub screw
27 Screw
28 Screw
29 Circlip
section
9 - 9.2 Engine
30 Timing belt driveshaft
31 O-ring
32 O-ring
33 Hose
34 Screw
35 Grub screw
36 Screw
37 Sealing washer
38 Vibration damper
39 Screw

Important
section
9 - 9.2 Engine
Separation of the crankcase halves

blies sembly
case cover
tridge
Use two screwdrivers to remove the circlip (29) from the timing belt driveshaft shaft (30) on the clutch-side crankcase half.
Note
Take care to avoid scoring the surface of the shaft while removing the circlip.
Unscrew the crankcase half screws on the chain side.
30
29
section
9 - 9.2 Engine
Unscrew the two screws (12) on the clutch side near the vertical cylinder.
12 12
Re-use the alternator cover or a service cover with puller 88713.1749 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 shims on the shafts and on the selector drum.
88713.1749
Remove gearbox shafts and gearbox selector drum from the crankcase halves (Sec. N 7.2, Removal of the gearbox assembly.
Drive out the crankshaft (L) using a plastic mallet, taking care not to lose the shims.
section
9 - 9.2 Engine
Remove the timing belt driveshaft (30).
30
Remove the screws (34), remove the pipes (33) and collect the O-rings (32).
34
33
section
9 - 9.2 Engine
Overhaul of the crankcase halves
Carefully examine the engine crankcase halves.
Check that the surfaces of the crankcase halves are perfectly flat using a reference surface.
Check that the bearings (1) and (18), and the bushings (2) and (17) are in optimum conditions. Note that the main bearings must
always be changed in pairs (refer to the procedure below in “Main bearings”).
18
17
Note
When overhauling an engine it is good practice to renew all the crankcase half bearings.
After having renewed the gearbox shaft bearings (28) and (9), secure them in the crankcase half with the spacers (21) and the
retaining plate (10).
21
21 28
10
section
9 - 9.2 Engine
At each overhaul it is recommended to renew also the sealing ring (8) on the outside of bearing (9).
Renew the bearings (7) and (23) on the ends of the gearbox shafts and timing belt driveshaft bearings (4) and (15).
15
23
Take care not to lose the shim (6) interposed between the bearing (7) on the end of the gearbox primary shaft and the chain side
crankcase half.
section
9 - 9.2 Engine
The sealing ring (14) on the external side of the roller bearing (15) must be renewed at each engine overhaul.
14
Check that the oilways are free of restrictions or clogging. Check the condition of locating bushes (22). If apparently distorted or
loose in their seats, change them using proper tools. When the locating bushes (22) are hard to remove from casing, use a left-
hand tap to force bushes out.
Important
The bushes (22) must always be renewed when they have been removed using the above procedure.
22
22
Remove the bearing (23), the circlip (5) and the roller bearing (4).
23
5
4
section
9 - 9.2 Engine
Main bearings
The main bearings have are of the angular contact type with offset inner races so that the balls transmit loads from one groove
to the other along straight lines at an angle to the axis of the bearing. The angle-contact ball bearings are designed for bearing
combined loading (radial-axial loads).
Bearings of this type can bear thrust loads in one direction only. In fact, under the action of a radial load inside the bearing,
an axial force is created that must be counterbalanced by an axial force acting in the opposite direction; that is why these
bearings are generally fitted back to back in pairs.
Note
The main bearings supplied can be bearings with bushing (A) or flanged bearings (B) with the bushing integrated in the external
ring of the bearing.
To renew the bearings proceed as follows:

- heat the crankcase in an oven to 100 °C;
- remove the bearing using a drift and hammer;
- install the new bearing (while the crankcase is still hot) keeping it perfectly square in its seat using a tubular drift that only bears
on the outer ring of the bearing;
- allow the parts to cool and check that the bearing is securely seated in the crankcase half.
Crankcase half contact surface
A A
section
9 - 9.2 Engine
B B
Bearings with bushing
Important
On worn engines, the bearing holder may no longer be a tight fit in the crankcase half.
After having removed the bushing, check that the interference fit between the crankcase and the bushing, with bearing fitted, is
no less than 0.03 mm, otherwise, replace the crankcase halves.
Note
Fit the bearings (1) and (18) orienting them so that the side with the “letter” (C) is facing the bushings (2) and (17).
18 1
2
C
17
section
9 - 9.2 Engine
Flanged bearings
Important
On badly worn engines, bearing outer rings may have developed clearance in the crankcase halves - normally, bearing outer rings
are interference-fit in the casing.
Check that the interference fit between the crankcase and the bearings (1) and (18) installed, is not less than 0.03 mm, otherwise,
replace the crankcase halves.
18
Important
After installing new main bearings, shim the crankshaft as described in the paragraph “Shimming the shafts” and “Reassembly
of the crankcase halves“ of this section.
section
9 - 9.2 Engine
Reassembly of 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.
Overhauling the alternator-side crankcase half

The following parts must be present on the internal side of the crankcase half:
- gearbox secondary shaft bearing (23): apply grease to the bearing rollers. Fit the inner race (A) removed previously from the
bearing. Apply grease to the inner ring;
- the primary shaft bearing (28), secured with screws (20) and retaining spacer (21): apply prescribed threadlocker to the screws
(20) and tighten to the specified torque (Sec. 3 - 3, Engine torque settings);
- the main bearing (18) with the corresponding bushing (17) (if present).
C
18
A
17
23
28 20
21
20 21
2
LOCK
The roller bearing (15) with retaining circlip (16) installed in correspondence with the end of the timing belt driveshaft.
Insert the seeger (5) in the crankcase half installing it in its seat on the bearing (4).
16
15
section
9 - 9.2 Engine
Refitting the alternator-side crankcase half
The following parts must be present on the internal side of the crankcase half:
the double race ball bearing (9) supporting the selector fork shaft. Apply threadlocker to the screws (11). Fit the retaining plate
(10) to the gearbox secondary shaft bearing (9) screwing the screws fully into the chain-side crankcase half (11).
Note
The bearing retaining plate must be positioned so that the countersunk side is facing upwards.
9
11
11 10
2
LOCK
The primary shaft bearing (7) with internal spacer (6), oriented so that the closed side of the plastic roller cage (M) faces the crank-
case half. apply grease to the bearing rollers. Fit the inner race (A) removed previously from the bearing. Apply grease to the inner
race.
The main bearing (1) with the corresponding bushing (2) (if present).
A
M
1
2 C
section
9 - 9.2 Engine
The bearing (4) with the retaining circlip (5) installed in correspondence with the timing belt driveshaft.
Insert the seeger (5) in the crankcase half installing it in its seat on the bearing (4).
Note
Bearings do not have a specific mounting position (except main bearings); however it is good practice to install the bearings so
that side bearing the writing is facing upwards.
Fit the mesh filter as described in Sec. D 4, Changing the engine oil and filter cartridge.
Important
To avoid damaging the filter, insert it by hand only. Do not use hammers or other metal tools.
Above the mesh filter seat there is a plug (19) which closes off the lubrication oilway. If it is to be renewed, apply the prescribed
threadlocker to its threads.
Tighten the screws and the plug to the specified torque (Sec. 3 - 3, Engine torque settings).
19
5
LOCK
section
9 - 9.2 Engine
Shimming the shafts
Before assembling the crankcase halves, calculate the shims required to obtain the correct endfloat of the crankshaft and gearbox
shafts.
To determine the correct shim thickness proceed as follows.
Shimming the crankshaft

After having installed the new main bearings (with bushing (A) or flanged bearings (B)) proceed as follows to determine the total
“SA” height of the shimming:
- measure the distance “LA” between the bearing contact surfaces on the crankshaft;
- measure the depths “LA1” and “LA2” corresponding to the distance between contact surface of the crankcase half and the
contact surface of the inner race of the bearings.
LA
LA2 LA1
A SA2 SA1 A
LA
LA2 LA1
B SA2 SA1 B
section
9 - 9.2 Engine
Add 0.30 mm preload for crankshaft axial bearings to bed in correctly into their seats (inner rings seated inside outer ring).
Thus, we obtain:
SA=LA1+LA2+0.30-LA.
To calculate the thickness of each shim note that:
SA=SA1+SA2
where “SA1” and “SA2” represent the shims for the clutch-side crankcase half 1 and the alternator-side crankcase half 2.
Considering the alignment of the shaft, this gives:
SA1=LA1+0.15-LA/2;
and finally, the second shim thickness: SA2=SA-SA1.
LA1
LA2
In addition to the above procedure, the following is a practical shimming method, providing a guide on how to calculate the crank-
shaft shim thicknesses accurately.
Install a shim of minimum thickness (1.90 mm) on each side of the crankshaft to prevent contact between the crankshaft web
and the crankcase.
Install the crankshaft and assemble the two crankcase halves.
Fit four M8 screws in the seats indicated in the figure and tighten them to the specified torque (Sec. 3 - 3, Engine torque settings).
section
9 - 9.2 Engine
Place a dial gauge (C) with magnetic base on a support plate fixed to crankcase.
Bring the stylus into contact with the end of the crankshaft and set the dial gauge to zero in this position.
Place a lever (D) between crankcase and crank web of the crankshaft pushing towards dial gauge.
Note on the dial gauge the total clearance and add a preload of (0.30 mm) plus the thickness of the shims used (1.90x2=3.8 mm).
Divide the resulting value by two to obtain the thickness of the shim packs to be installed at either end of the crankshaft.
Note
After assembling the crankcase halves, the crankshaft should turn with some interference in the new bearings.
Shimming the gearbox shafts

The following thickness spacers are supplied as spare parts.
Position Clutch side Chain side

(mm) (mm)
Gearbox primary shaft 1.2 1.6
Gearbox secondary shaft 3.15 0.8
Shimming the gearbox selector drum

The following thickness spacers are supplied as spare parts.
Position Clutch side Chain side

(mm) (mm)
Gear control drum 1.0 0.9
section
9 - 9.2 Engine
Reassembly of the crankcase halves
If removed, apply threadlocker on the screw (36), insert the screw with the washer (37) on the crankcase half and tighten the
screw to the specified torque (Sec. 3 - 3, Engine torque settings).
37 36
2
LOCK
If removed, apply threadlocker on the dowel thread (35) and tighten to the specified torque (Sec. 3 - 3, Engine torque settings).
5
LOCK
35
If removed, apply threadlocker on the plug (19) and tighten it to the specified torque (Sec. 3 - 3, Engine torque settings).
19 5
LOCK
Install the O-ring (32) on its seat (A) in the crankcase half. Fit the pipe (33) in the crankcase half, inserting the end (B) fully in the
O-ring. Align the hole (L) of the pipe with the threaded hole (M) in the crankcase half. Apply threadlocker to the screw (34) and
start it in the threaded hole (M). Tighten the screw to the specified torque (Sec. 3 - 3, Engine torque settings).
2
LOCK A B
32
33
34
M
L
34
33
Install the timing belt driveshaft (30) in the roller bearing (4) in the clutch-side crankcase half.
section
9 - 9.2 Engine
In order not to damage the sealing ring (14) corresponding to the timing system shaft, it is advisable to protect the shaft threaded
end with the corresponding protection cap with code 88700.5749. Damp the sealing ring (14) with alcohol and install it on the
timing system shaft taking it in contact with the roller bearings (4).
Fit the circlip (29) in the groove on the shaft and remove the protective cap.
30
88700.5749
29 30
14
Note
When refitting used components, before installing the gearbox assembly in the crankcase half, make sure that the inner
races (C) of the gearbox shaft bearings are fitted into the correct bearings and have not been left on the shafts.
Match gearbox shafts, fit the shims and fit them to the clutch-side crankcase half.
section
9 - 9.2 Engine
Note
A table and a list of the component parts of the gearbox appear in Sec. N 7.2, Reassembly of the gearbox shafts.
Insert the forks of 1st- 4th and 2nd- 3rd speed (D) in the corresponding sliding slots of the secondary shaft driven gears and insert
the pin (G) in the forks: the two forks must be fitted with the number that indicates the gear facing upwards.
Note
The two selector forks are identical.
section
9 - 9.2 Engine
Insert the fork of 5th- 6th speed (E) in the primary shaft driven gear and the pin (G) in the fork (E): the fork must be fitted with the
number indicating the gear facing the crankcase half.
Position the pin (G) of the forks (D) in the crankcase half. Holding the gear lever claw, position the gear drum (F) in the crankcase
half.
Position the pin (G) of the fork (D) in the crankcase half.
G
D
section
9 - 9.2 Engine
Install the crankcase with calculated shims in the crankcase half bearing: the shims (R) of the shaft must be placed with the cham-
fering facing the shaft. Position the connecting rods (H) matching the corresponding seats of the cylinder.
Important
Make sure that the connecting rods (H) are correctly positioned in the cylinders. Incorrect positioning of the connecting rods at
this stage will inevitably lead to the need to re-open the crankcase half.
Check that the two locating bushes (22) are correctly fitted.
Grease the O-ring (31) to hold it in position and install it.
22
22
31
section
9 - 9.2 Engine
Apply a uniform and continuous bead of DUCATI liquid gasket to the mating surfaces of the crankcase halves, going around all
the holes as shown in the figure.
Bring the crankcase halves (3) and (13) together, tapping with a rubber mallet in the area of the shafts if necessary.
13
Apply the recommended grease to the screws and insert them in the crankcase halves (note that the screws are different
lengths). Start with the larger diameter screws (M8), and follow the order indicated.
Ref. Qty Description

section
9 - 9.2 Engine
Tighten all the screws to the specified torque (Sec. 3 - 3, Engine torque settings).
B
12
1 7
B 24
4
25
5
25
12 25 2
3 6
24
27 24
Check that the crankshaft can be turned with a certain amount of interference with the main bearings (the crankshaft should
have a pre-load of 0.20 to 0.30 mm); check also that all the parts you have fitted are free to rotate or move correctly.
Install the cover to reach the mesh filter (Sec. D 4, Changing the engine oil and filter cartridge).
Install the cartridge filter (Sec. D 4, Changing the engine oil and filter cartridge).
Fit the sealing ring (8) on the gear secondary shaft with side (L) to the engine side.
Install the bushing of the tool with code 88713.2060 on the secondary shaft. Lubricate the new ring (8) and seat it.
Using the tool's drift, drive the sealing ring fully home so it seats against the crankcase half bearing.
88713.2060
section
9 - 9.2 Engine

tridge
checking backlash
cover
blies
fixed tensioners
Install the engine in the frame 9 - 1, Refitting the engine
1
section
9 - 9.3 Engine
9.3 - Crankcase assembly: crankshaft/connecting rods assembly
5
8
2 7
1 2
2 5
3
3
4 6
2
1
8
1 Banjo bolt
2 Connecting rod assembly
3 Half bearing
4 Grub screw
5 Bushes
6 Crankshaft
7 Grub screw
8 Shim

Important
section
9 - 9.3 Engine
Removal of the crankshaft/connecting rods assembly
blies sembly
case cover
Remove the oil pump N 2.1, Removal of the oil pump
Remove the primary gear 9 - 6.3, Refitting the primary drive gears
and checking backlash
tridge
Separate the crankcase halves 9 - 9.2, Separation of the crankcase halves
After separating the crankcase halves, withdraw the crankshaft (6) complete with connecting rods (2).
section
9 - 9.3 Engine
Disassembly of the crankshaft/connecting rods assembly
Unscrew the screws (1) and separate the connecting rods from the crankshaft.
Important
Take care not to mix up components of different connecting rods and maintain the original orientation.
section
9 - 9.3 Engine
Overhaul of the connecting rods
Make the following dimensional checks on the connecting rods:
- clearance with gudgeon pin on assembly.
In the event of excessive wear (Sec. C 1.1Crankshaft), replace the connecting rod.
The small end bushing must be in good condition and firmly driven into its seat.
Check for parallelism error measured at 100 mm from the connecting rod longitudinal axis:
the value must be H-h less than 0.02 mm; otherwise, renew the connecting rod.
100
100
The connecting rod is supplied in two size classes A and B relative to the big end diameter (Sect. C 1.1Crankshaft) as punch
marked on the side of the cap.
It is preferable to use crankshafts and connecting rods of the same size class.
B A
A B
section
9 - 9.3 Engine
Renewal of the small end bushing
To remove the worn bushing, use a suitable drift and a press.
Drill lubrication holes into the new bushing in correspondence with the existing lubrication holes on the connecting rod small end.
Now ream out the bushing until the inside diameter (D) is 20.035 to 20.045 mm.
90
= =
Connecting rod bearings

It is good practice to renew the bearings (3) each time the engine is overhauled.
Replacement bearings are supplied ready for assembly and they must not be reworked with scrapers or emery cloth.
The bearings may belong to two different size classes, each identified by a specific colour (YELLOW and BLUE).
The bearings are comprised of an external steel ring, the inner face of which is electro-plated with a lead-based compound.
The table shows the appropriate bearings to be fitted according to the size class of the crankshaft and connecting rod.
Crankshaft class Connecting rod class Bearings colour

B B BLUE/YELLOW
B A YELLOW/YELLOW
A B BLUE/BLUE
A A BLUE/YELLOW
Yellow or blue
section
9 - 9.3 Engine
Crankshaft
The main bearing and big-end journals 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: 2 mm.
0
2 -0,25 mm
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 setting the crankshaft between two opposing centres.
At each overhaul, it is advisable to clean the crankshaft’s internal oilways.
The prescribed values are given in Sec. C 1.1, Crankshaft.
The crankshaft is supplied in two size classes (connecting rod pin) A and B, as punch marked on the side of the crank web on
the pinion side.
Punching
B A
A B
section
9 - 9.3 Engine
Undo all crankshaft plugs (4) and (7); heating the crankshaft, if necessary, to remove the threadlocker applied at the time of as-
sembly.
Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues that have
accumulated and are restricting the oil flow.
Apply THREE BOND 1375B liquid gasket to the plug threads (4) and (7) and reinstall them.
Lock the plugs to the specified torque (Sec. 3 - 3, Engine torque settings).
Big-end bearing shell-journal clearance

To check the assembly clearance between the bearing shells and crankshaft journals you will lay a strip (A) of GREEN
“Plastigage PG-1” on the journal. Fit the connecting rod with the original bearings and tighten the screws to a torque of 50 Nm.
Remove the connecting rod and compare the width of the Plastigage strip to the scale (B).
If the width measured corresponding to the existing clearance is not within the prescribed limit (Sec. C 1.1, Crankshaft),
either the bearings or the crankshaft must be replaced.
section
9 - 9.3 Engine
Reassembly of the connecting rods
Before starting, check that the crankshaft main bearing journals and big-end journals are free of burrs or evident signs of machin-
ing: 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.
Clean the crank pin (O) on the crankshaft (6) thoroughly and lubricate.
O 6
Take the bearings (3) necessary to shaft/connecting rod coupling, following the indications prescribed (Sec. C 1.1, Cylinder/Pis-
ton).
Insert the bearings in the connecting rod seats matching the tooth (M) of the bearings with the corresponding marks (N) on the
connecting rod cap (F) and on the connecting rod small end (G). It is essential that the tooth (M) adheres perfectly with its own
mark (N).
Warning
In the case of BLUE and YELLOW bearing coupling, fit the YELLOW on the connecting rod and the BLUE on the connecting rod
cap.
Lubricate the bearing (3) fitted on the connecting rod small end.
F
G
N N
section
9 - 9.3 Engine
Check that each connecting rod (2) and cap are fitted with their locating pins (D).
Wash the pins and dry them with compressed air.
Fit the connecting rod on the crankshaft, in the same position in which it was removed.
Insert the connecting rod in the crankshaft, so that the centring pins face the internal side.
2 D
Join the connecting rod cap (F) with the corresponding connecting rod small end (G), checking that the progressive number
stamped on the two pieces is the same, as shown in the figure.
G F
Important
Check that the progressive numbers of a connecting rod are next to the selection of the other connecting rod.
section
9 - 9.3 Engine
Fill the recommended grease into the two ends of the hole to lubricate threads and underside of the new screws (1) and the
thread of the shaft.
Warning
The grease utilised is an irritant in contact with the skin. Wear protective gloves.
Important
Lubrication of big-end cap screws is essential to obtain the correct coupling and to prevent breakage of the parts.
The big-end cap screws may only be used for one tightening.
Tighten the screws (1) by hand.
If this proves difficult or if the screws jam, undo them and lubricate them again.
Remove excess grease. Tighten the screw by hand until the head seats against the connecting rod.
B
1
1 3
2
D
2
section
9 - 9.3 Engine
Fit the spacer (H) of the tool 88713.2878 between the connecting rods and take up residual axial clearance with the fork feeler
gauge (I) of the tool 88713.2878 which is available in the following thicknesses:
0.1 mm - 0.2 mm - 0.3 mm.
Temporarily fit the gudgeon pin (L) to align the connecting rods, and then tighten the screws.
88713.2878
I
Tighten the screws (1) with a torque wrench and angle reading (degree wheel) in accordance with the procedure described below
(observe the same tightening sequence at each step as that of the previous step):
1 first torque each screw to a value of 20 Nm;
2 now carry out a second tightening stage applying a torque of 35 Nm on each screw;
3 now tighten each screw, reading the angle of rotation, to 70 Nm, checking that the final angle is between 55° and 75°.
Important
If the final angle is less than 55° or greater than 75°, repeat the procedure using two new screws.
section
9 - 9.3 Engine
Refitting the crankshaft/connecting rod assembly
Install the connecting rod assembly (6) and (2) in the crankcase, carry out the shimming and crankcase half reassembly procedure
as described in Sec. N 9.2 Reassembly of the crankcase halves.
Important
Make sure that the connecting rods (2) are correctly positioned in the cylinders. Incorrect positioning of the connecting rods at
this stage will inevitably lead to the need to re-open the crankcase half.

Crankcase halves closure 9 - 9.2, Reassembly of the crankcase halves
tridge
Refit the primary gear 9 - 6.3, Removal of the primary drive gear
cover
blies
fixed tensioners
Install the engine in the frame 9 - 1, Refitting the engine

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GENERAL INDEX 0

6 - Electric system and engine control system 0

8 - Fuel System/Exhaust System 0

1 - How to use this manual 3

2 - Symbols - Abbreviations - References 5

3 - Hazardous Products - Warnings 8

2 - Fuel, lubricants and other fluids 12

2 - Scheduled maintenance chart 4

3 - Seat – seat cowling and side panels 34

5 - Rear mudguard - Splash guard 47

2 - Battery charging system 63

3 - Electric starting system 77

4 - Lights and indicating devices 86

6 - Protection and safety devices 99

8 - “Hands free” system 174

10 - Description of the system 189

11 - Fuel injection-ignition system 190

12 - System components 191

13 - Diagnostic instruments 204

3 - Front brake control 19

5 - ABS system information 41

7 - ABS components maintenance 61

8.1 - Handlebar assembly - Hand guards -

8.2 - Handlebar unit: clutch hydraulic control 75

10.2 - Front fork - Steering head: front fork (1200 S ABS) 99

10.3 - Fork - Steering head: yoke 112

12 - Rear shock absorber assembly 121

14 - Final drive 147

15 - Footrest brackets 156

17 - Frame inspection 164

6 - Airbox – Throttle Body 15

10 - Evaporative emissions canister 42

1 - Removal–refitting of the engine assembly 5

2.1 - Lubrication system: oil pump 10

2.2 - Lubrication system: oil cooler 15

3.1 - Cooling system: coolant expansion tank 26

3.2 - Cooling system: radiator 30

3.3 - Cooling system: water pump 45

4.1 - Cylinder head assemblies: checks and adjustments 53

4.2 - Cylinder head assemblies: timing system 61

4.4 - Cylinder head assemblies: camshafts 79

4.5 - Cylinder head assemblies: valves - rocker arms 94

6.1 - Clutch assembly: clutch 130

6.2 - Clutch assembly: clutch-side crankcase cover 141

6.3 - Clutch assembly: primary drive gears 146

7.1 - Gearbox assembly: gearchange mechanism 153

7.2 - Gearbox assembly: gearbox shafts 162

8 - Flywheel - alternator 184

9.1 - Crankcase assembly: external components 203

9.3 - Crankcase assembly: crankshaft/connecting rods assembly 244

2 - Symbols - Abbreviations - References 5

3 - Hazardous Products - Warnings 8

How to use this manual

Ducati Motor Holding S.p.A.

Symbol Specifications Recommended product

DOT 4 special hydraulic brake fluid. SHELL

Anti-freeze (nitride, amine and phosphate free) 30 to 40% SHELL

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

GREASE C Bearing/joint grease for parts subject to prolonged SHELL

GREASE D Protective grease, with anti-corrosive and waterproofing SHELL

GREASE E PANKL grease - PLB 05.

LOCK 2 Medium-strength thread locker, compatible with oil. Loctite 243

LOCK 3 High-strength thread locker for threaded parts. Loctite 270

ZDM 1198WC000 001