Service Station Manual: Nevada - Nevada Anniversario

SERVICE STATION MANUAL
B043105
NEVADA - NEVADA ANNIVERSARIO
SERVICE STATION
MANUAL
THE VALUE OF SERVICE

As a result of continuous updates and specific technical training programmes for Moto Guzzi products,
only Moto Guzzi Official Network mechanics know this vehicle fully and have the specific tools necessary
to carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, its regular maintenance and the use of original Moto Guzzi spare parts only are essential factors!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.motoguzzi.com
Only by requesting Moto Guzzi original spare parts can you be sure of purchasing products that were
developed and tested during the actual vehicle design stage. All Moto Guzzi original spare parts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
models should be confirmed with the official Moto Guzzi sales network.
The Moto Guzzi brand is owned by Piaggio & C. S.p.A.
Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL

NEVADA - NEVADA
ANNIVERSARIO
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have
been deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing motorcycles. Without this knowledge, repairing
or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER
DEPARTMENT, which will be prepared to provide any information on the subject and any further
communications on updates and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee
INDEX OF TOPICS
CHARACTERISTICS
CHAR
SPECIAL TOOLS
S-TOOLS
MAINTENANCE
MAIN
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
POWER SUPPLY
P SUPP
SUSPENSIONS
SUSP
CHASSIS
CHAS
BODYWORK
BODYW
PRE-DELIVERY
PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. Before handling these components, make sure that you are wearing
insulating gloves or wait until the engine and the exhaust system have cooled down.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VEHICLE.

THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
CHAR - 7
Characteristics
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
BEFORE REMOVING COMPONENTS
Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with different distinctive symbols.
Each component needs to be clearly marked to enable identification during reassembly.
Clean and wash the dismantled components carefully using a low-flammability detergent.
Keep mated parts together since they have "adjusted" to each other due to normal wear.
CHAR - 8
Some components must be used together or replaced altogether.
Keep away from heat sources.
Characteristics
REASSEMBLY OF COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTHERWISE, THEY NEED TO BE REPLACED.
Only use ORIGINAL Moto Guzzi SPARE PARTS.
Comply with lubricant and consumables use guidelines.
Lubricate parts (whenever possible) before reassembling them.
When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before applying the tightening torque.
Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), split pins
and screws with new ones if their tread is damaged.
When assembling the bearings, make sure to lubricate them well.
Check that each component is assembled correctly.
After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density.
Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble oil guards and bearings
with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the cable harness:
Press the relevant safety hooks, if any.
Grip the two connectors and disconnect them by pulling them in opposite directions.
If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
Ensure that the cables are correctly fastened to the internal connector terminals.
Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.

NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUES
CAUTION
IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE

IT WITH A NEW ONE.
CAUTION
CHAR - 9
Characteristics
DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON

WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A
KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the runin. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the
engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH DISCS
GET ADAPTED.
IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUN-IN PERIOD.
Follow these guidelines:
Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER
FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PARTICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
CHAR - 10
Characteristics
This number consists of numbers and letters, as in

the example shown below.
ZGULWE0012MXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LW: model;
E00 (V7 Stone), G00 (V7 Special), H00 (V7 Racer): versions;
0: free digit
12: variable year of manufacture (12 - for 2012)
M: production plant (M= Mandello del Lario);
XXXXXX: serial number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right hand
side of the headstock.
ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.
Dimensions and mass

WEIGHT AND DIMENSIONS
Specification
Maximum length
Maximum length (Anniversario)
Maximum width
Maximum width (Anniversario)
Maximum height (hand grips)
Maximum height (Except rear view mirrors) (Anniversario)
Saddle height
Wheelbase
Minimum ground clearance
Kerb weight
Desc./Quantity
2166 mm (85.27 in)
2210 mm (87.01 in)
805 mm (31.69 in)
800 mm (31.5 in)
1068 mm (42.04 in)
1120 mm (44.10 in)
770 mm (30.31 in)
1467 mm (57.75 in)
209 mm (8.22 in)
191 kg (421.08 lb)
CHAR - 11
Characteristics
Engine
ENGINE
Specification
Type
No. of cylinders
Engine capacity
Bore / stroke
Compression ratio
Starter
Engine idle speed
Intake valve clearance
Exhaust valve clearance
Clutch
Lubrication
Air filter
Cooling
Desc./Quantity
traverse-mounted twin-cylinder four-stroke V 90
2
744 cm (45.40 cu.in)
80x74 mm (3.14x2.91 in)
10.4 : 1
Electric
1350 +/- 100 rpm
0.15 mm (0.0059 in)
0.20 mm (0.0079 in)
dry single-disc clutch with flexible coupling
Pressure-fed, controlled by valves and trochoidal pump
cartridge-type dry filter
air
Transmission
TRANSMISSION
Specification
Gearbox / Type
Desc./Quantity
mechanical, 5 speeds with foot lever on the left-hand side of
the engine.
with gears, ratio: 16 / 21 = 1 : 1.3125
11 / 26 = 1 : 2.3636
14 / 23 = 1 : 1.6429
18 / 23 = 1 : 1.2778
18 / 19 = 1 : 1.0556
22 / 25 = 1 : 0.9
with cardan shaft, ratio: 8 / 33 = 1 : 4.825
Primary drive
Gear ratios, 1st gear
Gear ratios, 2nd gear
Gear ratios, 3rd gear
Gear ratios, 4th gear
Gear ratios, 5th gear
Final drive
Capacities
CAPACITY
Specification
Fuel (reserve included)
Fuel reserve
Engine oil
Gearbox oil
Transmission oil
Seats
Vehicle maximum load
Desc./Quantity
14 l (3.70 USgal)
4 l (1.056 US gal)
Oil change and oil filter replacement: 2000 cm (122.05 cu.in)
1 l (0.26 USgal)
170 cm (10.37 cu.in)
2
180 kg (396 lb) (rider + passenger + luggage)
Electrical system
ELECTRICAL SYSTEM
Specification
Battery
Fuses
Generator (alternator + rectifier)
Desc./Quantity
12V - 12 Ah
5 (2) - 10 - 15 (2) - 30 A
12V - 350 W
SPARK PLUGS
Specification
Standard
Alternatively
CHAR - 12
Desc./Quantity
NGK CPR8EB-9
CHAMPION RG6YC
Specification
Spark plug electrode gap
Resistance
Characteristics
Desc./Quantity
0.6 0.7 mm (0.024 0.027 in)
5 kOhm
BULBS
Specification
Low/High beam headlight (halogen)
Front daylight running light
Turn indicator light
Tail light / stop light
Dashboard lighting
License plate light
Desc./Quantity
12 V - 55 W / 60 W H4
12V - 5W
12 V - 10 W (orange RY 10 W bulb)
12 V - 5 / 21 W
LED
12V - 5W
WARNING LIGHTS
Specification
Gearbox in neutral
Turn indicators
Fuel reserve
High beam light
Engine oil pressure
Injection check warning light
Desc./Quantity
LED
LED
LED
LED
LED
LED
Frame and suspensions

CHASSIS
Specification
Type
Steering rake
Trail
Desc./Quantity
Modular double cradle, high strength steel tubular chassis
27.5
138 mm (5.43 in)
SUSPENSIONS
Specification
Front
Travel
Rear - V7 Special / V7 Stone
Rear - V7 Racer
Wheel travel
Desc./Quantity
hydraulic telescopic fork, 40 mm (1.57 in)
130 mm (5.12 in)
swinging arm in die-cast light alloy, 2 shock absorbers with adjustable spring preloading
die-cast light alloy swingarm with 2 adjustable shock absorbers
100 mm (3.93 in)
SIZES A AND B
Specification
Size A
Size B
Desc./Quantity
692 mm (27.24 in)
186 mm (7.32 in)
CHAR - 13
Characteristics
Brakes
BRAKES
Specification
Front
Rear
Desc./Quantity
stainless steel floating disc, 320 mm (12.59 in), callipers with
4 different and counteracting plungers
260 mm (10.24 in) stainless steel disc, floating calliper with two
25.4 mm (1.00 in) diam. pistons
Wheels and tyres

WHEEL RIMS
Specification
Type
Front
Rear
Desc./Quantity
with spokes, for tyres with inner tubes
2.5''x18''
3" x 16"
TYRES
Specification
Front (standard)
Front (size)
Front (inflation pressure)
Front (inflation pressure) (Anniversario)
Front (inflation pressure with passenger)
Rear (standard)
Rear (size)
Rear (inflation pressure)
Rear (inflation pressure) (Anniversario)
Rear (inflation pressure with passenger)
Desc./Quantity
METZLER LASERTEC
100/90 V18 MC (56V)
2.2 bar (220 kPa) (31.90 PSI)
2.5 bar (250 kPa) (36.3 PSI)
2.5 bar (250 kPa) (36.3 PSI)
METZLER LASERTEC
130/90 V16 MC (67V)
2.2 bar (220 kPa) (31.90 PSI)
2.5 bar (250 kPa) (33.6 PSI)
2.5 bar (250 kPa) (36.3 PSI)
Supply
FUEL SYSTEM
Specification
Type
Venturi
Fuel
Tightening Torques
Chassis
CHAR - 14
Desc./Quantity
Electronic injection (Marelli MIU G3)
38 mm (1.50 in)
Premium unleaded petrol, minimum octane rating of 95
(NORM) and 85 (NOMM)
Characteristics
Front side
FRONT SUSPENSION - STEERING

pos.
1
2
Description
Stanchion cap
Screw fixing wheel axle to right fork leg
Type
M6x30
M10x40
Screw fixing stanchions to upper and lower

plate
Headstock ring nut
M25x1
Headstock bushing
M23x1
Quantity
Torque
Notes
2
50 Nm (36.88 lbf ft)
2
10 Nm (7.37 lbf ft) Tighten using a 1-2-1 sequence
4
50 Nm (36.88 lbf ft)
7 Nm (5.16 lbf ft)
The fork must fall to one

side by itself
50 Nm (36.88 lbf ft)
-
CHAR - 15
Characteristics
INSTRUMENT PANEL
pos.
1
Description
Screw fixing instrument panel to headlamp support
Type
M6x10
Quantity
3
Torque
10 Nm (7.37 lbf ft)
Notes
-
HANDLEBAR AND CONTROLS

Pos.
Description
1
Switch fastener screw
2
Counterweight fixing screw
3
Screw fastening the clutch control U-bolt to
the semi-handlebar
CHAR - 16
Type
SWP 5
M6
M6x25
Quantity
1+1
2
2
Torque
1.5 Nm (1.11 lb ft)
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
Notes
Loctite 243
-
Characteristics
FRONT BRAKE SYSTEM

pos.
1
2
3
Description
Screw fastening the brake pump U-bolt to the
semi-handlebar
Front brake calliper fixing screw
Drilled screw for brake fluid pipe on pump and
calliper
Type
M6x25
Quantity
2
Torque
10 Nm (7.37 lb ft)
Notes
-
M10x30
-
2
2
50 Nm (36.88 lb ft)
25 Nm (18.44 lb ft)
CHAR - 17
Characteristics
FRONT LIGHTS
pos.
Description
Headlamp fixing screw
Front turn indicator fixing screw
Horn fixing screw
Headlamp support bracket fixing
screw
1
2
3
4
Type
M8x30
M6
M6x16
M10x40
Quantity
2
2
2
2
Torque
15 Nm (11.06 lb ft)
5 Nm (3.69 lb ft)
10 Nm (7.37 lb ft)
50 Nm (36.88 lb ft)
Notes
-
CARROZZERIA - PARTE ANTERIORE

Pos.
1
2
Descrizione
Screw fastening stabiliser plate to fork
Screw fastening mudguard to stabiliser
plate
CHAR - 18
Tipo
M8x40
M6x11
Quantit
4
4
Coppia
15 Nm (11.06 lbf ft)
10 Nm (7.37 lbf ft)
Note
Loctite 243
Loctite 243
Characteristics
FRONT WHEEL
pos.
1
2
Description
Front wheel axle
Front brake disc fixing screw
Type
M18x1.5
M8x20
Quantity
1
6
Torque
80 Nm (59.00 lbf ft)
25 Nm (18.44 lbf ft)
Notes
Loctite 243
Central part
CHAR - 19
Characteristics
FRAME
pos.
1
2
3
4
5
6
Description
Screw fixing tank mounting rubber
blocks to frame
Cradle front fixing screw
Screw fastening gearbox to frame
Pin fixing engine/gearbox to chassis
Screw fixing exhaust silencer mounting to frame
Battery supporting plate fixing screw
Type
M8x14
Quantity
2
Torque
25 Nm (18.44 lbf ft)
Notes
-
M10x30
M10x55
M10x205
M8x16
4
2
1
4
50 Nm (36.88 lbf ft)

50 Nm (36.88 lbf ft)
50 Nm (36.88 lbf ft)
25 Nm (18.44 lbf ft)
Loctite 243
M8x16
25 Nm (18.44 lbf ft)
Torque
50 Nm (36.88 lbf ft)
25 Nm (18.44 lbf ft)
50 Nm (36.88 lbf ft)
50 Nm (36.88 lbf ft)
Notes
-
FRAME CRADLES
pos.
1
2
3
4
Description
Screw fixing stand beam to cradle
Screw fixing stand beam to cradle
Screw fastening cradle to frame
CHAR - 20
Type
M10x260
M8
M10x250
M10x65
Quantity
1
1+1
1
2
Characteristics
DRIVER FOOTRESTS
pos.
1
2
Description
Pedal rubber fastening screw
Screw fastening rider footrest mounting to
frame
Type
M6x12
M8
Quantity
4
2+2
Torque
10 Nm (7.38 lb ft)
25 Nm (18.44 lb ft)
Notes
Loct. 243
SIDE STAND
pos.
1
Description
Side stand retainer pin
Lock nut for stand bolt
Type
M10x1.2
5
M10x1.2
5
Quantity
1
Torque
10 Nm (7.38 lb ft)
Notes
-
30 Nm (22.13 lb ft)
CHAR - 21
Characteristics
pos.
3
Description
Switch fixing screw
pos.
1
2
Description
Rear tank fixing screw
Screw fastening cap flange to tank
Type
M5x16
Quantity
2
Torque
6 Nm (4.42 lb ft)
Notes
-
Torque
25 Nm (18.44 lb ft)
4 Nm (2.95 lb ft)
Notes
-
FUEL TANK
CHAR - 22
Type
M8x45
M5x12
Quantity
1
2+3
Characteristics
FUEL SUPPLY SYSTEM

pos.
Description
Screw fixing fuel pump mounting to
tank
pos.
Description
Air filter box cover fastening screw
Air filter box fastening screw to frame
Air filter box fastening screw
Type
M5x16
Quantity
6
Torque
6 Nm (4.43 lbf ft)
Notes
-
TIGHTENING TORQUE - CENTRAL PART - FILTER BOX

1
2
3
Type
SWP 5x14
SWP 5x20
SWP 5x20
Quantity
4
2
9
Torque
3 Nm (2.21 lb ft)
3 Nm (2.21 lb ft)
3 Nm (2.21 lb ft)
Notes
-
CHAR - 23
Characteristics
BODYWORK CENTRAL SECTION - SADDLE

pos.
1
Description
Side fairing fixing screw
Type
M5x9
Quantity
2
Torque
4 Nm (2.95 lb ft)
Notes
-
LOCK KIT
pos.
1
Description
(Shear head) screw fixing ignition
lock
CHAR - 24
Type
M8x15
Quantity
1
Torque
-
Notes
At the point of failure
pos.
Description
Ignition lock fixing screw
Pos.
Description
Exhaust pipe fixing nut to the engine
Exhaust pipe fixing clamp screw to
the compensator
Compensator fixing clamp screw to
the silencer
Lambda probe on compensator
Nut fastening silencer to mounting
plate
Heat shield fixing screw
Screw fixing silencer mounting plate
to frame
Type
M8x16
Characteristics
Quantity
1
Torque
25 Nm (18.44 lb ft)
Notes
-
EXHAUST SYSTEM
1
2
3
4
5
6
7
Type
M6
M6
Quantity
4
1+1
Torque
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
Notes
-
M6
10 Nm (7.37 lb ft)
M18x1.5
M8
1
4
38 Nm (28.03 lb ft)
25 Nm (18.44 lb ft)
M6x12
M8x40
6
2
10 Nm (7.37 lb ft)
25 Nm (18.44 lb ft)
Loctite 270
-
CHAR - 25
Characteristics
Back side
REAR TRANSMISSION - SWINGARM

pos.
Type
M10x45
M16x1
Quantity
1
1
Torque
30 Nm (22.13 lbf ft)
25 Nm (18.44 lbf ft)
Notes
-
3
4
Description
Swingarm clamp retaining screw
Pin fixing the rear calliper holding
plate to swingarm
Nut fixing gearcase to swingarm
Pin fixing swingarm to gearbox
M8
M20x1
4
2
25 Nm (18.44 lbf ft)

-
Lock nut on swingarm pin
M20x1
50 Nm (36.88 lbf ft)
Hold the stud bolt

Fully home with no
preload
Hold the pin
1
2
CHAR - 26
Characteristics
REAR SUSPENSION
pos.
1
2
3
4
Description
Upper screw fastening shock absorber to
frame
Lower pin fastening left shock absorber to
swingarm
Stud bolt fixing right shock absorber to rear
box
Screw fastening right shock absorber to stud
bolt
Type
M6x35
Quantity
2
Torque
10 Nm (7.37 lbf ft)
Notes
Loctite 243
M10x1.5
35 Nm (25.81 lbf ft)
M12x1.5
35 Nm (25.81 lbf ft)
M6x16
10 Nm (7.37 lbf ft)
Loctite 243
CHAR - 27
Characteristics
PASSENGER FOOTRESTS
pos.
1
2
Description
Pedal rubber fastening screw
Screw fastening passenger footrest mounting
to frame
CHAR - 28
Type
M6x12
M8
Quantity
4
2+2
Torque
10 Nm (7.38 lb ft)
25 Nm (18.44 lb ft)
Notes
Loct. 243
Characteristics
REAR WHEEL
pos.
Description
Rear wheel axle nut
Rear brake disc fixing screw
pos.
Description
Rear brake calliper fixing screw
Drilled screw for brake pipe on calliper
1
2
Type
M16x1.5
M8x25
Quantity
1
6
Torque
120 Nm (88.51 lb ft)
25 Nm (18.44 lb ft)
Notes
Loctite 243
Torque
25 Nm (18.44 lb ft)
25 Nm (18.44 lb ft)
Notes
-
REAR BRAKE SYSTEM

1
2
Type
M8x30
-
Quantity
2
1
CHAR - 29
Characteristics
(ANNIVERSARIO)
REAR LIGHTS
pos.
1
2
Description
Screw fastening taillight support to
mudguard
Rear turn indicator fixing screw
CHAR - 30
Type
M5x14
Quantity
3
Torque
4 Nm (2.95 lb ft)
Notes
-
M6
5 Nm (3.69 lb ft)
Characteristics
(ANNIVERSARIO)
REAR MUDGUARD
pos.
1
2
3
Description
Rear mudguard front and central fixing screw
Rear mudguard side fixing screw
Screw fixing license plate holder to mudguard
reinforcement
Type
M6
M8x30
SWP
M5x20
Quantity
2+1
2
3
Torque
10 Nm (7.37 lb ft)
25 Nm (18.44 lb ft)
3 Nm (2.21 lb ft)
Notes
CHAR - 31
Characteristics
ELECTRICAL SYSTEM 01
pos.
1
2
3
Description
Speed sensor fastening screw
Fuse box bracket fixing screw
Battery holder bracket fastening screw
CHAR - 32
Type
M6
M5x12
M6
Quantity
1
2
2
Torque
10 Nm (7.37 lb ft)
4 Nm (2.95 lb ft)
Manual
Notes
-
Characteristics
pos.
1
2
Description
1 - Coil fixing nut
2 - Timing sensor fastener screw
Type
M6
-
Quantity
2+2
1
Torque
10 Nm (7.37 lb ft)
.. Nm (... lb ft)
Notes
-
Recommended products chart

RECOMMENDED PRODUCTS TABLE
Product
ENI i-RIDE PG 10W-60
AGIP GEAR MG SAE 85W-140

AGIP GEAR MG/S SAE 85 W-90
AGIP FORK 7.5W
AGIP GREASE SM 2
Neutral grease or petroleum jelly.

AGIP BRAKE 4
Description
Specifications
Lubricant formulated with advanced synJASO MA, MA2 - API SG
thetic technology and high performance
additives to cater specifically for 4-stroke
engines with high specific power outputs.
Transmission oil
API GL-4 and GL-5
Gearbox oil
API GL-5
Fork oil
SAE 5W / SAE 20W
Gray black smooth-textured lithium
grease, containing molybdenum disulphide.
Battery poles
Brake fluid
SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO
4925 - CUNA NC 956 DOT 4 synthetic
fluid
NOTE
USE ONLY NEW BRAKE FLUID. DO NOT MIX DIFFERENT BRANDS OR TYPES OF OIL WITHOUT
CHECKING THEIR BASE COMPATIBILITY.
CHAR - 33
INDEX OF TOPICS
SPECIAL TOOLS
S-TOOLS
Special tools
SPECIAL TOOLS
Stores code
19.92.61.00
Description
Punch for seal ring of bevel gear set pinion
19.92.88.00
Bevel gear set alignment pre-fitting tool
19.92.60.00
Punch for gearcase sealing ring
19.90.70.00
Extractor for internal ring on drilled bolt
19.92.75.00
Extractor for external ring of gearcase

bearing
19.92.62.00
Punch for bearing on bevel gear set pinion
S-TOOLS - 35
Special tools
Stores code
19.92.64.00
Description
Punch for external ring of tapered bearing
on bevel gear set pinion holding body
19.92.65.00
Punch for external ring of gearcase bearing
19.92.76.00
Extractor for swinging arm holder bearing

on gearbox cover
S-TOOLS - 36
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Maintenance chart
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
V: CHECK AND CLEAN, ADJUST AND REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Replace in case of leaks.
(2) Replace every 2 years or 20000 Km (12427 mi).
(3) Replace every 4 years.
(4) At each engine start.
(5) Check every month.
(6) Check every 3,000 km (1,864 mi)
(7) Check and clean and adjust or replace, if necessary, every 1,000 Km (621 mi)
ROUTINE MAINTENANCE TABLE

km x 1,000
Spark plugs
Transmission cables and controls
Steering bearings and steering clearance
Wheel bearings
Brake discs
Air filter
Engine oil filter
Lights operation / aiming
Vehicle general operation
Braking systems
Light circuit
Safety switches
Brake fluid (2)
Gearbox oil
Fork oil
Engine oil (6)
Final drive oil
Fork oil seal (1)
Tyres - pressure/wear (5)
Valve clearance adjustment
Wheels
Bolts and nuts tightening
Battery terminals tightening
Head screws tightening
Suspension and setting
Engine oil pressure warning light (4)
Fuel lines (3)
Brake lines (3)
Clutch wear
Brake pad wear (7)
Labour time (minutes)
MAIN - 38
1
I
I
I
R
I
I
I
I
I
R
R
R
I
I
A
I
I
I
A
I
V
100
10
R
I
I
I
I
R
R
I
I
I
I
I
I
I
A
I
I
20
R
I
I
I
I
R
R
I
I
I
I
I
I
R
R
R
R
I
I
A
I
I
30
R
I
I
I
I
R
R
I
I
I
I
I
I
I
A
I
I
I
I
I
I
V
70
I
I
I
V
130
40
R
I
I
I
I
R
R
I
I
I
I
I
I
R
R
R
R
I
I
A
I
I
50
R
I
I
I
I
R
R
I
I
I
I
I
I
I
A
I
I
I
I
I
I
V
70
I
I
I
V
130
60
R
I
I
I
I
R
R
I
I
I
I
I
I
R
R
R
R
I
I
A
I
I
I
I
I
I
V
70
I
I
I
V
130
Maintenance
Transmission fluid
Check
Keep the vehicle upright with both wheels on the
ground.
Unscrew and remove the cap/dipstick (1).
The level is correct if the oil is close to the hole
of the cap/dipstick (1).
If the oil is lower than specified, top-up until it
reaches the cap/dipstick hole (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO

THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Replacement
CAUTION
THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS
FLUID AND THEREFORE EASY TO DRAIN.
NOTE
RIDE SOME km (miles) TO WARM UP ENGINE OIL
Place a container with + 400 cm (25 cu in) capacity under the drainage plug (3).
Unscrew and remove the drainage plug (3).
Unscrew and remove the breather cap (2).
Drain the oil into the container; allow several minutes for oil to drain out completely.
Check and if necessary, replace the sealing washer of drainage plug (3).
Remove any metal scrap attached to the drainage plug (3) magnet.
Screw and tighten the drainage plug (3).
Pour new oil through the fill opening (1) until it reaches the cap/dipstick hole (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
MAIN - 39
Maintenance
Screw and tighten the caps (1 - 2).
Engine oil
Check
CAUTION
ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL

NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER
RUNNING FOR ABOUT 15 KM (10 miles).
Switch off the engine and wait at least five minutes to allow the lubricant to drain back into
the sump.
Keep the vehicle upright with both wheels on the ground.
Unscrew and remove the cap with dipstick.
Clean dipstick.
Refit the cap with dipstick into its hole without tightening.
Remove the cap with dipstick.
Check oil level by means of the oil dipstick.
The oil level is correct when it close to the "MAX" mark.
MAX = maximum level

MIN = minimum level
Add engine oil if required:
Unscrew and remove the cap with dipstick.
Top-up with engine oil until it goes above the minimum level marked "MIN".
MAIN - 40
Maintenance
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO
THE OIL. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Replacement
Place a container with + 2000 cm (122

cu.in) capacity under the drainage
plugs (1).
Unscrew and remove the drainage

plugs (1).
Unscrew and remove the filler cap (2).
Drain the oil into the container; allow

several minutes for oil to drain out completely.
Check and if necessary, replace the

sealing washers of drainage plugs (1).
Remove any metal scrap attached to

the magnet of drainage plugs (1).
Screw and tighten the drainage plugs

(1).
Drainage plugs tightening torque (1): 12 Nm

(1.2 kgm)
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

DISPOSE OF ENGINE OIL STORED IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE
NEAREST USED OIL RECLAMATION FIRM.
MAIN - 41
Maintenance
Engine oil filter
Loosen the screw (3) and remove the

cover (4).
Remove the engine oil filter (5).
NOTE
NEVER REUSE AN OLD FILTER.
Spread a thin layer of oil on the sealing ring (6) of the new engine oil filter.
Fit the new engine oil filter with the spring facing downwards.
Refit the cover (4), screw and tighten the screw (3)
Air filter
Remove the saddle
Unhook the connector from the air-box cover
Remove the air-box cover fixing screw
Remove the air-box cover
Extract the air filter
MAIN - 42
Maintenance
Throttle body removal
Loosen the clamps that secure the

sleeve to the intake manifolds
Remove the sleeve
Remove the battery
Remove the MIU G3 control unit connector support bracket fixing screw
MAIN - 43
Maintenance
Disconnect the MIU G3 control unit

connector
Unscrew the clamp that secures the

throttle body to the filter box
Extract the throttle body laterally
Remove the throttle body guard
Loosen the gas cables fixing nuts on

the throttle body and unhook them
MAIN - 44
Maintenance
Remove the throttle body
Throttle body installation
Connect the gas cables on the throttle

body
Correctly position the guides and tighten the nuts, checking correct operation
of the throttle grip
Install the throttle body guard
MAIN - 45
Maintenance
Insert the throttle body in the sleeve

and tighten the clamp to secure it
CAUTION
TAKE PARTICULAR CARE THAT THE CLAMP IS POSITIONED CORRECTLY. INCORRECT POSITIONING WILL
CAUSE VEHICLE MALFUNCTIONS
Connect the MIU G3 control unit connector
Install the MIU G3 control unit connector support bracket
Install the sleeve, taking care that they

are inserted correctly
MAIN - 46
Maintenance
Tighten the clamps, checking correct

positioning
Air filter housing
FRAME
pos.
1
2
Description
blocks to frame
Type
M8x14
Quantity
2
Torque
25 Nm (18.44 lbf ft)
Notes
-
M10x30
50 Nm (36.88 lbf ft)
MAIN - 47
Maintenance
pos.
Description
3
4
5
6
Type
M10x55
M10x205
M8x16
Quantity
2
1
4
Torque
50 Nm (36.88 lbf ft)
50 Nm (36.88 lbf ft)
25 Nm (18.44 lbf ft)
Notes
Loctite 243
M8x16
25 Nm (18.44 lbf ft)
TIGHTENING TORQUE - CENTRAL PART - FILTER BOX

pos.
Description
Air filter box cover fastening screw
Air filter box fastening screw to frame
Air filter box fastening screw
1
2
3
Type
SWP 5x14
SWP 5x20
SWP 5x20
Air filter housing removal
Remove the saddle and the side fairings
Remove the battery
Remove the rear wheel.
Remove the splash guard
Remove the fuse box support fixing

screws (1)
MAIN - 48
Quantity
4
2
9
Torque
3 Nm (2.21 lb ft)
3 Nm (2.21 lb ft)
3 Nm (2.21 lb ft)
Notes
-
Maintenance
Remove the brake pump unscrewing

the two fixing screws.
Move the filter box to the side enough

to allow removal of the fixing screws (2)
on the left side of the filter box support.
See also
Side body panels
Splash guard
Removing
Specific operations for the vehicle

to allow removal of the fixing screws (3)
on the right side of the filter box support.
Disconnect the neutral switch connector
Lift the air filter box enough to allow the

support plate to be removed, sliding
out neutral switch cabling
MAIN - 49
Maintenance
Unscrew the clamp that fastens the

throttle body to the air filter box
Disconnect the blow-by and breather

tubes
Remove the air-box cover
Remove sliding the complete filter box

out toward the rear
MAIN - 50
Maintenance
Air filter housing installation
Insert the filter box from the rear
Insert the throttle body in the sleeve

and tighten the clamp to secure it
CAUTION
TAKE PARTICULAR CARE THAT THE CLAMP IS POSITIONED CORRECTLY. INCORRECT POSITIONING WILL
CAUSE VEHICLE MALFUNCTIONS
Install the air-box cover
Connect the blow-by and breather

tubes
MAIN - 51
Maintenance
Position the air filter box support, taking car to pass the neutral switch cabling through the hole

to allow tightening of the fixing screws
(3) on the right side of the filter box
support.

to allow tightening of the fixing screws
(2) on the left side of the filter box support.
Correctly position the air filter box on

the support
Fix the screws (1) of the fuse box support
MAIN - 52
Maintenance
Braking system
FRONT BRAKE SYSTEM

pos.
1
2
3
Description
Screw fastening the brake pump U-bolt to the
semi-handlebar
Front brake calliper fixing screw
Drilled screw for brake fluid pipe on pump and
calliper
Type
M6
Quantity
2
M10x30
-
2
2
Torque
10 Nm (7.37 lbf ft)
Notes
Tighten using a 1-2-1 sequence
50 Nm (36.88 lb ft)
25 Nm (18.44 lb ft)
-
MAIN - 53
Maintenance
REAR BRAKE SYSTEM

pos.
Description
Rear brake calliper fixing screw
Drilled screw for brake pipe on calliper
1
2
Type
M8x30
-
Quantity
2
1
Torque
25 Nm (18.44 lb ft)
25 Nm (18.44 lb ft)
Notes
-
Level check
Brake fluid check
Rest the vehicle on its stand.
For the front brake, turn the handlebar fully to the right.
For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same
level with the plug.
Make sure that the fluid level in the reservoir is above the "MIN" reference mark:
MIN = minimum level

MAX = maximum level
If the fluid does not reach at least the "MIN" reference mark:
Check brake pads and disc for wear.
If the pads and/or the disc do not need replacing, top-up the fluid.
Top-up
Front brake:
Unscrew the two screws (1) of the

brake fluid reservoir (2) using a Phillips
screwdriver.
Lift and remove the cover (3) and

screws (1) as well.
Remove the gasket (4).
Rear brake:
Unscrew and remove the cap (5).
Remove the gasket (6).
Top-up the reservoir with brake fluid to

the correct level, which is between the
two "MIN" and "MAX" reference marks.
RISK OF BRAKE FLUID SPILLS. DO NOT OPERATE THE

BRAKE LEVER WITH BRAKE FLUID RESERVOIR CAP
LOOSENED OR REMOVED.
CAUTION
MAIN - 54
Maintenance
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE

FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS
MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE
BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME
NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.
TO AVOID SPILLING FLUID WHILE TOPPING-UP, KEEP

THE TANK PARALLEL TO THE RESERVOIR EDGE (IN
HORIZONTAL POSITION).
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID.
WHEN USING A FUNNEL OR ANY OTHER ELEMENT,
MAKE SURE IT IS PERFECTLY CLEAN.
DO NOT EXCEED THE "MAX" LEVEL MARK WHEN TOPPING UP.

TOP-UP TO "MAX" LEVEL MARK ONLY WHEN BRAKE
PADS ARE NEW. WHEN TOPPING UP DO NOT EXCEED
THE "MAX" LEVEL MARK WHEN BRAKE PADS ARE
WORN AS YOU RISK SPILLING FLUID WHEN CHANGING
THE BRAKE PADS.
CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE
TRAVEL OF THE BRAKE LEVER OR POOR PERFORMANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE
TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECESSARY TO PURGE THE AIR IN THE SYSTEM.
MAIN - 55
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
pos.
1
2
3
Description
Speed sensor fastening screw
Fuse box bracket fixing screw
Battery holder bracket fastening screw
pos.
1
Description
1 - Coil fixing nut
Type
M6
M5x12
M6
Quantity
1
2
2
Torque
10 Nm (7.37 lb ft)
4 Nm (2.95 lb ft)
Manual
Notes
Torque
10 Nm (7.37 lb ft)
Notes
-
Type
M6
Quantity
2+2
ELE SYS - 57
Electrical system
pos.
2
Description
2 - Timing sensor fastener screw
Components arrangement
key:
1. Instrument panel
2. Coil
ELE SYS - 58
Type
-
Quantity
1
Torque
.. Nm (... lb ft)
Notes
-
Electrical system
3. Fuel pump
4. Injector
5. Taillight
6. MIU G3 Control Unit
7. Speed sensor
8. Starter motor
9. Engine speed sensor
10.Fuses
11.Battery
12.Head temperature sensor
13.Instrument panel air sensor
14.Headlamp
15.Voltage regulator
16.Alternator
17.Oil pressure sensor
18.Lambda probes
Electrical system installation

INTRODUCTION
Scope and applicability
The position of the cable harnesses, how they are fixed to the motorcycle and potential problems are
defined on the following sections in order to reach the objectives of vehicle reliability.
Materials used and corresponding quantities
The electrical system consists of the following cable harnesses and parts:
1 Main Cable Harness
1 Ground cable Negative - Engine
1 Left H.V. Cable
1 Left H.V. Cable Sheath (Grey)
1 Right H.V. Cable
1 Right H.V. Cable Sheath (Black)
3 Relays 12V 30A
1 Pull Up Module (resistance-diode)
1 Stand switch
2 Lambda probes
2 NGK Plug Caps
Small parts and mountings
3 Large black clamps 290x4.5

ELE SYS - 59
Electrical system
13 Medium black clamps 190x4.5
5 Small black 160x2.5 clamps
1 Cable guides
3 Cable grommet (there are various types of cable grommets)
2 Profile guards (140mm long)
1 Miu3 bracket
1 Tcei M8x40 screw
1 Black sheath D16 S0.4
6 Cable guides (there are various types of cable guides)
Motorcycle division
The wiring timing is subdivided in three essential
sections, as indicated in the figure.
1. Front section
2. Central section
3. Rear part
4. ENGINE
SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES

It is extremely important that any security-locks for the following connectors are properly connected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
Carry out the checks listed below.
1. Check control unit connection and correct insertion of the relative rubber plug.
2. Check the correct fastening of metallic bracket screw on the throttle body.
3. Check the right and left injectors connection.
4. Check the water temperature sensor connection (Blue connector).
5. Check correct insertion of H.V. Cables with Coils.
6. Check whether the Grey H.V. Cable connects on the Coil with the Grey tape.
7. Check whether the Grey H.V. Cable goes to the Left engine head.
8. Check the Coils connection.
9. Check correct insertion of the engine oil hood and the presence of the clamp.
10.Check ground fastening on the engine, starter motor positive and relative hood.
11.Check NEUTRAL cable fastening.
12.Check whether the right lambda probe is connected to the output labelled "LAMBDA DX" (RH
LAMBDA).
13.Check Regulator and Flywheel connection.
14.Check whether the right lambda probe is inserted on the cable grommet under the clutch housing.
15.Check right and left Lambda connections.
ELE SYS - 60
Electrical system
16.Check the presence of the Pull Up module and the presence of the black hose under the transparent one.
17.Check the Pick Up connection.
18.Check correct insertion of the starter motor hood
19.Check the presence of the Red protective hood on the battery Positive.
20.Check that the stand switch connector is blue and clamped.
21.Check the side stand connection and left lambda.
22.Check that the H.V. cables are connected well to with the NGK plug caps.
23.Check the stand switch cable ties on the frame under the vehicle
THE CIRCLED CONNECTORS ARE DEEMED MORE CRITICAL THAN THE OTHERS
BECAUSE DISCONNECTION OF THESE MAY CAUSE THE VEHICLE TO STOP.
Undoubtedly the connection of the rest of connectors is also important and essential for the
correct operation of the vehicle.
Front side
CAUTION
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND

CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION.
TABLE A
1. Main cable harness
2. Clamp that secures the main cabling to the
headlamp support plate
3. Ambient temperature sensor
4. Clamp that secures the ambient temperature
sensor to the front headlamp support plate
5. GPS wiring connector
6. Front headlamp connector
ELE SYS - 61
Electrical system
TABLE A1
2. Clamp that secures the main cabling to the
headlamp support plate
3. Ambient temperature sensor
4. Clamp that secures the ambient temperature
sensor to the front headlamp support plate
5. GPS wiring connector
TABLE B
1. Voltage regulator connector
2. Profile guards
3. Key connector
4. Left turn indicator connector
5. Flywheel connector
If deemed necessary, the voltage regulator connector (1) and the flywheel
(2) can be tightened with a clamp in order to avoid them disconnecting.
TABLE C
1. Key connector
2. Left turn indicator connector
Both connectors, once connected, are positioned behind the steering tube.
ELE SYS - 62
Electrical system
TABLE D
2. Gas cables
3. Cable tie that secures the cables of the key and
left turn indicator
The gas cables must pass under the

main cabling.
After placing the plastic protection,

check that all the cables come out from
the specific slot.
ELE SYS - 63
Electrical system
TABLE E
1. Left light switch connector
2. Right turn indicator connector
3. Clutch switch connector
4. Right light switch connector
5. Cable tie that secures the cabling in correspondence to the grey tapings
6. Profile guards
TABLE F
Pass all the cabling as indicated and move all the connectors, ensuring that they have been
correctly connected, behind the steering tube.
After placing the plastic protection, check that all the cables come out from the specific slot.
TABLE G
ELE SYS - 64
Electrical system
1. Front brake switch

2. Clamps
3. Cable guide
TABLE G1
Add a cable guide
TABLE H
1. Clamp
2. Cable guide
ELE SYS - 65
Electrical system
TABLE H1
Add a cable guide
Central part
CAUTION

TABLE A
1. Oil pressure bulb
2. Engine head temperature sensor
3. Right injector
4. Rear stop switch
5. Gear in neutral switch
6. Left injector
TABLE B
1. Rear stop switch
2. Clamps
ELE SYS - 66
Electrical system
TABLE C
1. Side stand switch
2. Clamps
TABLE D
1. Side stand cabling
2. Cable tie that secures the side switch cabling to the frame
TABLE E
1. Side stand switch connector
ELE SYS - 67
Electrical system
TABLE F
1. Starter motor actuator connector
2. Side stand cabling
TABLE G
Check that the hood which covers the

starter motor positive is inserted well
and that the nut is secured correctly to
the prescribed torque.
TABLE H
1. Gear in neutral switch
2. Cable grommet
ELE SYS - 68
Electrical system
TABLE I
2. Cable ties that secure the main cabling to the
frame
3. Left cylinder coil
4. Right cylinder coil
TABLE L
2. Cable tie that secures the main cabling to the
frame
TABLE M
1. Left lambda probe
2. Right Lambda probe
Pay close attention that the right lambda probe cabling passes through the
cable grommet (3)
TABLE N
1. Left lambda probe connector
2. Cable tie that secures the cabling of the left
lambda probe
The left lambda probe goes behind to

the saddle lock.
ELE SYS - 69
Electrical system
TABLE O
1. Neutral switch connector
2. Right Lambda probe connector
3. Cable tie that joins the switch connectors and
the right lambda probe
TABLE P
1. Battery positive
Check the cable which goes from the battery positive to the fuse box to be sure it is covered
by the sheath and that the terminal is covered by the heat-shrink.
2. Battery negative
Check that the end of the engine ground leads is positioned as illustrated in the image and
that there is perfect surface contact once the screw is tightened.
3. Taillight connector
4. Speed sensor connector
5. Clamps
TABLE P1
1. Cable guide that secures the rear stop light cable and the rear brake caliper pipe
ELE SYS - 70
Electrical system
TABLE P2
1. Insert the cable tie to prevent the cables (right
and left turn indicators and license plate light) from
coming down in the hole.
2. Big clamp.
3. Taillight cable harness.
TABLE Q
1. Taillight connector
2. Speed sensor connector
Hide the taillight and speed sensor

connectors between the filter box and
mudguard
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Electrical system
TABLE R
1. Engine oil bulb
2. Clamp
TABLE S
1. Control unit connector
2. Control unit fastening bracket
TABLE T
1. Module with resistance (Pull UP)
TABLE U
1. Left cylinder coil
The grey taping marks the left cylinder coil connector
ELE SYS - 72
Electrical system
TABLE V
1. Voltage cable
2. Coil
Indication of correct connection of the high voltage cable on the coils
TABLE W
1. High voltage cable covered by black sheath for right cylinder
2. High voltage cable covered by grey sheath for left cylinder
ELE SYS - 73
Electrical system
TABLE X
1. Pick Up connector
TABLE Y
1. Left horn
2. Right horn
Back side
CAUTION

TABLE A
1. Rear speed sensor cabling
2. Medium clamps
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Electrical system
General wiring diagram
key:
1. Multiple connectors
2. Air temperature sensor
3. Speed sensor
4. Instrument panel
ELE SYS - 75
Electrical system
5. Light relay
6. Starter motor relay
7. Clutch switch
8. Right light switch
9. Horn
10.Left light switch
11.GPS wiring
12.Rear stop switch
13.Front stop switch
14.Ignition switch
15.Rear right turn indicator
16.Stop - position bulb
17.Rear light
18.Rear left turn indicator
19.Starter motor
20.Battery
21.Pull Up (resistance)
22.Fuses
23.Flywheel
24.Regulator
25.Lambda 1 (left exhaust)
26.Lambda 2 (right exhaust)
27.Side stand switch
28.Injection load relay
29.Fuel reserve sensor
30.Fuel pump
31.Injector 1 (left cylinder)
32.Injector 2 (right cylinder)
33.Coil 2 (right cylinder)
34.Coil 1 (left cylinder)
35.Neutral sensor
36.Oil sensor
37.Pick UP
38.Engine head temperature sensor
39.MIU G3 control unit
40.Diagnosis
41.Front left turn indicator
42.Headlight
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Electrical system
43.Front position
44.High/low beam bulb
45.Front right turn indicator
46.47.48.49.50.Cable colour:
Ar orange
Az sky blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi purple
Checks and inspections

Dashboard
Service warning light reset
The system displays the function as

follows:
the word "MAInt" is shown on the left LCD Display

(1) after the mileage corresponding to the first
servicing or any subsequent servicing is exceeded.
This is shown only after each start-up

for 5 seconds; afterwards, it will shift to
the standard view.
ELE SYS - 77
Electrical system
To reset Service proceed as follows:
Hold down the key (A).
Turn the ignition key to "ON".
Wait for the Key OFF.
The next time the vehicle is started, the value will

be reset and the word "MAInt" will not be displayed
until the next mileage for which maintenance is
foreseen.
Battery recharge circuit

RECHARGING SYSTEM
Slightly lift the fuel tank, being careful

not to pull the pipes with the relative
hooks;
Remove the connectors from the compartment behind the steering column
Disconnect the three-way connector

(1) (white).
NOTE
THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A"
Measurement of resistance (with engine off)
For a correct detection of the generator

resistance, an ambient temperature
measurement must be carried out and
afterwards a heat stabilisation by using
a tester, double tightening the 3 connector pins: stage "1" (pin 1-2), stage
"2" (pin 1-3), stage "3" (pin 2-3).
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Electrical system
Take the measurement; The correct value is determined by the value measured for each
stage in which from time to time the resistance of the tester wires is subtracted, obtained by
touching the two lugs.
Example:
Resistance of stage 1 read on the display = 0.67 Ohm
Resistance of the wires read on the display = 0.47 Ohm
Effective resistance stage 1 = 0.67-0.47 = 0.20 Ohm
RESISTANCE MEASURE
Winding stage
Stage 1
Ambient temperature (ohm)

0.18 - 0.23
Afterwards heat stabilisation (ohm)

0.20 - 0.25
Empty voltage
Disconnect the three-way connector (1);
For a correct detection of the alternator voltage, a measurement must be carried out using
alternatively the 3 engine side connector pins: stage "1" (pin 1-2), stage "2" (pin 1-3), stage
"3" (pin 2-3).
Take the measurements;
If there is a significant difference between one stage and another (other than 15 V), this
means that the alternator is defective and must be replaced.
CAUTION
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Electrical system
WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE
DETECTED WITH THE ENGINE COLD.
TENSIONE A VUOTO
Giri / min
Vm tensione concatenata Valori di riferimento ( V
rms )
2000
40 - 45
4000
82 - 87
6000
132 - 138
Short circuit current
For a correct detection of the short circuit current, a connector must be prepared that generates a downstream
short circuit between the three alternator cables;
Start the engine and with an ammeter

clamp measure each single cable.
If there is a significant difference between the measure of the single cables

(other than 10 A), this means that the
alternator is defective and must be replaced.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE
ON AVERAGE 2-3 A LESS THAN THOSE DETECTED WITH
THE ENGINE COLD.
WARNING
NEVER KEEP THE ENGINE RUNNING FOR MORE THAN
ONE MINUTE; FAILURE TO DO SO COULD CAUSE SERIOUS OVERHEATING DAMAGES TO THE MOTORCYCLE
CIRCUITS.
COLD SHORT CIRCUIT CURRENT

RPM
RMS DC current (Arms) (average of the 3 stage
currents)
2000
26 - 30
4000
20 - 25
6000
30 - 35
8000
30 - 35
Voltage on battery poles with engine speed always between 3000 - 5000 RPM
Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM,
then measure with a tester the voltage at the battery poles that must always be between
13V and 15V. Otherwise, if the correct operation of the alternator has already been checked,
replace the alternator.
CAUTION
PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION (START
VOLTAGE ABOUT 13V) MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIRCUIT.
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Electrical system
Start-up system check

pick-up input about 100 A
STARTER COMMAND
Function
Commands engine starting through the injection
control unit.
Operation / Operating principle
The starter button, the brake switches, the No. 6
starter command relay and the injection control
unit between PIN 6 and 10 are involved.
Level in electrical circuit diagram:Start-up relay
Location:
Under the fuel tank.
Pin-out:
1. control unit relay output (blue/yellow cable)
2. ignition switch live control unit (green/red cable)
3. starter motor (violet cable)
4. /
5. ignition switch live control unit (green/red cable)
ELECTRICAL ERRORS
Starter command P0170 - shorted to positive.
Error cause
Shorted to positive: excessive voltage at PIN 10 of the control unit connector.
Troubleshooting
Shorted to positive:
This malfunction is detected with a brake activated and the starter button pressed (voltage
of 12V read at PIN 6).
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Electrical system
If the battery voltage does not drop (thanks to the absorption of the No. 6 starter command
relay excitation coil) the control unit understands that PIN 10 is shorted to battery.
Restore the cabling (if the short is in the cabling) or the relay (if the short is in the relay).
NOTE
IN CASE OF SHORT TO GROUND / OPEN CIRCUIT NO ERROR WILL APPEAR: SEE THE TROUBLESHOOTING CHAPTER, THE ENGINE DOES NOT START.
level indicators
Petrol pump:
Input 4A (to be measured between pins 1 and 2
with 12V supply voltage)
Fuel level sensor:
Resistance 1.4 Ohm (to be measured between
pins 3 and 4 with fuel level equal to 0 litres)
Lights list
BULBS
Specification
Low/High beam headlight (halogen)
Front daylight running light
Turn indicator light
Licence plate light
Tail light / stop light
Dashboard lighting
ELE SYS - 82
Desc./Quantity
12 V - 55 W / 60 W H4
12V - 5W
12 V - 10 W (orange RY 10 W bulb)
12V - 5 W
12 V - 5 / 21 W
LED
Electrical system
Fuses
FUSE DISTRIBUTION
A) Stop, daylight running lights, horn (10 A).
B) GPS installation, low / high-beam lights, passing (15 A).
C) Control unit, engine kill, starter relay, instrument
panel, injection load relay (15 A).
D) (Battery positive) Instrument panel, turn indicators (5 A).
E) - (Battery positive), MIU G3 Control unit (5A).
F) Main fuse, coil 1 and 2, injector 1 and 2, lambda
1 and 2 (30 A).
Control unit
Engine control unit Magneti Marelli MIU G3
ELE SYS - 83
Electrical system
Battery
Characteristic
Battery
12V - 12 Ah
Speed sensor
Function
To indicate the vehicle speed by reading the rear
wheel turning speed.
Hall effect sensor: a square-wave pulse is generated with voltage between 12V and approximately
0.6 V.
Level in electrical circuit diagram:
Speed sensor
Location:
Sensor: on the swingarm, left side,

next to the rear brake calliper.
Connector: under right fairing, next to

the Marelli control unit.
Pin-out:
PIN:
PINS 1-3 Voltage: approx. 12 V
PINS 2-3 Voltage: between 0.6V-12V

(turning the rear wheel)
1. Power supply voltage (Orange/White - sensor side)

2. Output signal (Blue/Orange - sensor side)
3. Ground (Blue - sensor side)
ELECTRICAL ERRORS
Error cause
ELE SYS - 84
Electrical system
Faulty sensor or cabling, interference on the signal

Troubleshooting
Disconnect the sensor connector.
Verify, with the key ON, the voltage between sensor PIN 1-3.
If no voltage is detected, check the continuity of the cabling between sensor PIN 1 and
instrument panel connector PIN 13.
Carry out the check procedure on instrument panel connector PIN 13.
If the cabling is intact, check for continuity with the sensor PIN 3 ground.
Check continuity of the cabling between sensor PIN 2 and instrument panel connector PIN
17.
Carry out the check on instrument panel PIN 17.
In the event that these checks have not detected the fault, replace the sensor.
Engine rpm sensor

Function
It informs crankshaft position and speed to the
Marelli control unit.
Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the
reference position.
Level in electrical circuit diagram:engine speed
sensor
Location:
Sensor: engine front left section, under

the left cylinder.
Connector: under the fuel tank.
Electrical characteristics:
Winding resistance: 650 15% Output alternating voltage, value range:

minimum: 0.5 V - maximum: 5 V
Pin-out:
1. Engine speed sensor positive signal (cable
X2)
2. Engine speed sensor negative signal (cable
X1)
ELE SYS - 85
Electrical system
3. Engine speed sensor anti-jamming cable

(blue/green cable)
PARAMETERS
Target engine revs
Example value:1100 +/- 100 rpm
Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep
the engine running at this revs, acting on the ignition advance.
STATUSES
Synchronisation
Example value:Synchronised / Not synchronised
Indicates if the control unit detects the engine speed sensor signal correctly
ELECTRICAL ERRORS
Cause
Faulty cabling or pick up
Troubleshooting
An interruption in the sensor circuit has been detected, from PIN 20 to PIN 29 of the control
unit connector.
Check the sensor connector and the injection ECU connector:
If the values are incorrect restore them.
If the values are correct, check the continuity of the two cables that go from PIN 20 to PIN
29 of the control unit connector:
If there is no continuity, restore the cabling.
If there is continuity check interruption in the sensor and replace it.
Short circuit.
Conduct an electrical check of the sensor.
If the sensor check value is incorrect replace it.
If the value is correct, check insulation of the power from ground of the two cables.
Conduct tests from the sensor connector toward the sensor.
If the sensor value is incorrect restore the cabling/replace the sensor.
If the value is correct conduct tests from PIN 20 and 29 of the Marelli control unit connector
toward the cable harness.
Installation
ELE SYS - 86
Electrical system
Place the sensor plus the corresponding spacers; the air gap should be between 0.7 and 0.9 mm.
Engine temperature sensor

Function
indicates the engine temperature to the control unit
so as to optimise carburetion and idle control
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:
on the right head, next to the throttle

body
connector: on the sensor
Resistance at 0C: 9.75 k 5%
Pin-out:
Grey (cable harness side): 0-5 V signal
Blue/green (cable harness side):

Ground connection
ELECTRICAL ERRORS
Engine temperature sensor P0115 - open circuit or shorted to positive / shorted to negative.
Error cause
Open circuit or shorted to positive: interruption of the circuit or excessive voltage at PIN 13 of the control
unit connector.
Shorted to negative: null voltage between PIN 13 and 15 of the control unit connector.
Troubleshooting
The circuit is open:
Disconnect the connector of the control unit.
ELE SYS - 87
Electrical system
Measure the resistance value of the sensor at different temperatures between PIN 13 and
15.
Verify continuity of the cabling between the sensor connector and the control unit connector:
Control unit PIN 13 - sensor PIN 2 and control unit PIN 15 - sensor PIN 1. Restore the cabling
if necessary.
If the cabling is intact but the sensor resistance value is incorrect, this means that the sensor
is faulty and must be replaced, otherwise proceed with the checks.
With the sensor connector and the control unit disconnected, verify that the fault is shorted
with the battery positive of sensor connector PIN 2 (or control unit PIN 13) and restore the
cabling.
Shorted to negative:
Check the sensor connector PIN 2 ground insulation.
If there is no ground insulation restore the cabling.
If PIN 2 is insulated from the ground and the error persists, this means that there is a probable
fault in the control unit.
Lambda sensor
Function
In charge of telling the control unit whether the
mixture is lean or rich.
The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen content between the exhaust fumes and the
ambient. It does not require an external supply
source but, in order to work properly, it should
reach a high operating temperature: that is why
there is a heating circuit inside.
Level in electrical circuit diagram:Right Lambda probe
Location:
sensor: right exhaust pipe
ELE SYS - 88
Electrical system
connector: near the throttle body right

side
Heater circuit: 12 -14 at 20 C (68 F)
Pin-out:
1. Sensor signal + (grey/white wire)
2. Sensor signal - (green/white wire)
3. Heater ground (white/yellow)
4. Heater power supply (white)
ELECTRICAL ERRORS
Check the air-fuel ratio / right Lambda probe P0130 - short to positive / open circuit, short to negative
or carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault.
Error cause
Shorted to positive: excessive voltage at PIN 18 or PIN 12 of the control unit connector.
Circuit open or shorted to negative: interruption of the circuit or null voltage between control unit connector PIN 18 and 12.
Troubleshooting
Disconnect the control unit connector and the sensor connector.
Verify that there is no short to battery positive on sensor connector PIN 1 (corresponding to
control unit connector PIN 18); if there is a short, restore the cabling.
if necessary.
If the cabling is intact and the error persists, proceed with the following checks.
ELE SYS - 89
Electrical system
Disconnect the sensor connector and the control unit connector.
Check the sensor connector PIN 1 ground insulation. In the absence of insulation restore
the cabling.
the cabling.
If PIN 1 and PIN 2 are insulated from the ground and the error persists, this means that there
is a probable fault in the control unit.
Lambda probe heater P0135 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to negative: lack of insulation from ground on the sensor connector PIN 4.
The circuit is open: interruption of the circuit.
Troubleshooting
Control unit PIN 2 - sensor PIN 3. Restore the cabling if necessary.
Verify continuity of the cabling between the sensor connector and the injection relay: sensor
PIN 4 - injection relay PIN 3. Restore the cabling if necessary.
the cabling.
If PIN 3 is insulated from ground and in the absence of other errors (fuel pump, injector, coil),
this means that the control unit is most likely faulty.
ELE SYS - 90
Electrical system
LEFT LAMBDA
Level in electrical circuit diagram:Left lambda
probe
Location:
sensor: right exhaust pipe
connector: adjacent to the filter box, left

side
Heater circuit: 12 -14 at 20 C (68 F)
Pin-out:
1. Sensor signal + (pink wire)
2. Sensor signal - (green/white wire)
3. Heater ground (violet/white)
4. Heater power (red/brown cable)
ELECTRICAL ERRORS
Check the air-fuel ratio / right Lambda probe P0136 - short to positive / open circuit, short to negative
or carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault.
Error cause
Shorted to positive: excessive voltage at PIN 11 or PIN 12 of the control unit connector.
Circuit open or shorted to negative: interruption of the circuit or null voltage between control unit connector PIN 11 and 12.
Troubleshooting
ELE SYS - 91
Electrical system
if necessary.
Disconnect the sensor connector and the control unit connector.
the cabling.
the cabling.
If PIN 1 and PIN 2 are insulated from the ground and the error persists, this means that there
is a probable fault in the control unit.
Lambda probe heater P0141 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to negative: lack of insulation from ground on the sensor connector PIN 4.
Troubleshooting
Control unit PIN 31 - sensor PIN 3. Restore the cabling if necessary.
Verify continuity of the cabling between the sensor connector and the injection relay: sensor
PIN 4 - injection relay PIN 3. Restore the cabling if necessary.
ELE SYS - 92
Electrical system
the cabling.
If PIN 3 is insulated from ground and in the absence of other errors (fuel pump, injector, coil),
this means that the control unit is most likely faulty.
Injector
Function
To supply the correct amount of petrol at the right
timing.
Injector coil is excited for the petrol passage to
open.
Level in electrical circuit diagram:Coils and injectors
Right injector position:
on the intake manifold
connector: on injector
Electrical characteristics:14.8 Ohm +/- 5% (at

20 C - 68 F)
Pin-out:
1. Power 12V (red/brown cable)
2. Ground (grey/red cable)
ELECTRICAL ERRORS
Front injector P0201 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to negative: null voltage at PIN 1 of the injector connector.
Troubleshooting
ELE SYS - 93
Electrical system
Disconnect the injector connector, turn the key to ON and activate the component through
the diagnostics instrument.
Verify the absence of voltage at the injector connector PIN 2; if present, restore the cabling,
otherwise proceed with the following checks.
Verify the presence of voltage at the ends of the injector connector; if there is no voltage,
restore the cabling, otherwise proceed with the following checks.
Carry out the check procedure of the injector and control unit connectors.
Verify continuity of the cabling between the control unit connector and the injector connector
(control unit PIN 32 - injector PIN 2). In the absence of continuity restore the cabling.
LEFT INJECTOR
Level in electrical circuit diagram:Coils and injectors
Left injector position:
on the intake manifold
connector: on injector
Electrical characteristics:14.8 Ohm +/- 5% (at

20 C - 68 F)
Pin-out:
1. Power 12V (red/brown cable)
2. Ground (grey/black cable)
ELECTRICAL ERRORS
Left injector P0202 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to negative: null voltage at PIN 1 of the injector connector.
Troubleshooting
ELE SYS - 94
Electrical system
Verify the absence of voltage at the injector connector PIN 2; if present, restore the cabling,
otherwise proceed with the following checks.
Verify the presence of voltage at the ends of the injector connector; if there is no voltage,
restore the cabling, otherwise proceed with the following checks.
Carry out the check procedure of the injector and control unit connectors.
Verify continuity of the cabling between the control unit connector and the injector connector
(control unit PIN 34 - injector PIN 2). In the absence of continuity restore the cabling.
Fuel pump
Function
Fuel pump: keeps pressure of the injectors supply
duct.
Low fuel: tells to the instrument panel about low
fuel
Low fuel: it is a resistance that if correctly supplied
varies its electrical resistance if it is damped or not
by petrol.
Level in electrical circuit diagram:
Injection load relay
Location:
on the vehicle: on the tank.
connector: on the front left part of the

bike, under the fuel tank.
Pin out:
1. + 12V (red/brown cable)
2. ground (black cable)
3. Signal + to instrument panel (orange/violet
cable)
ELE SYS - 95
Electrical system
4. Ground (blue cable)

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
ELECTRICAL ERRORS
Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit.
Error cause
Shorted to negative: null voltage at PIN 2 of the injection relay.
Troubleshooting
Disconnect the injection relay (No. 28 on the electrical circuit diagram), turn the key to the
ON position and activate the relay through the diagnostics instrument.
Verify the presence of voltage between relay connector PIN 1 and 2 toward the cabling.
If no voltage is read, disconnect the control unit and verify insulation from battery positive
of the relay PIN 1 (or control unit PIN 22). Restore the cabling if necessary.
Disconnect the injection relay (No. 28 on the electrical circuit diagram) and the control unit.
Verify ground insulation of the relay connector PIN 1 and 2 toward the cabling: if there is no
insulation, restore the cabling.
Disconnect the injection relay (No. 28 on the electrical circuit diagram) and the control unit.
Verify continuity of the cabling between the relay and control unit: Relay PIN 1 - control unit
PIN 22. Restore the cabling if necessary.
Coil
Function
It controls the ignition spark plug in order to generate the fuel ignition spark.
Inductive discharge system.
Level in electrical circuit diagram:Left coil and
injector
Location:
ELE SYS - 96
centred under the fuel tank.
connector: on the coils.
Electrical system
Primary winding resistance: 550 k

10%
Secondary winding resistance: 3 k

10%
Tube resistance 5 k
Pin-out:
1. Circuit ground (orange/white cable)
2. Power (red/brown cable)
ELECTRICAL ERRORS
H.V. Coil P0351 - shorted to positive / open circuit or shorted to negative.
Error cause
Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 1 of the control unit
connector.
Troubleshooting
Disconnect the coil connector, turn the key to ON and activate the component through the
diagnostics instrument.
Verify the presence of voltage on the coil connector PIN 1: if present, restore the cabling,
otherwise replace the coil.
Carry out the check procedure of the coil and control unit connectors.
Verify continuity of the cabling between the coil and control unit: Coil PIN 1 - control unit PIN
1. In the absence of continuity restore the cabling.
Verify, with the key turned ON, the presence of voltage on the coil connector PIN 2. If no
voltage is read, verify the continuity of the cabling between coil and injection relay (No. 34
on the electrical circuit diagram): Coil PIN 2 - relay PIN 3.
If the above tests provided a positive result, the coil should be replaced.
ELE SYS - 97
Electrical system
Disconnect the control unit connector and the coil connector.
Verify the coil connector PIN 1 ground insulation (or control unit connector PIN 1). Restore
the cabling if necessary.
RIGHT COIL
Level in electrical circuit diagram:Right coil and
injector
Location:
centred under the fuel tank.
connector: on the coils.
Primary winding resistance: 550 k

10%
Secondary winding resistance: 3 k

10%
Tube resistance 5 k
Pin-out:
1. Power (red/brown cable)
2. Power ground 2 (blue cable)
3. Circuit ground (orange/red cable)
ELECTRICAL ERRORS
H.V. Coil P0352 - shorted to positive / open circuit or shorted to negative.
Error cause
Circuit open or shorted to negative: interruption of the circuit or null voltage at PIN 8 of the control unit
connector.
Troubleshooting
Disconnect the coil connector, turn the key to ON and activate the component through the
diagnostics instrument.
Verify the presence of voltage on the coil connector PIN 3: if present, restore the cabling,
otherwise replace the coil.
Carry out the check procedure of the coil and control unit connectors.
Verify continuity of the cabling between the coil and control unit: Coil PIN 3 - control unit PIN
8. In the absence of continuity restore the cabling.
ELE SYS - 98
Electrical system
Verify, with the key turned ON, the presence of voltage on the coil connector PIN 1. If no
voltage is read, verify the continuity of the cabling between coil and injection relay (No. 33
on the electrical circuit diagram): Coil PIN 1 - relay PIN 3.
If the above tests provided a positive result, the coil should be replaced.
Disconnect the control unit connector and the coil connector.
Verify the coil connector PIN 3 ground insulation (or control unit connector PIN 8). Restore
the cabling if necessary.
Engine oil pressure sensor

Function:Indicates the instrument panel if there is
enough oil pressure (0.35 +/- 0.2 bar) (5.1 +/- 2.9
PSI) in the engine.
Operation / Operating principle: normally closed
switch. With oil pressure above 0.35 +/-0.2 bar (5.1
+/- 2.9 PSI), open circuit.
Level in wiring diagram:fuel reserve and oil pressure.
Location:
sensor: between the two heads, at the

back.
connector: on the sensor.
With engine off: closed circuit (continuity).
With engine started: open circuit (infinite resistance).
Pin-out: Voltage 12V

Instrument panel
Warning light always off
Troubleshooting
Check the sensor connector and the instrument panel connector (PIN 11): If not OK, restore.
If OK, check the continuity of the purple cable between the sensor connector and the instrument panel connector PIN 11: if not OK, restore the cable harness; if OK, replace the
sensor
Warning light always on

Troubleshooting
ELE SYS - 99
Electrical system
Detach the sensor connector and check the purple cable is ground insulated: if there is
continuity to ground, restore the cable harness; if it is ground insulated, replace the switch.
It this error persists, use a pressure gauge to check the pressure of the oil in the engine
circuit
Neutral sensor
Function
it tell the gear position to the instrument panel: if it
is in neutral or in gear.
for neutral gear, the circuit is closed to ground connection: the instrument panel turns on the neutral
warning light.
Level in electrical circuit diagram:Start-up enabling switches
Location:
sensor: rear / upper section of the gearbox
connector: on the sensor
Gear in neutral: closed circuit (0 V on

wire from control unit to sensor / switch
in continuity).
Gearshift engaged: circuit open (12 V

on the wire from control unit to sensor)
Pin-out:
1. Voltage 12V (green/black cable)
Instrument panel
NEUTRAL warning light always off
Troubleshooting
Carry out the check procedure on the green black sensor/control unit cable.
Restore if damaged.
If OK, with the transmission in neutral, check for continuity to ground of the sensor connector.
If there is no continuity, replace the sensor.
If OK, carry out the check procedure of the brown black cable between control unit and
instrument panel.
ELE SYS - 100
Restore if damaged.
If OK, check continuity.
If OK, replace the instrument panel if the vehicle performs properly.
Electrical system
NEUTRAL Warning light always on

Troubleshooting
Disconnect the terminals from the sensor and verify that, with the transmission in gear, there
is continuity with the ground.
If there is continuity, replace the sensor.
If there is no continuity this means that there is a short to ground of the green black cable
which goes to PIN 3 of the control unit, therefore restore the cabling.
If the error persists, disconnect the terminals from control unit PIN 17 to instrument panel
PIN 10 and verify continuity.
If there is no continuity, replace the cabling.
Clutch lever sensor

Function
It tells the clutch lever position to the control unit.
In order to start the engine, pull the clutch also with
the gear in neutral.
Level in electrical circuit diagram:Start-up enabling switches.
Location:
sensor: under clutch lever
connector: under the fuel tank on right

side
Clutch pulled: closed circuit (continuity)
Clutch released: open circuit (infinite

resistance)
Pin-out:
1. 12 V Voltage (brown white cable)
2. Ground (blue black cable)
Even with the clutch lever pulled, the vehicle does not start
ELE SYS - 101
Electrical system
Troubleshooting
Verify that, if a gear is engaged, the stand is up.
If it is up, check continuity of the brown/white cable and control unit PIN 14.
If there is continuity, disconnect the sensor and, with the clutch pulled, check for continuity
between the two sensor PINs.
If absent, replace the sensor.
If present, check for continuity of the blue violet cable between the sensor and control unit
PIN 15.
If absent, restore the cable harness.
The vehicle starts even without pulling the clutch lever

Troubleshooting
Disconnect the terminals from the sensor and check that, with the clutch released, there is
continuity between the two PINs.
If there is continuity, replace the sensor.
If there is no continuity, this means that the blue violet cable which goes from the sensor
PIN 2 to the control unit PIN 15 is shorted to ground.
Side stand sensor

Function
It tells the side stand position to the control unit.
If the gear is engaged and the side stand is unfolded, and therefore the circuit is open, the control
unit does not enable vehicle start-up or shuts off
the engine if it is rotating.
Level in electrical circuit diagram:Start-up enabling switches
Location:
sensor: on side stand supporting plate
connector: left side, near the starter

motor
Side Stand Up: closed circuit (continuity)
ELE SYS - 102
Electrical system
Side Stand Down: open circuit (infinite

resistance)
Pin-out:
Blue green (cable harness side):

ground connection
Grey yellow (cable harness side): Voltage 12V
Troubleshooting
The vehicle with clutch pulled, gear engaged and side stand retracted does not start (side
stand switch always open): verify continuity of the grey/yellow cable between the sensor and
PIN 19 of the control unit.
If absent, restore the cable harness, if present, with the stand up, check for continuity between the 2 PINs on the sensor. If absent, replace the sensor. If present, check for continuity
to ground of the blue/green cable on the cable harness side connector.
The vehicle, with clutch operated and gear engaged, starts but with the side stand extended:
disconnect the sensor connector and check that, with side stand extended, there is not
continuity between the 2 PINS.
If present, replace the sensor. If absent, disconnect from control unit PIN 19 and check
insulation from the ground of the grey/yellow cable between sensor and control unit.
Air temperature sensor - instrument panel

Function
It tells the ambient air temperature to the instrument panel.
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:
under instrument panel supporting

bracket
connector: under the start-up lock
Resistance at 0C: 32.5 kOhm +/- 5%
Resistance at 25C: 10.0 kOhm +/- 5%
ELE SYS - 103
Electrical system
Pin-out:
1. Voltage 5V (pink cable)
2. Ground (blue cable)
Air temperature sensor fault

Error cause
An instrument panel temperature sensor failure is signalled when it is detected that the
sensor circuit is open or shorted to positive/negative
Troubleshooting
Check the sensor connector and the instrument panel connector (PIN 12):
Restore if not OK.
If OK check continuity of pink cable between the sensor connector (cable harness side) and
PIN 12 of the instrument panel connector.
If there is continuity check correct resistance of the sensor:
If the sensor resistance is not OK replace the sensor.
If OK check, with the key turned ON, for the presence of voltage at sensor connector PIN
1:
If there is no voltage at PIN 1 replace the instrument panel.
If about 12 V is present, restore the cabling (there is a short to battery).
If about 5 V is present, connect a 10 kOhm resistance to PIN 1 of the sensor connector and
the vehicle ground.
If, with the key ON, the voltage measured upstream of the resistance drops, replace the
instrument panel. If it continues to stay at about 5 V restore the pink cable (there is a short
to + 5V).
ELE SYS - 104
Electrical system
In case there is a short circuit to ground connection of PIN 12 of the instrument panel connector:
Check the ground insulation of the sensor connector pink cable:
If connected to ground, restore the cabling. If insulated from ground, check correct resistance
of the sensor:
if not OK, replace the sensor; if OK, replace the instrument panel
RUN/STOP switch
Function
It tells the control unit if the rider wishes to enable
engine start-up or to keep the engine running.
If the driver wants to shut off the engine or to disable engine start-up, the switch should be open,
i.e. the Marelli control unit should not detect voltage at PIN 26 of the control unit connector.
Level in electrical circuit diagram:start-up enabling switches.
Location:
sensor: right light switch
connector: next to the headstock, right

side
STOP position: the circuit is open
RUN position: closed circuit (continuity)
PIN:
pink/yellow cable (looking at the cabling):
voltage 0 V with engine kill in STOP;
12V if engine kill in RUN.
Blue/Green cable (cable harness side): always voltage 12 V (with key on)
DIAGNOSIS
The engine does not start: disconnect the connector and check, with the switch set to RUN,
that there is continuity between the two grey/light blue and red/white cables (sensor side):
if absent replace the sensor; if present carry out the check procedure on the connector; if
not OK restore the cabling; if OK verify, with the key ON, the presence of voltage on the
blue/green cable (cable harness side); if absent, restore cabling; if present verify insulation
ELE SYS - 105
Electrical system
from ground of the red/yellow cable (cable harness side). If there is continuity with ground
connection, restore the cable harness; if it is OK, set the key to KEY OFF and check the
control unit connector; if it is OK, replace the Marelli control unit
Engine does not shut off with switch in "STOP": disconnect the connector and verify, with
the switch set to STOP, that there is continuity between the two grey/light blue and red/white
cables (sensor side). If present, replace the switch; if absent this means that, with the key
ON, the pink/yellow cable shorts to positive: restore the cable harness. If cable harness is
OK, replace the Marelli control unit
Connectors
ECU
PIN:
1. Throttle position sensor supply - Power output
2. Lambda probe signal (ground) - Analogue
input
3. Rpm indicator control - Frequency output
4. Cylinder head temperature sensor signal Analogue input
5. 6. Right injector control - Power output
7. Engine revolution sensor - Frequency input
8. Lambda probe signal (positive) - Analogue
input
9. Diagnosis line (K) - Communication line
10.Diagnosis line (L) - Communication line
11.Throttle position signal - Analogue input
12.Engine revolution sensor - Frequency input
13.Right injector control - Power output
14.Right coil control - Power output
15.Injection telltale light control - Digital output
16.Fall sensor signal - Digital input
17.Control unit supply - Power input
18.Intake air temperature sensor signal - Analogue input
19.Injection relay control - Digital output
ELE SYS - 106
Electrical system
20.Left coil control - Power output

21.22.Sensors supply (ground) - Power output
23.Control unit supply (ground) - Power input
24.Control unit supply (ground) - Power input
25.26.Control unit supply (+15) - Power input
Dashboard
PIN:
1. Right arrow input
2. Set rework input
3. High-beam lights input
4. n.c.
5. n.c.
6. Rear left arrow output
7. Front left arrow output
8. EFI input
9. Left arrow input
10.Neutral input
11.Oil input
12.Air temperature input
13.Speed sensor power supply
14.Ground connection
15.K Line
16.n.c.
17.Speed input
18.Engine revs input
19.n.c.
20.Reserve input
21.Key
22.Ground connection
23.Battery
24.Front right arrow output
25.Rear right arrow output
26.Battery
ELE SYS - 107
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
FRAME
pos.
1
2
3
4
5
6
Description
blocks to frame
Type
M8x14
Quantity
2
Torque
25 Nm (18.44 lbf ft)
Notes
-
M10x30
M10x55
M10x205
M8x16
4
2
1
4
50 Nm (36.88 lbf ft)

50 Nm (36.88 lbf ft)
50 Nm (36.88 lbf ft)
25 Nm (18.44 lbf ft)
Loctite 243
M8x16
25 Nm (18.44 lbf ft)
Vehicle preparation
To arrange for the removal of the engine block, you must first remove the saddle, fuel tank,
side fairings and the battery
From the front, secure the vehicle with belts attached to a hoist
Position a centre stand under the engine sump
Position an engine support so as not to damage the rubber bellows of the drive shaft
See also
Side body panels
Fuel tank
Specific operations for the vehicle
ENG VE - 109
Engine from vehicle
Removing the engine from the vehicle
Remove the spark plug covers
Disconnect the caps from the spark

plugs
Remove the timing sensor fixing

screws.
Remove the sensor, being careful to

recover the gasket.
Disconnect the alternator connector
ENG VE - 110
Engine from vehicle
Remove the fixing screws of the injectors and disconnect them
Disconnect the engine temperature

sensor connector
Loosen the clamps securing the sleeve

and remove it
Disconnect the oil pressure bulb connector
ENG VE - 111
Engine from vehicle
Remove the fixing screw of the engine

ground wires
Disconnect the clutch cable from the

lever
Disconnect the clutch cable from the

disengagement lever
Remove the screws which fix the air filter box to the frame
ENG VE - 112
Secure the filter box to the frame
Disconnect the neutral sensor connec-
Engine from vehicle
tor.
Lift the filter box and slide the cabling

out through the support plate
After removing the clamp, disconnect the speed sensor and rear stop
Disconnect the side stand switch connector
ENG VE - 113
Engine from vehicle
Remove the cradle fixing screws

guards
Remove the screws fixing the cradle,

making sure to recover the nuts and
washers
Remove the central pin by pulling it

from the right side of the motorcycle
Remove the fixing pin of the rear left

shock absorber
ENG VE - 114
Engine from vehicle
Remove the screw fixing the right-hand

rear right shock absorber and pull it
from the pin on the drive shaft
Remove the side pins, taking care to recover the nuts
Lift the frame and separate it from the

engine block
Installing the engine to the vehicle
Place the frame on the engine block
ENG VE - 115
Engine from vehicle
Insert the central pin from the right side

of the motorcycle, place the washer
and the nut from the opposite side
Insert the side pins and their retainer nuts
Insert the screws with the relative retainer nuts and washers of the cradles
to the frame
Tighten the fixing screws of the cradle to the prescribed torque, the central pin and the side
pins of the engine to the frame
Install the protections of the fixing

screws of the cradles
ENG VE - 116
Engine from vehicle
Insert the right rear shock absorber on

the pin and secure it
Attach the rear left shock absorber via

the appropriate pin with corresponding
nut
Connect the side stand switch connector
Lift the filter box and thread the cable

through the backing plate
Connect the neutral sensor connector
Connect the speed sensor and rear stop
ENG VE - 117
Engine from vehicle
Connect the clutch cable to the trip lever
Connect the clutch cable to the lever
Install the sleeve, paying attention to

the correct positioning of the clamps
before tightening them
ENG VE - 118
Engine from vehicle
Connect the oil pressure bulb connector
Attach the engine ground leads
Connect the engine temperature sensor connector
Connect and secure the injectors
ENG VE - 119
Engine from vehicle
Install the timing sensor with its seal
Connect the alternator connector
Connect the spark plug tubes
Install the covers of the spark plugs
ENG VE - 120
INDEX OF TOPICS
POWER SUPPLY
P SUPP
Power supply
Circuit diagram
Key:
1. Fuel tank
2. Throttle body
3. Fuel filter
4. Fuel delivery pipe
5. Fuel pump unit
Injection
P SUPP - 122
Power supply
Diagram
key:
1. Control unit position
2. Ignition switch
3. Battery
4. Fuel pump
5. Coils
6. Instrument panel
7. Air temperature sensor
8. Throttle valve position sensor
9. Injectors
10.Crankshaft position sensor
11.Engine temperature sensor
12.Lambda probe
P SUPP - 123
Power supply
13.Side stand
ECU INFO screen page

This screen page shows general data regarding
the control unit, for example software type, mapping, control unit programming date
INFO ECU SCREEN PAGE

Specification
Mapping
Desc./Quantity
-
PARAMETERS screen page

This screen page shows the parameters measured by the several sensors (engine revs, engine
temperature, etc.) or values set by the control unit
(injection time, ignition advance, etc.)
SCHERMATA LETTURA PARAMETRI MOTORE

Caratteristica Navigator
Giri motore
Posizione farfalla complessiva
Temperatura motore
P SUPP - 124
Caratteristica P.A.D.S.
Giri motore
Angolo farfalla
Temperatura motore
Descrizione / Valore
Giri al minuto: il valore minimo impostato dalla centralina e
non regolabile
Giri al minuto: il valore minimo impostato dalla centralina e
non regolabile
C
Power supply
Tensione sonda lambda sinistra
Tensione sonda lambda 1
Tensione sonda lambda destra
Tensione sonda lambda 2
Correzione lambda cilindro

sinistro
Correzione lambda cilindro
destro
Passi attuati
Anticipo accensione attuato
Anticipo accensione programmato
Tempo di iniezione
Correzione adattativa cilindro
sinistro
Correzione adattativa cilindro
destro
Pressione atmosferica
Pressione aspirazione
Giri minimo obiettivo
Fattore correzione lambda 1
100 - 900 mV (valori indicativi) Segnale in tensione che la centralina riceve dalla sonda lambda: inversamente proporzionale
alla presenza d'ossigeno
100 - 900 mV (valori indicativi) Segnale in tensione che la centralina riceve dalla sonda lambda: inversamente proporzionale
alla presenza d'ossigeno
-
Fattore correzione lambda 2
Passi attuati
Anticipo attuato
Anticipo programmato
Passi impostati dalla centralina in fase di controllo del minimo

Valore riferito al cilindro sinistro
Valore riferito al cilindro sinistro
Tempo di iniezione
Gain adattativo lambda 1
Gain adattativo lambda 2
Pressione atmosferica
Pressione aspirazione
Regime minimo obiettivo
Il valore stimato dalla centralina

Pressione rilevata nel condotto di aspirazione
E' un valore obiettivo per i giri motore al minimo impostato dalla
centralina (a motore caldo)
Passi corrispondenti alla posizione di riferimento del motore
minimo
Esprime il contributo di aria del motorino minimo in gradi farfalla
Passi programmati
Farfalla equivalente motorino
minimo
Passi programmati
Farfalla equivalente stepper
ACTIVATION screen page

This screen page is used to delete errors in the
control unit memory and to activate some systems
controlled by the control unit.
ATTIVAZIONE DISPOSITIVI
Bobina A.T. cilindro sinistro
Bobina A.T. cilindro destro
Contagiri
Bobina 1
Bobina 2
Contagiri
-
P SUPP - 125
Power supply
Iniettore sinistro
Iniettore destro
Motorino minimo
Riscaldamento sonda lambda
sinistra
Riscaldamento sonda lambda
destra
Rel fari
Rel pompa benzina
Comando warning lamp o
icona EFI
Cancellazione errori
Lettura parametri ambientali
errori
Congela e salva i valori dei
parametri degli stati
Iniettore 1
Iniettore 2
Stepper
Riscaldatore lambda 1
-
Riscaldatore lambda 2
Rel fari
Rel pompa carburante
Spia warning
Using P.A.D.S. for injection system

STATUS screen page
This screen page shows the status (usually ON/
OFF) of the vehicle devices or the operation condition of some vehicle systems (for example, lambda probe functioning status).
STATO DISPOSITIVI
Caratteristica
Navigator
Titolo magro (cilindro
sinistro)
Titolo magro (cilindro
destro)
Motorino minimo
Descrizione / Valore Navigator
Descrizione / Valore P.A.D.S
Titolo magro cilindro 1
Si / No
Si / No
Titolo magro cilindro 2
Si / No
Si / No
Controllo lambda cilindro sinistro
Circuito lambda 1
P SUPP - 126
Motorino minimo
Pronto per l'avviamento / Open loop / OK avvio / O.Loop / ClosLoop / ChiuClosed loop
so
Open loop / Closed loop
Aperto / Chiuso / Diagnosi / Errore
Power supply
Caratteristica
Descrizione / Valore P.A.D.S
Navigator
Controllo lambda cilinCircuito lambda 2
Open loop / Closed loop
Aperto / Chiuso / Diagnosi / Errore
dro destro
Titolo ricco (cilindro sin- Titolo ricco cilindro 1
Si / No
Si / No
istro)
Titolo ricco (cilindro
Titolo ricco cilindro 2
Si / No
Si / No
destro)
Stato motore
Stato motore
Indeterminato / Power-On e Motore Indeterminato / ON/Stop / Key/Stop /
Fermo / Chiave-On e Motore Fermo / Rotaz. / Stallo / PL corso / PL Term /
Motore in rotazione / Stallo Motore /
Sinc_4t
Power-Latch in corso / Power-Latch
terminato / Motore in fase di arresto
Controllo motore
Sincronizzato sul ciclo 4 tempi / Non
sincronizzato sul ciclo 4 tempi
Farfalla
Stato farfalla
Minima apertura / Apertura parzializMinimo / Parziale / PienaPot
zata / Massima apertura
Richiesta di avviamento Richiesta di avviamento
Si / No
Assente / Presente
Quadro segnali del sen- Quadro sincronizzato
Non sincronizzato / Sincronizzato / Parziale / NO / SI / Magro / Ricco /
sore di giri
Parzialmente sincronizzato
Titolo ricco / Errore / Titolo magro
Pulsante di arresto del
Interruttore OFF-Run Marcia consentita / Marcia non conRUN / OFF
motore
sentita
Cavalletto laterale
Su / Gi
Diagnosi short term
Completata / Non completata
sonda lambda sinistra
Diagnosi short term
sonda lambda destra
Errore short term sonda
Si / No / Non rilevabile
lambda sinistra
Errore short term sonda
lambda destra
Diagnosi short term moDiag.motorino
Completa / No eseg.
torino minimo
min.comp
Errore short term motor- Err.motorino minimo
Si / No
ino minimo
Rel ventola
Rel ventola
Non attivato / Attivato
OFF / 2 attivo / 1 attivo / rich. 1 / rich.
2
Modo motore
Modo motore
Indeterminato / Avviamento / AvviaIndeterm / Avviam / Stabiliz /
mento stabilizzato / Avviamento con Avv_dec / Avv_acc / Min_Comp /
decelerazione / Avviamento con ac- Stabile / Minimo / Accel. / Decel. /
celerazione / Minimo compensato
Cut-Off / RCUT-OFF
per l'avviamento / Motore stabile
fuori minimo / Motore al minimo
Modo motore
Modo motore
Motore in accelerazione / Motore in
decelerazione / Cut-Off /
Cambio in folle
Marcia inserita
Si / No
Si / No
Frizione
Frizione
Rilasciata / Tirata
Rilas.ta / Premuta
Sonda lambda sinistra
Operativa / Non operativa (Errore) /
Non operativa (Ricco) / Non operativa (Magro) / Non operativa (Riscaldamento) / Non operativa (Avviamento) / Non abilitata
Sonda lambda destra
Operativa / Non operativa (Errore) /
Non operativa (Ricco) / Non operativa (Magro) / Non operativa (Riscaldamento) / Non operativa (Avviamento) / Non abilitata
Abilitazione alla marcia Consenso avviamento
Si/No
Stato stepper motor
OK avvio / O.Loop / ClosLoop
Sensore ribaltamento
Inibito / Consenso / --- / Crack Decel. / Crank Acceleraz. / Crank Minimo / Stabilizzato / Minimo / Accelerato / Decelerato / Stato CAT-OFF /
Uscita CAT-OFF
Stato ric. Abil . Accen.
OFF / ON / Kick Down / Close Loop /
Diag ShortTerm / Error ShortTerm
P SUPP - 127
Power supply
ERRORS screen page

This screen page shows potential errors detected
in the vehicle (ATT) or stored in the control unit
(MEM) and it allows to check error clearing (STO).
VISUALIZZAZIONE ERRORI
Err
or
e
P0
10
5
P0
11
0
P0
11
5
P0
12
0
P0
13
0
P0
13
5
P0
13
6
P0
14
1
P0
16
9
Caratteristica
Navigator
Caratteristica
P.A.D.S.
Sensore pressione aria
Sensore pressione ambiente
Descrizione / Valore P.A.D.S.
corto circuito a positivo / circuito aperto o Circuito in corto verso il positivo / Circuito
corto circuito verso il negativo / segnale aperto o in corto verso la massa / Segnon plausibile
nale non plausibile
Sensore temper- Sensore temper- circuito aperto o corto circuito a positivo / Circuito aperto o in corto verso il positiatura aria
atura aria
corto circuito verso il negativo
vo / Circuito in corto verso la massa
Sensore temper- Sensore temper- circuito aperto o corto circuito a positivo / Circuito aperto o in corto verso positivo /
atura motore
atura motore
Circuito in corto verso la massa
TPS
Sensore posizione farfalla

(TPS)
Controllo del rap- Segnale sonda
porto aria-benzi- lambda (Bancata
na / Sonda lamb1)
da sinistra
Riscaldamento Circ.riscaldatore
sonda lambda
lambda(Bancata
sinistra
1)
Controllo del rap- Segnale sonda
porto aria-benzi- lambda (Bancata
na / Sonda lamb2)
da destra
Riscaldamento Circ.riscaldatore
sonda lambda
lambda(Bancata
destra
2)
Pulsante starter
Segnale avviamento
P SUPP - 128
circuito aperto o corto circuito a positivo / Circ.aperto o in corto verso positivo / Circorto circuito verso il negativo
cuito in corto verso la massa
corto circuito a positivo / circuito aperto, Circuito in corto verso il positivo / Circuito
corto circuito verso il negativo o carbur- aperto o in corto verso massa / Segnale
azione eccessivamente magra / segnale
non plausibile
non plausibile per correzione titolo
corto circuito a positivo / corto circuito Circuito in corto verso positivo / Circuito
verso il negativo / circuito aperto
in corto verso massa / Circuito aperto
corto circuito a positivo / circuito aperto, Circuito in corto verso positivo / Circuito
corto circuito verso il negativo o carbur- aperto o in corto verso massa / Segnale
azione eccessivamente magra / segnale
non plausibile
non plausibile per correzione titolo
corto circuito a positivo / corto circuito Circuito in corto verso positivo / Circuito
corto circuito a positivo
Circuito in corto verso il positivo
Err
or
e
P0
17
0
P0
20
1
P0
20
2
P0
23
0
P0
33
5
P0
33
6
P0
35
1
P0
35
2
P0
50
5
P0
53
0
P0
56
0
P0
60
1
P0
60
4
P0
60
5
P0
60
6
P0
65
0
Power supply
Caratteristica
Navigator
Caratteristica
P.A.D.S.
Descrizione / Valore P.A.D.S.
Comando starter
Diagnosi starter
(teleruttore)
TBD
Circuito in corto verso il positivo / Circuito

aperto o in corto verso massa
Iniettore cilindro
sinistro
Circuito iniettore
cilindro 1
corto circuito a positivo / corto circuito


in corto verso la massa / Circuito aperto
Iniettore cilindro
destro
Circuito iniettore
cilindro 2


Circ.comando
rel pompa carburante
Sensore giri mo- Sensore Giri Motore (elettrico)
tore


circuito aperto
Circuito Aperto
segnale non plausibile
Segnale non plausibile
Rel pompa carburante
Sensore giri motore (funzionale)
Sensore giri motore (Plausibilit)
Bobina A.T.
Circuito bobina N corto circuito a positivo / circuito aperto o Circuito in corto verso il positivo / Circuito
1
aperto o in corto verso la massa
Bobina A.T.
Circuito bobina N corto circuito a positivo / circuito aperto o Circuito in corto verso il positivo / Circuito
2
aperto o in corto verso la massa
Controllo minimo Controllo minimo

(Stepper motor)
Rel luci
Comando rel
fari

verso il negativo / circuito aperto / sovraccorrente
Tensione batteria Tensione batteria sopra soglia massima / sotto soglia minima

in corto verso la massa / Circuito aperto /
Corrente superiore alla specifica
La tensione eccede il limite massimo
Centralina
Errore EEPROM
(emul. Flash)
errore EEPROM
Avaria interna alla ECU
Centralina
Errore RAM
errore RAM
Centralina
Errore ROM
(Flash)
errore ROM (Flash)
Centralina
Errore microprocessore
errore microprocessore
Warning lamp
Comando Warning Lamp


P SUPP - 129
Power supply
SETTINGS screen page

This screen page is used to adjust some control
unit parameters.
PARAMETRI REGOLABILI
Autoapprendimento della posizione farfalla
Scarico file dati memorizzati
Cancellazione dati memorizzati
Reset parametri autoadattativi
P SUPP - 130
Azzeramento TPS
-
Scaricamento dati mem.

(Download + Cancellazione)
Scaricamento dati mem.
(Download + Cancellazione)
Azz.param autoadattativi
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
Front
FRONT WHEEL
pos.
Description
Front wheel axle
Front brake disc fixing screw
1
2
Type
M18x1.5
M8x20
Removing the front wheel
Place the vehicle on a stable support

so that the front wheel does not touch
the ground.
Remove the brake calliper without disconnecting the oil pipes
Remove the front wheel.
Handlebar
(V7 SPECIAL / V7 STONE)
SUSP - 132
Quantity
1
6
Torque
80 Nm (59.00 lbf ft)
25 Nm (18.44 lbf ft)
Notes
Loctite 243
Suspensions
HANDLEBAR AND CONTROLS

Pos.
Description
1
Switch fastener screw
2
Counterweight fixing screw
3
Screw fastening the clutch control U-bolt to
the semi-handlebar
Type
SWP 5
M6
M6x25
Quantity
1+1
2
2
Torque
1.5 Nm (1.11 lb ft)
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
Notes
Loctite 243
-
Front fork

pos.
1
Description
Stanchion cap
Type
-
Quantity
Torque
2
50 Nm (36.88 lbf ft)
Notes
-
SUSP - 133
Suspensions
pos.
2
Description
Type
M6x30
Quantity
2
M10x40

plate
Headstock ring nut
M25x1
Headstock bushing
M23x1
Diagram
Key:
1. Screw
2. Washer
3. Screw
4. Complete left sleeve
5. Upper bushing
6. Washer
7. Sealing ring
8. Snap ring
9. Dust guard
10.Stem
11.Lower bushing
12.Buffer
13.Counter spring
14.Complete pumping member
SUSP - 134
Torque
10 Nm (7.37 lbf ft)
Notes
Tighten using a 1-2-1 sequence
50 Nm (36.88 lbf ft)
7 Nm (5.16 lbf ft)

side by itself
50 Nm (36.88 lbf ft)
-
Suspensions
15.Spring
16.Pipe
17.Complete cap
18.Screw
19.Base with headstock
20.Ring nut
21.Fork upper plate
22.Washer
23.Nut
24.Rubber ring
25.Spacer
26.Cap
27.Nut
28.Ring
29.Complete right sleeve
30.Lower U-bolt
31.Upper U-bolt
32.Screw
33.Screw
34.O-ring
35.Stem protection
36.Chrome-plated cap
37.Gasket kit
38.Oil seal kit
Removing the fork legs

NOTE
PAY ATTENTION TO THE TYPE OF FORK FITTED DURING

REMOVAL AND FITTING. TWO DIFFERENT SUPPLIES
CAN BE FOUND ON THIS MOTORCYLCE, MARZOCCHI OR
KAIFA. TO DISTINGUISH BETWEEN THEM IT IS NECESSARY TO PROCEED WITH THE REMOVAL. THE MARZOCCHI FORK, UNLIKE THE KAIFA ONE IS EQUIPPED WITH A
WASHER ABOVE THE PRELOAD TUBE AND A SHIM
HOUSED BELOW.
The vehicle is equipped with a non adjustable fork. The operations described below are valid for both
stanchions.
CAUTION
SUSP - 135
Suspensions
DURING THE OPERATIONS DESCRIBED BELOW, THE STANCHIONS AND THEIR INTERNAL
COMPONENTS SHOULD BE TIGHTENED ON A VICE. MAKE SURE NOT TO DAMAGE THEM BY
OVERTIGHTENING; ALWAYS USE ALUMINIUM JAW CAPS.
Remove the front wheel.
Remove the front mudguard.
Remove the key switch cover.
Undo and remove the two screws and

collect the washers.
Move the instrument panel forwards.
SUSP - 136
Suspensions
Undo the upper sealing screw.
Undo the lower sealing screw.
Slide off the stem downwards by turning it slightly first in one direction then to the opposite
direction.
Draining oil
To drain out the oil follow these steps.
Remove the stanchion.
Tighten the removed stanchion in a

vice fitted with aluminium jaw caps in
order to avoid damaging them.
SUSP - 137
Suspensions
Unscrew the upper closing cap. Pay

attention to the possible thrust that the
spring can cause to the loosened cap.
KAIFA FORK PROCEDURE
Be careful not to damage the O-Ring

during extraction.
Press the bearing tube inside the

wheel holder fork leg.
Remove the preload tube and the

spring.
MARZOCCHI FORK PROCEDURE
Be careful not to damage the O-Ring

during extraction.
Remove the washer.
Press the bearing tube inside the

Remove the preload tube and the

spring.
SUSP - 138
Remove the shim.
Suspensions
Drain out all the oil inside the stanchion.
NOTE
FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON
ROD, PRESS THE STANCHION IN THE WHEEL HOLDER
SLEEVE TO PUMP OIL OUT.
Carefully check each part of the stanchion and make sure that there are no
damaged elements.
If there are no damaged or worn elements, refit the stanchion; otherwise,

replace the damaged elements.
NOTE
FOR EASY DRAINAGE OF THE OIL INSIDE THE PISTON
ROD, PRESS THE STANCHION IN THE WHEEL HOLDER
SLEEVE TO PUMP OIL OUT.
Disassembling the fork
Drain all the oil from the stem.
Block the wheel holder fork leg on the

vice.
Undo the bottom screw and remove it

with the corresponding gasket.
SUSP - 139
Suspensions
Remove the dust scraper using a

screwdriver as a lever.
CAUTION
BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM AND
THE DUST SCRAPER.
Slide the dust scraper off and upwards.
Remove the locking ring inside the fork

leg using a thin screwdriver.
CAUTION
BE CAREFUL NOT TO DAMAGE THE FORK LEG RIM.
Slide off the bearing tube from the

wheel holder fork leg together with the
sealing ring, the cap, the upper bushing and lower bushings.
NOTE
WHEN REMOVING THE PIPE FROM THE WHEEL HOLDER
FORK LEG SOME PARTS MAY REMAIN INSIDE THE FORK
LEG. IF THIS OCCURS, THESE PARTS MUST BE REMOVED AFTERWARDS, BEING CAREFUL NOT TO DAMAGE THE FORK LEG RIM AND THE UPPER BUSHING
SEAT
SUSP - 140
Suspensions
Checking the components
Check every component removed from

the fork leg, specially: the sealing ring
and the dust guard as they are elements that guarantee sealing; replace
them if some of them are damaged.
Check the bushing on the bearing tube;

remove it and replace it if damaged or
worn.
Slide off the pumping member unit

from the holding tube; if it is damaged,
replace the counter spring and the ring.
Reassembling the fork

CAUTION
ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BEFORE REFITTING.
Carry out any necessary service operation.
Insert the pumping member unit with

the counter spring and the ring in the
bearing tube.
Check that the upper guide bushing is

fitted on the wheel holder fork leg.
SUSP - 141
Suspensions
Insert the lower sliding bushing in its

seat on the bearing tube.
Reassemble the bearing tube in the

Insert the bearing tube in the wheel

holder and push it until it stops.
Screw the bottom screw and tighten it

to the prescribed torque.
SUSP - 142
Suspensions
Insert the cap and the well-lubricated

sealing ring on the bearing tube.
Use a suitable inserting tool to push the

sealing ring in the fork leg until it stops.
Fit the locking ring.
Fit the dust scraper.
Pour oil into the bearing tube so that it

also fills the internal grooves of the
pumping member rod.
Pump with the bearing tube, making

sure the oil has completely filled the
pumping member rod.
Introduce the spring and the preload

tube.
Place the cap on the bearing tube, taking care not to damage the O-ring.
Then, tighten the cap to the prescribed
torque.
SUSP - 143
Suspensions
Filling oil
Place the sleeve upright in a vice fitted

with protection jaws.
Compress the sleeve in the stanchion.
Pour part of the fork oil into the sleeve.
Wait some minutes until the oil fills all

the ducts.
Pour the remaining oil.
Pump out oil a few times.
Measure the air gap between the oil

level and the rim.
THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER

TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL
MUST BE THE SAME IN BOTH STANCHIONS.
Characteristic
Marzocchi Oil level (from the sleeve edge, without the spring and with stanchion to end of
stroke)
150 mm (5.9 in)
Kaifa Oil level (from the sleeve edge, without
the spring and with stanchion to end of stroke)
120 +/- 1.5 mm (4.72 +/- 0.06 in)
Introduce the spring and the preload

tube.
SUSP - 144
Suspensions
Place the cap on the bearing tube, taking care not to damage the O-ring.
Then, tighten the cap to the prescribed

torque.
Installing the fork legs
Insert the stem on the vehicle going through the lower plate and the upper plate.
Tighten the screws to the prescribed torque.
SUSP - 145
Suspensions
Steering bearing

pos.
1
2
Description
Stanchion cap
Type
M6x30
M10x40

plate
Headstock ring nut
M25x1
Headstock bushing
M23x1
SUSP - 146
Quantity
Torque
Notes
2
50 Nm (36.88 lbf ft)
2
10 Nm (7.37 lbf ft) Tighten using a 1-2-1 sequence
4
50 Nm (36.88 lbf ft)
7 Nm (5.16 lbf ft)

side by itself
50 Nm (36.88 lbf ft)
-
Suspensions
Adjusting play
Remove the key switch cover.
Undo and remove the screws and collect the U-bolt, holding the handlebar.
Move the handlebar forward, be careful not to turn over the front brake fluid
reservoir.
Remove the instrument panel.
Working from both sides, undo and remove the screw locking the upper plate
to the front fork.
Unscrew and remove the central nut.
SUSP - 147
Suspensions
Remove the upper plate from the front

fork.
Adjust the ring nut.
Fit the upper plate on the front fork.
Tighten the central nut.
Working from both sides, tighten the screw locking the upper plate to the front fork.
Fit the handlebar.
Fit the instrument panel.
SUSP - 148
Suspensions
Rear
Shock absorbers
REAR SUSPENSION
pos.
1
2
3
4
Description
Upper screw fastening shock absorber to
frame
Lower pin fastening left shock absorber to
swingarm
Stud bolt fixing right shock absorber to rear
box
Screw fastening right shock absorber to stud
bolt
Type
M6x35
Quantity
2
Torque
10 Nm (7.37 lbf ft)
Notes
Loctite 243
M10x1.5
35 Nm (25.81 lbf ft)
M12x1.5
35 Nm (25.81 lbf ft)
M6x16
10 Nm (7.37 lbf ft)
Loctite 243
Removing
Undo and remove the upper screw.
SUSP - 149
Suspensions
SUSP - 150
Undo and remove the lower screw.
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Swinging arm
REAR TRANSMISSION - SWINGARM

pos.
Type
M10x45
M16x1
Quantity
1
1
Torque
30 Nm (22.13 lbf ft)
25 Nm (18.44 lbf ft)
Notes
-
3
4
Description
Swingarm clamp retaining screw
Pin fixing the rear calliper holding
plate to swingarm
Nut fixing gearcase to swingarm
Pin fixing swingarm to gearbox
M8
M20x1
4
2
25 Nm (18.44 lbf ft)

-
Lock nut on swingarm pin
M20x1
50 Nm (36.88 lbf ft)
Hold the stud bolt

Fully home with no
preload
Hold the pin
1
2
CHAS - 152
Chassis
REAR WHEEL
pos.
Description
Rear wheel axle nut
Rear brake disc fixing screw
1
2
Type
M16x1.5
M8x25
Quantity
1
6
Torque
120 Nm (88.51 lb ft)
25 Nm (18.44 lb ft)
Notes
Loctite 243
Removing
Remove the left silencer.
CHAS - 153
Chassis
Remove the rear calliper, releasing the

brake pipe from the retainers on the
swingarm.
Unscrew and remove the fixing screw

of the calliper holder.
Remove both rear suspensions.
Unscrew and remove the nut and collect the washer.
CHAS - 154
Loosen the wheel pin locking screw.
Remove the wheel pin and collect the
Chassis
spacer.
Remove the rear wheel.
Unscrew the seal clamp.
Lift the bellows.
CHAS - 155
Chassis
Unscrew the nuts.
Loosen the pins so that the oscillating

swingarm can be removed from the
gearbox.
Remove the shimming washer between the swingarm right arm and the
gearbox.
Checking
Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves
and the grooves on the joint are not deformed or damaged; otherwise, replace the joint.
Check that the rubber bellows are not cut or pierced; otherwise, replace it.
Check that the swingarm pin threads and the swingarm fixing nuts are not damaged, deformed or flattened; otherwise, replace them.
Check that the sleeve grooves are not damaged, deformed or deteriorated; otherwise, replace the sleeve.
Check that the spring is not deformed; otherwise, replace it.
Check that the sealing ring (Seeger) is still flexible and is not deformed.
Check that the sleeve outer toothing and internal grooves are not damaged.
CHAS - 156
Chassis
Installing
Insert the swingarm on the gearbox

cover.
Tighten thoroughly the pin on the left

side until the shimming washer on the
right side rests on the bearing fitted on
the gearbox cover.
Tighten thoroughly the pin on the right

side, without locking it.
Operate the swingarm and make sure

it oscillates freely without clearance.
Screw in the lock nuts on the pins, locking them thoroughly.
Screw the clamp.
CHAS - 157
Chassis
Fit the rear wheel.
Bevel gears
Removing
Undo the four nuts and collect the

washers.
Slide off the gearcase together with the

swingarm.
Slide off the sleeve from the pinion.
Slide off the spring.
Slide off the sealing ring.
Slide off the base.
CHAS - 158
Chassis
Slide off the gear.
Checking
Gruppo pignone
Remove the housing of the swingarm .
Slide the complete case of the gearcase.
Lock on the vice the sealing tool

(19907100) of the bevel gear pair.
Insert the grooved shank of the pinion

on the tool and unscrew the nut.
CHAS - 159
Chassis
Slide off the spacer.
Slide off the pinion.
Slide off the shim adjustment washer.
Slide off the O-ring.
Slide off the oil seal.
Slide of the tapered bearing from the

case.
Slide off the O-ring.
Slide off the spacer.
Slide off the two shim washers.
CHAS - 160
Chassis
Slide off the tapered bearing from the

case.
Controllo
Check that the pinion toothing is not damaged, worn or deformed; otherwise, replace the
pair.
Check that both tapered bearings are not damaged, that the rollers are not damaged or
worn; otherwise, replace them.
Check that the adjustment washers are not deformed or broken; otherwise, replace them.
Check that the sealing rings are not shattered, spoiled or worn; otherwise, replace them.
Montaggio
If the bevel pinion should be replaced,

replace also the crown fitted on the
housing. The pinion and the crown
should have the same number stamped.
CHAS - 161
Chassis
Fit the external ring of the tapered

bearings on the bevel pinion holder
case using the suitable punch
(19926400).
Fit the adjustment shim washer.
Fit the internal ring of the bearing on

the pinion using the suitable punch
(19926200).
Fit both shim washers on the pinion.
Fit the spacer on the pinion.
Fit the O-ring.
CHAS - 162
Chassis
Fit the complete pinion on the case using the suitable punch (19926100).
Fit the oil seal.
Fit the O-ring.
Fit the spacer.
Insert the grooved shank of the pinion

on the tool (19907100) and tighten the
nut.
Smontaggio gruppo scatola
CHAS - 163
Chassis
Undo the screws and collect the washers.
Remove the braking disc from the drilled bolt.
Undo the screws and collect the plates

and the wave washers.
Slide off the complete cover.
Slide off the gaskets.
Slide off the shimming ring.
Remove the O-ring from the groove on

the drilled bolt.
From the cover, slide off:
The needle bearing.
Remove the internal ring of the needle

bearing using a suitable punch
(19907000).
Remove the washer.
Remove the washer.
CHAS - 164
Chassis
Undo the screws and collect the corresponding safety plates.
Remove the conical crown.
Slide off the drilled bolt from the bearing.
Remove the sealing ring.
CHAS - 165
Chassis
Slide off the bearing from the cover using the suitable punch.
Remove the external ring of the needle

bearing from the housing using the
suitable extractor (19927500).
Remove the sealing ring and the washer.
Controllo
Check that the drilled bolt tongues, where the anti-vibration rubbers operate, are not spoiled;
that the surfaces of: the sealing ring; the bearing on the cover, the external ring of the bearing
on the housing; the groove for the circlip on the drilled bolt are not worn, deformed or spoiled;
otherwise, replace them.
Check that the sealing ring on the housing is not shattered or is still flexible; otherwise,
replace it.
That the needle bearing on the housing does not have flattened or worn rollers; otherwise,
replace it.
Check efficiency of every component and that the coupling surfaces of the housing and cover
are not scored or distorted.
Accoppiamento pignone corona

CHAS - 166
Chassis
For coupling, proceed as follows:
Provisionally lock the complete pinion

case on the housing with two nuts and
appropriate spacers.
Fit the corresponding tool on the crown

(19928800).
Insert the tool on the bearing cage in

the housing.
Check alignment between pinion teeth

and the crown teeth.
If alignment is not regular, properly

vary the thickness of the ring between
the pinion and the tapered bearing.
Also check the contact area between

the pinion teeth and the crown teeth,
proceeding as follows:
Apply suitable colours available in the

market on the pinion teeth.
CHAS - 167
Chassis
Fit the drilled bolt-crown unit cover and

their spacers and gaskets on the housing and provisionally tighten the
screws.
On the crown holder drilled bolt, fit a

"Universal" extractor that with appropriate central spacers slightly presses
the crown towards the brake disc side.
Turn the pinion in the riding direction,

with the crown braked so that the rotation is carried out under load, and
leaves a contact mark on the pinion
surface.
If the contact is regular, the mark on the

pinion teeth will be like this (the pinion
is seen from the crankshaft side
If the contact is like this, the crown is

too near the pinion rotation axis: detach the crown by increasing spacer
thickness.
CHAS - 168
Chassis
If the contact is like this, the pinion is

too near the rotation axis of the crown:
detach the pinion by reducing spacer
thickness
If the contact is like this, the pinion is

too far from the rotation axis of the
crown: approach the pinion by increasing spacer thickness
If the contact is like this, the crown is

too far from the pinion rotation axis: approach the crown by reducing spacer
thickness.
Montaggio gruppo scatola
Fit the washer on the gearcase.
CHAS - 169
Chassis
Fit the sealing ring on the housing using the suitable punch (19926000).
Fit the external ring of the needle bearing on the housing using the suitable
punch (19926500).
Fit the bearing on the cover using the

suitable punch.
CHAS - 170
Chassis
Fit the internal ring of the needle bearing on the drilled bolt using the suitable
punch (19927900).
Insert the sealing ring in the drilled bolt.
Fit the drilled bolt on the cover.
Fit the crown.
Fit the plates and tighten the screws.
CHAS - 171
Chassis
Insert the washer.
Insert the washer.
Fit the O-ring.
Insert the gaskets and the shimming

ring on the cover.
Tighten the screws with plates and

washers.
Fit the braking disc on the drilled bolt

by locking the screws with the washers
using a torque wrench.
CHAS - 172
Chassis
When refitting the bevel pinion case on

the transmission, bear in mind that the
oil passage grooves with holes should
be fitted vertically (observing the
grooves, one should be facing upwards and the other facing the ground).
Installing
Insert the sleeve and base on the bevel

pinion of the gearcase.
CHAS - 173
Chassis
Correctly insert the stud bolts of the

gearcase in the holes of the swingarm .
Screw the nuts with the washers without locking them.
Exhaust
EXHAUST SYSTEM
Pos.
1
Description
Exhaust pipe fixing nut to the engine
CHAS - 174
Type
M6
Quantity
4
Torque
10 Nm (7.37 lb ft)
Notes
-
Pos.
2
3
4
5
6
7
Description
Exhaust pipe fixing clamp screw to
the compensator
Compensator fixing clamp screw to
the silencer
Lambda probe on compensator
Nut fastening silencer to mounting
plate
Heat shield fixing screw
Screw fixing silencer mounting plate
to frame
Chassis
Type
M6
Quantity
1+1
Torque
10 Nm (7.37 lb ft)
Notes
-
M6
10 Nm (7.37 lb ft)
M18x1.5
M8
1
4
38 Nm (28.03 lb ft)
25 Nm (18.44 lb ft)
M6x12
M8x40
6
2
10 Nm (7.37 lb ft)
25 Nm (18.44 lb ft)
Loctite 270
-
key:
1. Right exhaust pipe
2. Left exhaust pipe
3. Exhaust manifold fitting
4. Left silencer clamp
5. Gasket
6. Spacer
7. Ring nut
8. Washer
9. Nut
10.Left silencer
11.Right silencer
12.Clamp
13.Right plate
14.Left plate
CHAS - 175
Chassis
15.Right silencer clamp

16.Muffler rubber ring
17.TCEI screw
18.Silencer fixing bushing
19.Nut
20.Elastic plate
21.Lambda probe
22.Spacer
23.Bushing
24.Insulating washer
25.Silencer heat protection
26.U-bolt
27.Flanged TBEI screw
Removing the tail pipe

The engine and the exhaust system components get very hot and remain in this condition for a certain
time interval after the engine has been switched off. Before handling these components, make sure that
you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Loosens the clamps between the exhaust pipes and catalytic converter.
Unscrew and remove the muffler fixing

nut and collect the screw and the bushing.
CHAS - 176
Remove the silencer
Chassis
Removing the exhaust manifold
Remove the exhaust ring fixing nuts,

taking care to recover the washers
Remove the spacers
Remove the ring nuts
Remove the starter motor in order to be able to disconnect the left lambda probe connector
CHAS - 177
Chassis
Disconnect the right Lambda probe

connector and slide the cabling from
the cable grommet
Loosen the clamps between the joint

and the exhaust manifolds
Remove the manifolds
Removing the lambda sensor
Disconnect the left lambda probe (1) and right lambda probe (2) connector.
Unscrew and remove the lambda

probes.
CHAS - 178
INDEX OF TOPICS
BODYWORK
BODYW
Bodywork
BODYWORK - FRONT SECTION

pos.
1
2
Description
Screw fastening stabiliser plate to fork
Screw fastening mudguard to stabiliser
plate
Top fairing fixing screw
Type
M8x40
M6x11
Quantity
4
4
Torque
15 Nm (11.06 lbf ft)
10 Nm (7.37 lbf ft)
M6
10 Nm (7.37 lbf ft)
Driving mirrors
Loosen the lock nut (2).
Undo and remove the mirror by operating the nut (1).
BODYW - 180
Notes
Loctite 243
Loctite 243
Disconnect the connector.
Operating from both sides, undo the
Bodywork
fixing screw, taking care not to drop the

headlight assembly.
Working from both sides, disconnect

the two connectors.
Remove the horn by undoing the

screw.
Disassembling the lock
Remove the left side fairing.
Remove the ignition switch assembly

by loosening the two screws (1).
See also
Side body panels
BODYW - 181
Bodywork
Taillight assy.
Remove previously the rear mudguard.
Disconnect the rear headlight assembly connector.
Undo and remove the three fixing

screws.
Remove the rear headlight.
See also
Rear
mudguard
Passenger footrest plate
Unscrew and remove the screw (1).
Unscrew and remove the two screws

(2), remove the footrest holder.
BODYW - 182
Bodywork
Side body panels
Remove the saddle.
Working on both sides, remove the upper screw.
Remove the side fairing.
Rear mudguard
(ANNIVERSARIO)
BODYW - 183
Bodywork
REAR MUDGUARD
pos.
1
2
3
Description
Rear mudguard front and central fixing screw
Rear mudguard side fixing screw
Screw fixing license plate holder to mudguard
reinforcement
Type
M6
M8x30
SWP
M5x20
(NEVADA ANNIVERSARIO)
Remove the saddle
Remove the upper central screw (1)

that secures the mudguard to the
frame
BODYW - 184
Quantity
2+1
2
3
Torque
10 Nm (7.37 lb ft)
25 Nm (18.44 lb ft)
3 Nm (2.21 lb ft)
Notes
Bodywork
Remove the front screws (2) that secure the mudguard to the frame, taking
care to recover the nuts
Remove the lateral screws (3) that secure the mudguard and the passenger
handgrips from both sides, taking care
to recover the nuts
Disconnect the taillight connector.
Remove the rear mudguard by sliding

the light cabling through the wheel
housing
(NEVADA)
BODYW - 185
Bodywork
Undo and remove the two screws

placed on the internal side of the mudguard.
Undo the fixing screw of the rear shock

absorber.
Remove the side bar.
Unscrew and remove the two fixing

screws of the handgrip.
Remove the handgrip.
BODYW - 186
Bodywork
Undo the two front fixing screws of the

rear mudguard.
Undo and remove the two fixing screws

placed under the rear mudguard.
Disconnect the taillight connector.
Remove the rear mudguard.
BODYW - 187
Bodywork
Disconnect the turn indicators and the

license plate light connectors.
Undo and remove the two fixing screws

of the wheel housing.
Remove the wheel housing.
Splash guard
Remove the lower screws (1)
Remove the upper screws (2) taking

care to recover the nuts
BODYW - 188
Bodywork
Remove the splash guard, pulling it to

the rear
Fuel tank
Unscrew and remove the rear screw.
Partially lift the fuel tank in order to be

able to disconnect the fuel hose fitting,
avoiding damaging it.
CAUTION
PAY PARTICULAR ATTENTION DURING THE LIFTING OPERATION IN THAT THE FUEL HOSE FITTING CAN BE DAMAGED
Disconnect the connector.
BODYW - 189
Bodywork
Disconnect the fuel pipe.
Remove the fuel breather pipe.
Remove the fuel tank by sliding it off and back.
BODYW - 190
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Carry out the listed checks before delivering the motorcycle.

WARNING
HANDLE FUEL WITH CARE.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection

- Safety fasteners:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 192
Pre-delivery
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK MEDICAL ATTENTION IMMEDIATELY.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
PRE DE - 193
Pre-delivery
- Response to throttle control

- Stability when accelerating and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
Static test
Static check after test drive:
- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system
- Stroke of brake and clutch levers (if present)
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.

CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 194
A
Air filter: 42, 47, 48, 51
Air temperature sensor: 103
B
Battery: 78, 84
Brake:
Bulbs:
C
Clutch: 101
Coil: 96
Connectors: 106
E
ECU: 106, 124
Electrical system: 12, 57, 59, 192
Engine oil: 40
Engine temperature sensor: 87
Exhaust: 174, 177
Exhaust manifold: 177
F
Filter box:
Fork: 133, 135, 139, 141, 145
Front wheel: 132
Fuel: 95, 109, 189
Fuel pump: 95
Fuses: 83
H
Handlebar: 132
I
Identification: 10
Instrument panel: 103
M
Maintenance: 8, 38
Maintenance Table:
Mirrors: 180
Mudguard: 182, 183
O
Oil filter: 42
Oil pressure sensor: 99
R
Rear wheel:
Recommended products: 33
Run/Stop switch: 105
S
Saddle:
Shock absorbers: 149
Side stand: 102
Side stand sensor: 102
Spark plugs:
Speed sensor: 84
Stand: 102
Start-up: 81
T
Tank: 109, 189
Throttle body: 43, 45
Transmission: 12, 39
Tyres: 14
W
Warning lights:
Wiring diagram: 75

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SERVICE STATION MANUAL

NEVADA - NEVADA ANNIVERSARIO

NEVADA - NEVADA ANNIVERSARIO

THE VALUE OF SERVICE