Moto Guzzi V100 Service

SERVICE STATION MANUAL
2Q000541
V100 E5
SERVICE STATION
MANUAL
V100 E5
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
versions should be checked with the Official Moto Guzzi sales network.
The Moto Guzzi brand is owned by Piaggio & C. S.p.A.
© Copyright 2023 - 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
V100 E5
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 scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Piaggio & C. s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all 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
PRE-DELIVERY PRE DE
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
CLUTCH SYSTEM CLU SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
INDEX OF TOPICS
PRE-DELIVERY PRE DE
V100 E5 Pre-delivery
Carry out the listed tests before delivering the vehicle.

WARNING
PROCEED WITH THE UTMOST CAUTION WHEN HANDLING PETROL.

CAUTION
USE THE DIAGNOSTIC TOOL TO CHECK FOR ANY ERRORS AND CHECK THAT ALL PARAM-
ETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION HAS BEEN UPDATED TO LATEST VERSION
AVAILABLE, AFTER UPDATING THE DIAGNOSTIC TOOL.
Aesthetic inspection
• Paintwork
• Fitting of Plastics
• Scratches
• Dirt
Tightening torques inspection

Safety fasteners:
• Front and rear suspension assembly
• Front and rear brake calliper clamping assembly
• Front and rear wheel assembly
• Engine - frame fastenings
• Steering assembly
• Plastics fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail-lights (front and rear) and relevant 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 cluster lights
- Instrument cluster: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
PRE DE - 7
Pre-delivery V100 E5
- Electric helmet compartment lock release switch (if applicable)

- Through the diagnostic 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 avail-
able upgrades and details regarding the operation.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC

ACID, MAY CAUSE BURNING IF IT COMES INTO 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. IN THE EVENT OF CON-
TACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON-
SULT AN EYE SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES;
KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. EN-
SURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
CAUTION
Do not leave the vehicle with the engine off and the ignition key to "ON". The sophisticated on-
board instruments have a high current draw which, if left on with the engine switched off, will
discharge the battery in a short time.
PRE DE - 8
TRADITIONAL BATTERY ACTIVATION PRO-

CEDURE
• Place the battery on a flat surface.

• Remove the cell's protective sticker.
• Take the acid container.
• Remove the cap 1 of the container 2.
• Place the container upside down, per-
pendicularly above the battery, align-
ing the outlets with the battery cells.
• Apply pressure to the container to
break the seals. The liquid will begin to
flow into the cells.
• Check that air bubbles come out of the

cells; let the liquid flow into the cells for
at least 20 minutes.
• If no air bubbles escape and the liquid
does not flow, tap lightly on the bottom
of the container until the liquid begins
to flow into the cells. Never remove the
container from the battery, pierce it or
cut it to facilitate the exit of the liquid.
• Make sure the liquid container is com-
pletely empty before removing it.
• Allow the battery to stand for at least 1
hour, before starting the charging proc-
ess, without closing the six cells. This
operation is extremely important in or-
der to have the best battery perform-
ance over time.
• Recharge the battery following the
specifications indicated on the battery
(see photo ) and using a suitable bat-
tery charger.
NOTE
IN THE SHOWN EXAMPLE IT IS IMPORTANT TO USE A
BATTERY CHARGER WITH 1.2 AMPERE (CHARGING TIME
5-10 HOURS) OR 5 AMPERE (CHARGING TIME 1 HOUR).
PRE DE - 9
After performing the battery activation procedure,

install it on the vehicle in the dedicated compart-
ment. Then connect the cables to the battery,
starting from the positive (1).
Install the battery cover (2) and tighten the fixing

screws (3). Place the OBD2 cable (4) and the GMP
preparation cable (5) on the cover.
Levels check
• Braking system liquid level (front and rear)

• Hydraulic clutch fluid level
• Engine oil level
• Coolant level
Road test
• Cold start
• Instrument operations
• Throttle control response
• Stability on acceleration and braking
• Front and rear brake efficiency
• Front and rear suspension efficiency
• Abnormal noise
CAUTION
V100 is equipped with an advanced transmission that makes it easy to engage neutral between
first and second gear when stationary. Due to the peculiar architecture of this transmission, IT
IS NOT POSSIBLE, AT A STANDSTILL, TO SHIFT INTO ANOTHER GEAR BEYOND THE FIRST
GEAR.
CAUTION
PRE DE - 10
Static test
Static control after the test drive:
• Restarting when warmed up

• Minimum holding (turning the handlebar)
• Uniform turning of the steering
• Any leaks
CAUTION
Functional inspection
• Hydraulic braking system

• Brake and clutch lever stroke (where applicable)
• Clutch - check proper operation
• Engine - check for proper general operation and absence of abnormal noise
• Check documents, frame number and engine number
• Check included tools (where applicable)
• License plate fitting
• Locks check
• Tyre pressure check
• Installation of mirrors and any accessories
• Battery installation
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

CAUTION
PRE DE - 11
Specific operations for the vehicle
UNPACKING
CAUTION
THE UNPACKING OF THE VEHICLE REQUIRES THE INTERVENTION OF 2 OPERATORS AND

MUST NOT BE CARRIED OUT BY A SINGLE OPERATOR. ALWAYS USE PERSONAL PROTEC-
TIVE EQUIPMENT WHEN WORKING.
• Position the packing on a flat surface
and check its integrity.
• Cut the plastic strapping of the pack-

aging using a cutter.
• Grasp the cardboard cover by the

openings on the short sides of the
packaging and lift it off the wooden
platform.
PRE DE - 12
CAUTION
LIFT THE CARDBOARD COVER VERTICALLY, DO NOT

ROTATE OR TILT IT AND TAKE EXTRA CARE NOT TO
DAMAGE THE VEHICLE WHEN LIFTING IT.
• Store the cardboard cover away from

the vehicle.
• Check the integrity of the footrest and
ensure that the vehicle is free from
dents and/or scratches.
• Remove the boxes of the components

supplied (mirrors and battery) from the
footrest.
• Support the vehicle while the second

operator removes the retaining straps,
starting with the rear straps.
PRE DE - 13
• Then remove the front retaining straps.

CAUTION
DO NOT REMOVE THE VEHICLE FROM THE WOODEN
PLATFORM AT THIS TIME.
• Using suitable tools, remove the front

cross member of the wooden platform.
• Making sure that the platform remains

stationary, lower the vehicle from the
front of the wooden platform, support-
ing it by the handlebar and the rear
handles.
• Place the vehicle on the side stand and

remove the windscreen protection bag.
PRE DE - 14
• Remove the protective bags of the two

cylinders.
• Install the battery according to the op-
erations described in the section "Body
- Battery".
• Install the rear-view mirrors.
FITTING THE REAR-VIEW MIRRORS
• Screw the mirror into the clutch master

cylinder (left) or front brake master cyl-
inder (right) support.
• Tighten the nut (1) to the prescribed
torque.
Locking torques (N*m)

Rear view mirror fastener nut 4 ± 0.5 Nm (2.95 ± 0.37
lb ft)
• Position the mirror rod in line with the

relative knob.
• Tighten the lock nut (2) to the prescri-
bed torque.
• Position the protective rubber (3) on
the mirror fixing.

Rear-view mirror lock nut 4 ± 0.5 Nm (2.95 ± 0.37 lb
ft)
PRE DE - 15
INDEX OF TOPICS
CHARACTERISTICS CHAR
V100 E5 Characteristics
Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY INFLAMMABLE AND CAN BECOME
EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY
OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE EN-
GINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID
ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY
CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.
Hot parts
The engine and the exhaust system components get very hot and remain in this condition for a certain
time interval after the engine has been switched off. Before handling these components, make sure that
you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE PARTICULAR CARE NOT TO SPILL COOLANT ONTO HOT PARTS OR THE ENGINE AND
EXHAUST SYSTEM; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN
CARRYING OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. WHILE POISON-
OUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY APPEALING TO ANI-
MALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE REACHED AND
DRUNK BY AN ANIMAL.
CHAR - 17
Characteristics V100 E5

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

TIVE IMPERMEABLE GLOVES.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
BRAKE FLUID CAN DAMAGE PAINT FINISH, PLASTIC AND RUBBER. WHEN SERVICING THE
BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR
PROTECTIVE EYEWEAR WHEN WORKING ON THE BRAKE SYSTEM. BRAKE FLUID IS EX-
TREMELY HARMFUL FOR THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE
EYES, RINSE THE EYES IMMEDIATELY WITH PLENTY OF COOL, CLEAN WATER AND SEEK
IMMEDIATE MEDICAL ATTENTION.
Battery electrolyte and hydrogen gas (WHERE REQUIRED)
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC

ACID, MAY CAUSE BURNING IF IT COMES INTO 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. IN THE EVENT OF CON-
TACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON-
SULT AN EYE SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES;
KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. EN-
SURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-
mendations strictly.
BEFORE DISASSEMBLING COMPONENTS
CHAR - 18
• Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com-
ponents. Wherever required, use the special tools designed for this vehicle.
DISASSEMBLING COMPONENTS
• Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use
the specific wrench.
• Mark the positions on all the connection joints (hoses, cables, etc.) before separating them
and identify them with different distinctive marks.
• Each piece should be clearly marked in order to be identified during the installation phase.
• Carefully clean and wash the disassembled components with detergents with a low flam-
mability grade.
• Keep the coupled parts together because they have "adapted" to one another following
normal wear.
• Some components must be used together or replaced entirely.
• Keep away from heat sources.
REASSEMBLING THE COMPONENTS

CAUTION
THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE
THEY MUST BE REPLACED.
• Only use ORIGINAL Moto Guzzi SPARE PARTS.
• Always use the recommended lubricants and consumable material.
• Lubricate the parts (when possible) before reassembling them.
• When tightening screws and nuts, begin with the larger diameter or internal ones, proceeding
diagonally. Tighten with subsequent steps before applying the prescribed torque.
• Always replace the locknuts, gaskets, seal rings, snap rings, O-Rings (OR), cotter pins and
screws if they have damaged thread, with new ones.
• When disassembling the bearings, lubricate them abundantly.
• Ensure that each component has been assembled correctly.
• After a repair or periodic maintenance operation, carry out the preliminary checks and test
the vehicle on private property or in an area with light traffic.
• Clean all coupling surfaces, oil seal rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with
the brand or lot number facing outward (visible side).
ELECTRICAL CONNECTORS
The electrical connectors should be disconnected as follows. Failure to observe these procedures will
cause irreparable damage to the connector and the wiring:
If present, press on the specific safety catches.
• Grip the two connectors and unplug them, pulling them apart in opposite directions.
CHAR - 19
• If there is dirt, rust, moisture, etc., carefully clean the inside of the connector using pressur-
ised air.
• Ensure that the cables make correct contact with the terminals inside the connectors.
• Then plug in the two connectors, ensuring correct coupling (if the specific catches are
present, you will hear a typical "click").
CAUTION
TO UNPLUG THE TWO CONNECTORS, DO NOT PULL ON THE CABLES.
NOTE
THE TWO CONNECTORS CAN BE PLUGGED IN ONLY IN ONE DIRECTION, THEREFORE JOIN
THEM TOGETHER IN THE RIGHT DIRECTION.
TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELEMENTS LOCATED ON
WHEELS, BRAKES, WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A FUN-
DAMENTAL ROLE IN GUARANTEEING THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT
THE PRESCRIBED VALUES. REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING
ELEMENTS AND ALWAYS USE A TORQUE WRENCH WHEN REFITTING. IF THESE WARNINGS
ARE NOT OBSERVED, ONE OF THESE COMPONENTS COULD LOOSEN AND COME OFF,
BLOCKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA-
NOEUVRABILITY, LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN
DEATH.
Running-in
Running in is essential to ensure the durability of the vehicle. During the first 1500 Km (932 mi), observe
the following rules to ensure the reliability and performance of the vehicle throughout its lifetime:
• Avoid full throttle starts and hard acceleration;
• Avoid exceeding 4,500 rpm;
• Avoid hard or prolonged braking;
• Do not ride for prolonged periods at sustained high speed; preferably ride the motorcycle
on varied routes with frequent, gentle acceleration and deceleration;
• Ride prudently to gradually gain familiarity with the motorcycle, testing progressively higher
throttle apertures only as you gain confidence
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow these guidelines:
• Do not 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.
CHAR - 20
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 MAINTE-
NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI-
CLE.
Vehicle identification
SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
FRAME NUMBER
The chassis number is stamped on the RH side of
the headstock.
This number consists of numbers and letters, as in
the example shown below.
ZGUMGA00XNMXXXXXX
KEY:
ZGU: WMI (World Manufacturer Identifier) code;
MG: vehicle type;
A00: variant and version (A00: V100 Mandello -
B00: V100 Mandello S);
X: check digit
N: year of manufacture, variable (N - for 2022)
M: production plant (M= Mandello del Lario);
XXXXXX: serial number of the frame (6 digits);
ENGINE NUMBER
The engine number is stamped on the left side of
the crankcase, under the cylinder.
Dimensions and mass
DIMENSIONS AND MASS

Specification Desc./Quantity
Maximum Length 2125 mm (83.66 in)
CHAR - 21
Maximum width 835 mm (32.87 in)
Height (adjustable at the windshield) 1210 - 1300 mm (47.63 - 51.18 in)
Wheelbase 1475 mm (58.07 in)
Kerb weight 233 kg (513.68 lb)
Engine
ENGINE
Type Four-stroke, 90° transverse V-twin
Number of cylinders 2
Engine capacity 1042 cc (63.59 cu in)
Bore / stroke 96 x 72 mm (3.77 x 2.83 in)
Compression ratio 12.6 ± 0.5 : 1
Ignition Electric
Idle engine speed 1400 +/- 100 rpm
Clutch Multi plate wet clutch with anti-judder function.
Lubrication system pressure-fed, controlled by valves and trochoidal pump
Air filter cartridge-type dry filter
Cooling Forced coolant circulation system.
Transmission
TRANSMISSION
Primary drive with gears, ratio: 31/48 = 1 : 1,548
Gear ratios, 1st gear 14 / 37 = 1 : 2.642
Gear ratios, 2nd gear 17 / 33 = 1 : 1,941
Gear ratios, 3rd gear 20 / 31 = 1 : 1,55
Gear ratios, 4th gear 22 / 28 = 1 : 1,272
Gear ratios, 5th gear 24 / 26 = 1: 1,083
Gear ratios, 6th gear 25 / 24 = 1: 0,96
Final drive with shaft, ratio 12 / 38 = 1 : 3,166
GEARBOX
Type mechanical, 6 speeds with foot lever on the left hand side of
the engine
Capacities
CAPACITY
Fuel tank capacity (including reserve) 17 l (3.74 UK gal; 4.49 US gal)
Fuel tank reserve capacity 3.5 +/- 0.5 l (0.77 +/- 0.11 UK gal; 0.92 +/- 0.13 US gal)
Engine oil Oil change and oil filter replacement: 4900 cc in (299.02 cu in)
Bevel gear set oil 250 cm³ (15.26 cu in)
Bevel gear oil (in case of replacement) 225 cc (13.73 cu in) MAX
Seats 2
Max. vehicle load 443 kg (976.64 lb) (rider + passenger + luggage)
CHAR - 22
Electrical system
ELECTRICAL SYSTEM
Battery 12 V - 12 Ah
Fuses 40- 30 - 20 - 15 (3) - 10 (2) - 7.5 (6) - 5 (3) - 3 A
Permanent magnet alternator 12V - 550W
BULBS
High beam/low beam light LED
Fog lights LED
Front DRL LED
Turn signal lights LED
Rear running light / brake light LED
Dashboard lighting LED
INDICATOR LAMPS
Gearbox in neutral LED
High beam headlight LED
Cruise control warning light LED
ABS warning light LED
MI warning light LED
Turn indicators LED
Overspeed threshold / gear shift warning lights LED
Immobilizer warning light LED
Fuel reserve LED
MGCT warning light LED
General alarm LED
Daytime running lights warning light LED
Side stand warning light LED
SPARK PLUGS
Standard NGK LMAR8EI-7
Spark plug electrode gap 0.8 mm (0.031 in)
Resistance 7.5 KOhm (MAX)
Frame and suspensions
CHASSIS
Type high strength tubular steel frame
Steering rake angle 24.7°
Trail 104 mm (4.095 in)
SUSPENSION
Front (V100 Mandello) hydraulic telescopic fork, Ø 41 mm (1.61 in)
Rear (V100 Mandello S) electronically controlled hydraulic telescopic fork, diameter 43
mm (1.69 in)
Travel (V100 Mandello) 130 mm (5.11 in)
Travel (V100 Mandello S) 130 mm (5.11 in)
Rear Swingarm in die-cast light alloy with 1 shock absorber with ad-
justable spring pre-loading and hydraulic brake extension.
Travel (V100 Mandello) 130 mm (5.11 in)
Travel (V100 Mandello S) 130 mm (5.11 in)
CHAR - 23
Brakes
BRAKES
Front two 320 mm (12.59 in) diam. stainless steel floating discs, cal-
liper with 4 32 mm (1.26 in) diam. counteracting plungers
Rear 280 mm (11.02 in) stainless steel disc, floating calliper with two
28 mm (1.10 in) diameter pistons
Wheels and tyres
RIMS AND WHEELS

Type die-cast alloy
Front 3.5" x 17"
Rear 6.00" x 17"
TYRES
Front 120 / 70 ZR17 (58W)
Tyre pressure 2.5 bar (250 kPa) (36.26 PSI)
Rear 190 / 55 ZR17 (75W)
Tyre pressure 2.8 bar (280 Kpa) (40.61 PSI)
Supply
FUEL SYSTEM
Type Electronic injection (Marelli 11MP)
Throttle body Ø 52 mm (2.05 in)
Fuel Unleaded gasoline E10 (95 R.O.N.)
Tightening Torques
Chassis
CHAR - 24
Front side
TOP FAIRING
Pos. Description Type Quantity Torque Notes
1 Fixing screw for actuator connecting SWP 5x30 1 1 ± 0.3 Nm (1.11 ± 0.22 -
rod lb ft)
2 Fixing screw for actuator Self-tapping 4 2.5 ± 0.3 Nm (1.84 ± -
5.1x18 0.22 lb ft)
3 Fixing screw for actuator assembly M5 4 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
4 Top fairing fastener screw M6 4 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
CHAR - 25
FRONT FAIRING
1 Fixing screw for front spoiler M5 2 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
2 Fixing screw for side fairing to spoiler M5 1+1 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
3 Upper front fixing screw M5 4 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
4 Lower front fixing screw M5 5 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
CHAR - 26
INSTRUMENTS
1 Fixing screw for TFT instrument pan- SWP 4.9 3 3 ± 0.5 Nm (2.21 ± 0.37 -
el lb ft)
2 Instrument panel bracket fastening M6 2 10 ± 2 Nm (7.38 ± 1.48 Screw and nut
lb ft)
HEADLAMP
2 Fixing screw for lower fork closure M6 4 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
2 Turn indicator fastener screw M6 2 3 ± 0.5 Nm (2.21 ± 0.37 With self-locking nut
lbf ft)
CHAR - 27
HANDLEBAR-CONTROLS
1 Screws fastening the lower U-bolts to M10 2 50 Nm (36.88 lbf ft) Loctite 243
the upper steering yoke
2 Screws fastening the lower U-bolt M8 4 25 Nm (18.44 lbf ft) -
clamp to the handlebar
3 Screws fastening the anti-vibration M6 1+1 10 Nm (7.38 lbf ft) -
weights to the handlebar
4 Screws fastening the light switch to M5 1+1 4 Nm (2.95 lbf ft) Pre-fitted on the
handlebar light switch
5 Clutch pump U-bolt fastening screws M6 2 10 Nm (7.38 lbf ft) -
6 Front brake master cylinder U-bolt M6 2 10 Nm (7.38 lbf ft) -
fixing screws
7 Screw fastening the electronic throt- M4 1 4 Nm (1.62 lbf ft) Pre-fitted on the
tle control to handlebar throttle control
CHAR - 28
CLUTCH CONTROL
1 Actuator fixing screw to clutch crank- M6 3 10 ± 2 Nm (7.38 ± 1.48 -
case lb ft)
2 Fixing screw for clutch lever U-bolt M6 2 10 ± 1.5 Nm (7.38 ± 1.11 -
lb ft)
CHAR - 29
MIRRORS
1 Fixing nut for mirror bracket M6 2+2 4 ± 0.5 Nm (2.95 ± 0.37 -
lbf ft)
STEERING
1 Ring nut fastening the bottom yoke/ - 1 - First tightening tor-
steering pin assembly to the head- que 60 Nm (44.25
stock lbf ft) - Second tight-
ening torque 30 Nm
+/- 5 Nm (22.13 +/-
3.69 lbf ft)
2 Counter-lock ring fastening the bot- - 1 - Manual
tom yoke/steering pin assembly to
the headstock
3 Screw fastening the fork stanchions M8 4 25 Nm (18.44 lbf ft) -
to the lower steering yoke
4 Top steering yoke fastener bush - 1 100 Nm (73.76 lbf ft) -
to the upper steering yoke
CHAR - 30
INTAKE ASSEMBLY
1 Fixing screw for intake ducts to throt- M6 4 10 ± 1.5 Nm (7.38 ± 1.11 -
tle bodies lb ft)
2 Fixing screws for air filter and filter SWP 4.9 6 3 ± 0.5 Nm (2.21 ± 0.37 -
case cover lbf ft)
3 Intake duct fastening to filter case Pipe clamp 2 25 ± 5 Nm (18.44 ± 3.69 -
lb ft)
4 Filter casing/frame fastening screw M5 2 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
CHAR - 31
COOLING SYSTEM
1 Upper radiator fixing screw M6 1 7 ± 1.5 Nm (5.16 ± 1.10 -
lb ft)
2 Lower radiator fixing nut M6 2 7 ± 1.5 Nm (5.16 ± 1.10 -
lb ft)
3 Fixing nut for electrical fan to radiator M4 3 0.5 ± 0.1 Nm (0.37 ± -
0.074 lb ft)
4 Screw for fastening the expansion M6 1 5 ± 0.75 Nm (3.69 ± 0.37 -
tank lb ft)
5 Side radiator fixing screw M6 4 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
FRONT MUDGUARD
1 Front mudguard fixing screw M5 4 5.5 ± 1 Nm (4.06 ± 0.78 -
lbf ft)
2 Fixing screw for lower fork closure M6 4 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
CHAR - 32
FRONT WHEEL
1 Nut fastening the front wheel axle M25x1.5 1 80 Nm (59.01 lbf ft)
2 Brake disc fixing screw M6 6+6 30 Nm (22.13 lbf ft) Loctite 243
3 ABS sensor fixing screw M5 1 6 Nm (4.46 lbf ft) -
CHAR - 33
FRONT BRAKE MASTER CYLINDER

1 Screws fixing brake pump clamp to M6 2 10 ± 1.5 Nm (7.38 ± 1.11 -
the handlebar lb ft)
FRONT BRAKE CALLIPER

1 Screws fastening front brake calliper M10x1.25 2+2 50 ± 5 Nm (36.88 ± 3.69 -
lb ft)
CHAR - 34
Central part
FUEL TANK COVER

1 Screw for filter case cover M5 4 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
2 Fixing screw for tank cover M5 4 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
3 Fixing screw for side fairing to tank M5 2+2 4 ± 0.8 Nm (2.95 ± 0.59 -
cover lb ft)
4 Tank plug fixing screw M5 7 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
CHAR - 35
FUEL TANK
1 Screws fastening the fuel tank to M6 4 10 Nm (7.38 lbf ft) -
frame
2 Ring nut fastening the fuel pump to - 1 20 Nm (14.75 lbf ft) -
the fuel tank
3 Nuts fixing the fuel level probe to the M4 5 1 Nm (0.74 lb ft) -
fuel tank
CHAR - 36
CHASSIS
1 Rear fixing screw for motor to chas- M10 x 1.25 2 50 ± 7.5 Nm (36.88 ± -
sis 5.53 lbf ft)
2 Side fixing screw for motor to chassis M10 6 50 ± 7.5 Nm (36.88 ± -
5.53 lbf ft)
CANISTER SYSTEM
1 Fixing screw for canister bracket M6 2 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
2 Fixing nut for the air solenoid valve M6 1 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
CHAR - 37
FOOTRESTS
1 Fixing screw for the right footboard M8 3 25 ± 3.5 Nm (18.44 ± -
2.58 lbf ft)
2 Fixing screw for the left footboard M8 2 25 ± 3.5 Nm (18.44 ± -
2.58 lbf ft)
3 Fixing screw for the left footboard M8 1 25 ± 3.5 Nm (18.44 ± -
2.58 lbf ft)
4 Fixing screw for the passenger foot- M8 2+2 25 ± 3.5 Nm (18.44 ± -
rest 2.58 lbf ft)
CHAR - 38
REAR BRAKE MASTER CYLINDER

1 Rear brake rod lock nut M6 1 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
2 Rear brake pump fastening screws M6 2 10 ± 1.5 Nm (7.38 ± 1.11 -
lb ft)
3 Brake oil tank fixing screw M6 1 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
4 Brake switch fixing screw M5 1 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
5 Rear brake lever rod screw M6 1 8 ± 1 Nm (5.90 ± 0.74 lbf -
ft)
6 Spring coupling pin for brake lever M5 2 6 ± 1 Nm (4.43 ± 0.74 lbf -
ft)
7 Brake switch cable gland M4 2 3 ± 0.5 Nm (2.21 ± 0.37 -
lbf ft)
8 Rear brake lever fixing pin M8 1 25 ± 3.5 Nm (18.44 ± -
2.58 lbf ft)
GEARBOX LEVER
1 Fixing screw for the gear lever to en- M6 1 10 ± 1.5 Nm (7.38 ± 1.10 -
gine lbf ft)
2 Fixing screw for gear shift lever rod M6 1 8 ± 1 Nm (5.90 ± 0.74 lbf -
ft)
3 Gearbox lever fixing pin M8 1 25 ± 3.5 Nm (18.44 ± -
2.58 lb ft)
4 Gear shaft rod fastening M6 2 8 ± 1 Nm (5.90 ± 0.74 lbf -
ft)
CHAR - 39
STAND
1 Nut for fastening the stand to the M8 1 25 ± 3.5 Nm (18.44 ± -
stand plate 2.58 lb ft)
2 Stand switch lock pin M6 1 10 ± 2 Nm (7.38 ± 1.48 Pre-applied Loct.
lb ft) 243
3 Pin fastening the spring to the stand M8 1 25 ± 5 Nm (18.44 ± 3.69 Pre-applied Loct.
plate lb ft) 243
4 Pin fastening the spring to the stand M6 1 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
5 Stand switch fixing nut M6 1 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
6 Stand sensor cable guard fixing M5 2 5.5 ± 1 Nm (4.06 ± 0.74 Pre-applied Loct.
screws lb ft) 243
7 Screws fastening the stand plate to M8 2 25 ± 3.5 Nm (18.44 ± -
the engine crankcase 2.58 lb ft)
CHAR - 40
LOCKS
1 Fixing screw for ignition lock (RH M8 1 Manual Breaking the screw
side) head
2 Fixing screw for ignition lock (LH M8 1 25 ± 3.5 Nm (18.44 ± -
side) 2.58 lb ft)
3 Fixing screw for saddle mounting M6 2 10 ± 2 Nm (7.38 ± 1.48 -
plate lb ft)
4 Tank plug fixing screw M5 7 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
CHAR - 41
Back side
REAR WHEEL TRANSMISSION

1 Screw fixing gearcase to swingarm M10 3 45 ± 6.75 Nm (33.2 ± 5 -
lb ft)
CHAR - 42
REAR WHEEL TRANSMISSION - COMPONENTS

1 Fixing screw for rear gearbox cover M8x1 11 25 Nm (18.43 lb ft) Screws with pre-ap-
plied threadlocker
2 Pinion fixing ring nut - 1 140 Nm (103.25 lb ft) With Loctite 243
3 Flanged nut fixing pinion M20x1 1 100 Nm (73.75 lb ft) With Loctite 243
4 Pinion fastening cap M14x1 1 50 Nm (36.87 lb ft) With Loctite 243
5 Oil drainage plug M10x1.5 1 30 Nm (22.1 lb ft) -
6 Oil load cap M12x1.5 1 25 Nm (18.43 lb ft) -
SWINGARM
1 Swingarm fastening pin M16x1.5 1 65 ± 9.75 Nm (47.93 ± -
7.2 lb ft)
2 Fixing screw for swingarm pin M8 1 25 ± 3.75 Nm (18.43 ± -
2.76 lb ft)
CHAR - 43
UNDER-SEAT COMPARTMENT
1 Rear storage compartment fixing M5 3 4 ± 0.8 Nm (2.95 ± 0.59 -
screw lb ft)
2 Fixing screw for lower saddle mount- M5 8 4 ± 0.8 Nm (2.95 ± 0.59 -
ing closure lb ft)
CHAR - 44
REAR WHEEL
1 Rear wheel nut M60x2 1 260 ± 39 Nm (191.75 ± -
28.76 lb ft)
2 Rear brake disc fixing screw M8 5 30 ± 4.5 Nm (22.12 ± Screws with pre-ap-
3.32 lb ft) plied threadlocker
CHAR - 45
REAR BRAKE CALLIPER

1 Rear brake calliper fixing screw M10 2 50 ± 5 Nm (36.87 ± 3.7 With a torque
lb ft) wrench
CHAR - 46
REAR MUDGUARD
1 Fixing screw for centre rear cover M5 2 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
2 License plate holder fixing screw M5 4 5.5 ± 1.1 Nm (4.1 ± 0.8 -
lb ft)
3 Fixing screw for lower licence plate SWP 4.9 4 3 ± 0.6 Nm (2.2 ± 0.44 -
holder lb ft)
REAR LIGHTS
1 Fixing screw for rear light to rear stor- M5 2 4 ± 0.8 Nm (2.95 ± 0.59 -
age cover lb ft)
2 Fixing screw for rear light to central SWP 4.9 4 3 ± 0.6 Nm (2.2 ± 0.44 -
rear cover lb ft)
3 Fixing screw for rear turn indicators M6 2 3 ± 0.6 Nm (2.2 ± 0.44 With self-locking nut
to mudguard lb ft)
CHAR - 47
REAR BODYWORK
1 Fixing screw for passenger grab han- M8 4 34 ± 5 Nm (25.1 ± 3.7 lb Screws with pre-ap-
dle ft) plied threadlocker
2 Fixing screw for rear side covers M5 4 4 ± 0.8 Nm (2.95 ± 0.59 -
lb ft)
3 Front fixing screw for luggage holder M8 4 34 ± 6.8 Nm (25.1 ± 5 lb Screws with pre-ap-
ft) plied threadlocker
4 Rear fixing screw for luggage holder SWP 4.9 2 3.5 ± 0.7 Nm (2.6 ± 0.52 -
lb ft)
CHAR - 48
SILENCER
1 Screw fastening outer silencer sup- M8 1 25 ± 5 Nm (18.43 ± 3.68 -
port bracket lb ft)
2 Upper silencer fixing screw to the M6 2 10 ± 2 Nm (7.37 ± 1.47 -
footrest lb ft)
3 Lower silencer fixing screw to the M8 1 25 ± 5 Nm (18.43 ± 3.68 -
footrest lb ft)
4 Fixing screw for silencer manifold M6 2 10 ± 2 Nm (7.37 ± 1.47 Screw with pre-ap-
protection lb ft) plied threadlocker
5 Fastening the silencer to the exhaust Pipe clamp 1 25 ± 5 Nm (18.43 ± 3.68 -
manifold lb ft)
6 Heat shield protection fastening M6 2 10 ± 2 Nm (7.37 ± 1.47 Screw with pre-ap-
screws lb ft) plied threadlocker
7 Heat shield protection fixing Pipe clamp 4 3 ± 0.6 Nm (2.21 ± 0.44 -
lb ft)
8 Lambda probe fastener M12x1.25 2 25 ± 5 Nm (18.43 ± 3.68 -
lb ft)
9 Exhaust manifold flange fastening M8 4 25 ± 5 Nm (18.43 ± 3.68 -
nuts lb ft)
10 Fixing screw for silencer support out- M6 2 10 ± 2 Nm (7.37 ± 1.47 -
er bracket lb ft)
11 Lower fixing screw for exhaust mani- M8 1 25 ± 5 Nm (18.43 ± 3.68 -
fold lb ft)
CHAR - 49
REAR SHOCK ABSORBER

1 Upper shock absorber fixing screw M10 1 50 ± 7.5 Nm (36.87 ± -
5.53 lb ft)
2 Lower shock absorber clamping M10 1 50 ± 7.5 Nm (36.87 ± -
screw 5.53 lb ft)
3 Fixing screw for preload tank to M6 2 10 ± 2 Nm (7.37 ± 1.47 -
bracket lb ft)
CHAR - 50
REAR ELECTRICAL SYSTEM

1 Fixing screw for battery cover to M5 2 4 ± 0.8 Nm (2.95 ± 0.59 -
chassis lb ft)
2 Fixing screw for ECU holder SWP 4.9 1 3 ± 0.45 Nm (2.2 ± 0.33 -
lb ft)
3 Fixing screw for IMU ECU to lower M6 2 7 ± 1 Nm (5.16 ± 0.73 lb -
seat latch ft)
CHAR - 51
INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS

V100 E5 Special tools
SPECIAL TOOLS
Stores code Description
020851Y Camshaft timing pin
020382Y Valve cotters equipped with part 012 re-

moval tool
020853Y Compresses intake valve springs
020376Y Adaptor handle
020360Y 52 x 55 mm adaptor
020714Y Dial gauge mount
S-TOOLS - 53
Special tools V100 E5

020888Y Pre-load tube clamp
020922Y Diagnostic tool
021017Y OBD cable for E5 vehicles
021058Y Clutch retainer
021059Y Primary retainer
021061Y Ring clamp
021062Y Crankshaft support U-bolt
S-TOOLS - 54

021063Y Water pump seal insertion tool
021064Y Large pin for engine timing
021065Y Engine support frame
021066Y Gearbox mounting
021067Y Pinion side fixing ring nut socket
021068Y Ring gear side roller cage extraction

punch
021069Y 52 mm adaptor for single arm lift stand
S-TOOLS - 55
Special tools V100 E5

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

diameter hole
AP8140146 Weight
AP8140150 Bored shaft for bleeding plunger air
AP8140149 Guard for assembly operations
021072Y Right chain tensioner
021073Y Central chain tensioner
S-TOOLS - 56

021074Y Left chain tensioner
01761-04 Ohlins fork cap ring nut
Commercially available tool Bushing of 65 mm
S-TOOLS - 57
INDEX OF TOPICS
MAINTENANCE MAIN
V100 E5 Maintenance
Scheduled maintenance table

NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-
HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
SCHEDULED MAINTENANCE TABLE VALID FOR EU-USA-LATAM-JA MARKETS
SCHEDULED MAINTENANCE TABLE

I: Check and clean, adjust, lubricate or replace, if necessary
C: clean
R: replace
A: adjust
(1): Replace in case of leaks
(2): Check every month
(3): Check every 500 km (310 miles)
(4): Check and clean, adjust or replace if necessary every 1000 km (621 miles)
(5): Replace at whichever of the following occurs first: 48,000 km (29,800 mi) or 4 years
km x 1,000 (mi x 1,000) 1,5 12 24 36 48 60 72 EVERY EVERY

(0.9) (7.5) (14.9) (22.4) (29.8) (37.3) (44.7) 12 24
MONTH MONTH
S S
Engine oil filler plug O-ring I I I I I I I I I
Fork plug O-ring I
Spark plugs I R I R I R
Alternator belt I R I R I R R
Steering bearings and steering play I I I I I I I I I
Front wheel bearings I I I I I I I I
Diagnosis by tool I I I I I I I I I
Brake discs - Pads wear (4) I I I I I I I I I
Air filter R R R R R R
Engine oil filter R R R R R R R R R
Vehicle general operation I I I I I I I I I
Valve clearance I I I
Head cover gasket I I I I I I I
Engine oil discharge plug aluminium gasket R R R R R R R R R
Transmission oil discharge plug gasket R R R
Gasket for the engine oil filter fastening R R R R R R R R R
screw
Brake systems I I I I I I I I I
Light circuit I I I I I I I I I
Safety switches I I I I I I I I I
Brake fluid I I I I I I I I R
Clutch fluid I I I I I I I I R
Coolant I I I I I I I I R
Fork oil (5) R
Engine oil (3) R R R R R R R R R
Final drive oil R R R
Headlight aiming I I I I I I
Fork oil seals (1) I I I I I
Tyres - pressure / wear (2) I I I I I I I I I
Transmission oil filler plug washer R R R
Nut/bolt tightness I I I I I I I
Suspensions and stability I I I I I
Head cover fastening screws dampers I I I I I I I
Filter box drain plug C C C C C C C C
Brake lines I I I I I I
Fuel pipes I I I I I I I I
MAIN - 59
Maintenance V100 E5
km x 1,000 (mi x 1,000) 1,5 12 24 36 48 60 72 EVERY EVERY

(0.9) (7.5) (14.9) (22.4) (29.8) (37.3) (44.7) 12 24
MONTH MONTH
S S
Labour time (minutes) 70 170 200 170 290 170 200 60 60
NOTE
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.
CAUTION
AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE
MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 10,000 Km OR 10
MONTHS
SCHEDULED MAINTENANCE TABLE RESERVED FOR THE ASIA-PACIFIC MARKET
SCHEDULED MAINTENANCE TABLE

I: Check and clean, adjust, lubricate or replace, if necessary
C: clean
R: replace
A: adjust
(1): Replace in case of leaks
(2): Check every month
(3): Check every 500 km (310 miles)
(4): Check and clean, adjust or replace if necessary every 1000 km (621 miles)
(5): Replace at whichever of the following occurs first: 48,000 km (29,800 mi) or 4 years
km x 1,000 (mi x 1,000) 1,5 (0.9) 12 (7.5) 24 (14.9) 36 (22.4) 48 (29.8) 60 (37.3) 72 (44.7)
Engine oil filler plug O-ring I I I I I I I
Fork plug O-ring I
Spark plugs I R I R I R
Alternator belt I R I R I R
Steering bearings and steering play I I I I I I I
Front wheel bearings I I I I I I
Diagnosis by tool I I I I I I I
Brake discs - Pads wear (4) I I I I I I I
Air filter R R R R R R
Engine oil filter R R R R R R R
Vehicle general operation I I I I I I I
Valve clearance I I I
Head cover gasket I I I I I I I
Engine oil discharge plug aluminium gasket R R R R R R R
Transmission oil discharge plug gasket R R R
Gasket for the engine oil filter fastening R R R R R R R
screw
Brake systems I I I I I I I
Light circuit I I I I I I I
Safety switches I I I I I I I
Brake fluid I I I I I I I
Clutch fluid I I I I I I I
Coolant I I I I I I I
Fork oil (5) R
Engine oil (3) R R R R R R R
Final drive oil R R R
Headlight aiming I I I I I I
Fork oil seals (1) I I I I I
Tyres - pressure / wear (2) I I I I I I I
Transmission oil filler plug washer R R R
Nut/bolt tightness I I I I I I I
Suspensions and stability I I I
Head cover fastening screws dampers I I I I I I I
Filter box drain plug C C C C C C
Brake lines I I I I I I
Fuel pipes I I I I I I
MAIN - 60
V100 E5 Maintenance
km x 1,000 (mi x 1,000) 1,5 (0.9) 12 (7.5) 24 (14.9) 36 (22.4) 48 (29.8) 60 (37.3) 72 (44.7)
Labour time (minutes) 70 170 200 170 290 170 200
NOTE
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.
CAUTION
AFTER THE PROVIDED MAINTENANCE PROGRAM IS INDICATED TO PROCEED WITH THE
MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 10,000 Km OR 10
MONTHS
Recommended products
Piaggio Group recommends the use of prod-

ucts from its Castrol official partner for the
scheduled maintenance of its vehicles.
Only use lubricants and fluids which meet or ex-
ceed the performance characteristics specified.
This also applies when topping up only.
TABLE OF RECOMMENDED PRODUCTS

Product Description Specifications
Engine oil 10W -50 Synthetic-based lubricant for high per- SAE 10W 50; API SL; JASO MA2
formance four-stroke engines.
75W-140 lubricant for gearboxes and Synthetic lubricant for gearboxes and SAE 75W-140 - API GL5
transmissions transmissions
Anti-freeze liquid, ready to use, colour red Glycol ethylene based antifreeze liquid ASTM D 3306 - ASTM D 4656 - ASTM D
with organic additive technology corro- 4985 - CUNA NC 956-16
sion inhibitor. Colour red, ready to use.
Fork oil 7.5W Fork oil. SAE 7.5W
Molybdenum disulphide grease Lithium grease with molybdenum disul- Grey black grease
phide.
Petroleum jelly neutral grease for battery terminals -
DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
Spark plug
REMOVAL AND CHECK
• Remove the fixing screw (1).
MAIN - 61
Maintenance V100 E5
• Remove the spark plug cover (2).
• Release the cable from their seats on

the valve cover.
• Remove the fixing screw (3) of the coil.
• Extract the coil (4) from the head.
MAIN - 62
V100 E5 Maintenance
• Using a dedicated wrench, unscrew

the spark plug and remove it from the
head.
• Check the state of wear of the spark

plug and measure the distance be-
tween the electrodes.
• If the value does not lie within the
specified value, replace the spark plug
with a new one.
Characteristic
Spark plug electrode gap
0.7 mm (0.028 in)
Transmission fluid
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 suitable container with a capacity greater
than 250 cc (15.26 cu in) under the drain plug (1).
MAIN - 63
Maintenance V100 E5
Loosen the drain plug without removing it.
Unscrew and remove the filler plug (2).
Completely unscrew and remove the drain plug.

Drain the oil into the container for at least 5 mi-
nutes for oil to drain out completely.
Once the oil has drained out, screw in and tighten

the drain plug with its washer to the prescribed
torque.
Remove metal residues attached to the drain plug
magnet.
NOTE
DURING REPLACEMENT, USE A NEW SEALING WASHER.

Oil drainage plug 30 Nm (22.1 lb ft)
MAIN - 64
V100 E5 Maintenance
Using a special syringe, fill in with new oil through

the filler cap.
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
75W-140 lubricant for gearboxes and transmis-
sions Synthetic lubricant for gearboxes and
transmissions
SAE 75W-140 - API GL5
Characteristic
Bevel gear set oil
250 cm³ (15.26 cu in)
Bevel gear oil (in case of replacement)
225 cc (13.73 cu in) MAX
Screw and tighten the filler cap with its washer to

the prescribed torque.
NOTE
CAUTION
IF IT IS NECESSARY TO INSTALL A NEW TRANSMISSION
GEARBOX, PAY SPECIAL ATTENTION TO THE PROCE-
DURE BELOW

Oil load cap 25 Nm (18.43 lb ft)
Since they are already run-in at the factory, the

complete transmission boxes coming from the
Spare parts department contain a minimum resid-
ual oil quantity and therefore after installing them
on the vehicle, the following procedure must be
performed:
•Open the filler plug and drain any residual oil from
the lower drain plug leaving it to drip for at least 5
minutes.
•Refit and tighten the lower drain plug and fill with
oil from the filler cap.
•Refit and tighten the filler cap.
•Assemble the breather cap. If the gearbox arrived
with the breather plug already assembled, remove
MAIN - 65
Maintenance V100 E5
it and blow it with compressed air to carefully re-

move any oil residues.
CAUTION
DURING REPLACEMENT, USE A NEW SEALING WASHER
FOR THE BREATHER CAP.
Engine oil
Check
Check the engine oil level frequently.

NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-
HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
WARNING
THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.
CAUTION
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE
ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL. THE CORRECT PRO-
CEDURE IS TO CHECK AFTER A JOURNEY OR AFTER RUNNING 15 km (10 mi) ON AN EXTRA-
URBAN ROUTE (ENOUGH TO RAISE ENGINE OIL TEMPERATURE).
• Shut off the engine and wait a few sec-
onds;
• Keep the vehicle upright with both
wheels on the ground;
• Make sure that the vehicle is on a level
surface;
• Unscrew the oil filler cap with dipstick;
• Wipe the dipstick clean and put the dip-

stick and filler cap back into place with-
out tightening;
• Remove the cap and dipstick again
and check the engine oil level;
• The level is correct if it reaches the
''MAX'' level approximately. Otherwise
top off the engine oil.
CAUTION
THE OIL LEVEL MUST NEVER DROP BELOW THE MINI-
MUM MARKING OR EXCEED THE MAXIMUM MARKING;
MAIN - 66
V100 E5 Maintenance
AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM

MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE.
Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
Place a collection container of suitable capacity
under the drain plug (1).
Unscrew and remove the filler plug (2).
Unscrew the drainage cap.
Remove the drain plug and allow the oil to drip into
the container for a few minutes.
MAIN - 67
Maintenance V100 E5
Once the oil has drained out, screw in and tighten

the drain plug with its washer to the prescribed
torque.
Remove metal residues attached to the drain plug
magnet.
NOTE
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT.

DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND
TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED
OIL COLLECTION CENTRE.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERV-
ICING THE VEHICLE.

Oil drainage plug 20 ± 2 Nm (14.75 ± 1.47 lb ft)
Fill with new oil through the filler cap.
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL-
EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Engine oil 10W -50 Synthetic-based lubricant
for high performance four-stroke engines.
SAE 10W 50; API SL; JASO MA2
Characteristic
Engine oil
Oil change and oil filter replacement: 4900 cc in
(299.02 cu in)
Screw and tighten the filler cap with its washer to

NOTE

Oil load cap 2 ± 0.5 Nm (1.47 ± 0.37 lb ft)
MAIN - 68
V100 E5 Maintenance
Engine oil filter
Loosen the 3 screws securing the engine oil filter

cover.
Place a container with adequate collecting capaci-

ty at the engine oil filter cover and completely
unscrew the 3 fixing screws.

Remove engine oil filter cover with the spring.
Remove the engine oil filter.
MAIN - 69
Maintenance V100 E5
When reassembling, use a new O-ring seal for the

engine oil filter cover.
Insert the new engine oil filter.

NOTE
NEVER REUSE AN OLD FILTER.
Refit the cover with the spring facing downwards.
Screw in and tighten the 3 fixing screws for the

engine oil filter cover to the prescribed torque.

Fixing screws for engine oil filter cover 12 ± 1 Nm
(8.85 ± 0.73 lb ft)
MAIN - 70
V100 E5 Maintenance
Air filter
REMOVAL
• Remove the four fixing screws and

then remove the cover (1) of the tank.

then remove the cover (2) of the filter
box.
• Remove the two fixing screws indica-

ted in the figure.
• Remove the air filter support (3) from

the filter box.
MAIN - 71
Maintenance V100 E5
• Remove the air filter (4) from the filter

box.
Air filter housing
Air filter housing removal
• First remove the fuel tank.

• Loosen the two clamps (1) of the throt-
tle body manifolds.
• Open the clamp and disconnect the left

breather pipe (2) from the filter box.
• Remove the left fixing screw of the filter

box.
MAIN - 72
V100 E5 Maintenance
• Open the clamp and disconnect the

right breather pipe (3) from the filter
box.
• Remove the right fixing screw of the fil-

ter box.
• Remove the filter box from the vehicle

by extracting it upward.
DURING REASSEMBLY, ENSURE THE CORRECT INSER-

TION OF THE AIR FILTER HOUSING MANIFOLDS ON THE
THROTTLE BODIES.
• To remove the air filter inside the filter box, carry out the procedure described in paragraph
"air filter" in the "maintenance" chapter.
See also
Air filter
MAIN - 73
Maintenance V100 E5
Checking the valve clearance
• Install a workshop stand to the rear

wheel of the vehicle so as to lift it from
the ground.
• Remove the spark plugs from both
heads.
• Turn the rear wheel until the left-hand
piston is at top dead centre (TDC) and
in compression (all cams facing up and
with the lobes converging).
NOTE
Checking the valve clearance should be performed first on
the left head.
• Remove the three fixing screws (1).
• Remove the valve cover (2) from the

head.
• Using a feeler gauge reed valve (3),

measure the distance between the
rocker (4) and the valve (5).
Characteristic
Intake valve clearance
0.10 - 0.15 mm (0.0039 - 0.0059 in)
Exhaust valve clearance
0.30 - 0.35 mm (0.0118 - 0.0138 in)
MAIN - 74
V100 E5 Maintenance
• Repeat the operation for the remaining

valves.
If the valve clearance is not within the tolerance

range, adjust the valve clearance as shown below.
• Turn the rear wheel and bring the right-

hand piston to TDC and in compres-
sion (the lobes of the camshafts must
face upwards and diverge from each
other, as shown in the figure).
• Repeat the valve clearance control op-
erations on the right head.
If the valve clearance is not within the tolerance

range, adjust the valve clearance as shown below.
VALVE CLEARANCE ADJUSTMENT

RIGHT HEAD
• Preventively remove: radiator, timing

cover, spark plug valve covers.
• Turn the engine counter-clockwise and
bring the RH piston to Top Dead Cen-
tre.
NOTE
THE HOLE ON THE PINION MARKED "PMS DX" MUST BE
ALIGNED WITH THE HOLE ON THE CRANKCASE.
• Insert the centring pin in the crankshaft

pinion, making sure to intercept the
holes of the pinion and of the crank-
case.
Specific tooling
020851Y Camshaft timing pin
MAIN - 75
Maintenance V100 E5
• Check that the cam lobes are divergent

from each other.
• Insert the special tool (1) into the hole

on the exhaust camshaft.
Specific tooling
021064Y Large pin for engine timing
• Continue to insert the tool (1) to inter-

cept the hole on the intake manifold.
• For safety, mark the position of the

sprockets on the chain and of the chain
in relation to the upper chain tensioner
shoe.
MAIN - 76
V100 E5 Maintenance
• Remove the fixing screws of the upper

mounting, following the sequence A-B-
C-D-E-F-G-H- I.
• Remove the upper mounting (2) from

the head.
• Remove the tool (1) from the cam-

shafts, taking care that the chain ten-
sioner, still loaded with oil, does not
cause the shafts to drop from the head.
• Remove the intake camshaft (3).

CAUTION
MAKE SURE THAT THE CHAIN TENSIONER DOES NOT
COME OUT OF ITS SEAT AND FALL INTO THE ENGINE.
MAIN - 77
Maintenance V100 E5
• Remove the exhaust camshaft (4).
• Fasten the timing chain to the vehicle,

taking care that it does not get out of
the sprocket on the service shaft.
• Lift the rocker arm of the valve(s) to be

adjusted.
• Using a magnet, remove the calibrated

pads (5) from the valves to be adjusted
and replace them with pads of a suita-
ble thickness to achieve the specified
valve clearance.
To find the thickness of the pads to be installed,

use the following formula:
Installed pad thickness + measured clearance -
specified clearance = new pad thickness
CAUTION
PAY CLOSE ATTENTION NOT TO DROP THE CALIBRA-

TED PADS INTO THE ENGINE.
MAIN - 78
V100 E5 Maintenance
• After replacing the pad(s), install the

intake shaft (3) on the timing chain, so
that the sprocket and the chain marks
coincide, then position it in its seat on
the head.
• Install the exhaust shaft (4) on the tim-

ing chain, by aligning the references
the sprocket and chain, then place it in
its seating on the head.
CAUTION
WHEN INSTALLING THE EXHAUST SHAFT, TAKE CARE
NOT TO DROP THE INTAKE SHAFT.
• Refit the special tool (1) back into the

intake and exhaust camshafts.
• While holding the camshafts in posi-

tion, install the upper mounting (2).
NOTE
WHEN REMOUNTING THE PUMP, REPLACE THE "O-
RINGS"
MAIN - 79
Maintenance V100 E5
• Tighten the fixing screws to the speci-

fied torque, following the sequence A-
B-C-D-E-F-G-H- I.

Camshaft support screw 11-13 Nm (8.11 - 9.59 lbf ft)
NOTE
The screw (6) in the hole of the spark plug has a washer,
while the screw (7) is the single shorter screw compared
to the others.
• Remove the special tool (1) from the

camshafts.
• Remove the pin from the pinion of the

crankshaft.
• Refit the cover valves, spark plug, tim-
ing system cover and the radiator.
• Restore the water level in the radiator
and in the expansion tank.
MAIN - 80
V100 E5 Maintenance
LH HEAD
To adjust the valves of the LH head, follow the
procedures for the RH head but with the difference
of:
• Turn the engine COUNTER-CLOCK-

WISE and bring the LH piston to Top
Dead Centre.
NOTE
THE HOLE ON THE PINION MARKED "PMS SX" MUST BE
ALIGNED WITH THE HOLE ON THE CRANKCASE.
• Make sure that the lobes of the cam-

shafts are facing up and convergent.
Cooling system
Level check
• Shut off the engine and wait until it

cools off.
• Keep the vehicle upright with both
wheels on a flat surface.
• Looking from right side of the vehicle,
behind the steering headstock, make
sure that the fluid level in the expansion
tank is between the "MIN" (minimum)
and "MAX" (maximum) marks.
WARNING
CARRY OUT THE CHECK AND TOP UP THE REFRIGER-
ANT LIQUID WITH THE ENGINE SWITCHED OFF AND
COLD.
MAIN - 81
Maintenance V100 E5
Top-up
• Remove the expansion tank cap.

• Top up with the recommended fluid, to
reach a level between the notch "MIN"
and "MAX"of the expansion tank, visi-
ble from the right side of the vehicle
behind the steering headstock.
Braking system
Level check
FRONT BRAKE
• Rest the vehicle on its stand.

• Turn the handlebar so that the fluid is
at the same level as the plug.
• Make sure that the fluid level in the res-
ervoir is above the "MIN" reference
mark:
MIN = minimum level

MAX = maximum level
If the fluid does not reach at least the "MIN" refer-
ence mark:
• Check the state of wear of the discs

and of the brake pads.
• If the pads and / or the discs do not
need replacing, check that the lack of
fluid is not due to leaks in the braking
system.
• When the system is in good condition,
top up the brake fluid.
MAIN - 82
V100 E5 Maintenance
REAR BRAKE
• Keep the vehicle upright so that the flu-

id in the reservoir is at the same level
as the plug.
• Make sure that the fluid level in the res-
ervoir is above the "MIN" reference
mark:
MIN = minimum level

MAX = maximum level
If the fluid does not reach at least the "MIN" refer-
ence mark:
• Check the state of wear of the brake

disc and of the brake pads.
• If the pads and / or the disc do not need
replacing, check that the lack of fluid is
not due to leaks in the braking system.
• When the system is in good condition,
top up the brake fluid.
Top-up
RISK OF BRAKE FLUID SPILLING. DO NOT OPERATE THE BRAKE LEVER IF THE BRAKE FLUID
RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED.
CAUTION
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC
AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESER-
VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING-UP PROCEDURE.
TO AVOID SPILLING FLUID WHILE TOPPING UP, KEEP THE LEVEL OF THE FLUID IN THE RES-
ERVOIR PARALLEL WITH THE EDGE OF THE RESERVOIR ITSELF (IN HORIZONTAL POSITION).
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. FUNNELS OR ANY OTHER
IMPLEMENTS USED MUST BE PERFECTLY CLEAN.
BRAKE FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH THE SKIN, EYES AND PARTS
OF THE MOTORCYCLE.
WHEN TOPPING UP, PROTECT PARTS OF THE MOTORCYCLE IN THE VICINITY OF THE RES-
ERVOIR WITH ABSORBENT MATERIAL.
DOT 4 brake fluid Synthetic brake fluid.
MAIN - 83
Maintenance V100 E5
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4
Front braking system
• Use a short Philips screwdriver, un-

screw the screws (1) of the front brak-
ing system fluid tank (2).
• Lift and remove the cover (3) and

screws (1) as well.
• Remove the gasket (4).

• Top up the reservoir (2) with recom-
mended brake fluid to above the mini-
mum level marking "MIN".
CAUTION
ONLY FILL TO THE "MAX" LEVEL AFTER FITTING NEW

BRAKE PADS. DO NOT FILL TO THE "MAX" LEVEL WITH
WORN PADS, AS THIS WILL CAUSE FLUID TO ESCAPE
WHEN REPLACING BRAKE PADS.
CHECK BRAKING EFFICIENCY.
IF THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE
LEVER IS TOO LONG, OR IN CASE OF FLUID LOSS, IT
MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN
THE SYSTEM.
Rear braking system
• Unscrew the cap (5) and remove to-

gether with the gasket (6).
• Top up the reservoir (7) with recom-
mended brake fluid to above the mini-
mum level marking "MIN".
CAUTION
MAIN - 84
V100 E5 Maintenance
ONLY FILL TO THE "MAX" LEVEL AFTER FITTING NEW

BRAKE PADS. DO NOT FILL TO THE "MAX" LEVEL WITH
WORN PADS, AS THIS WILL CAUSE FLUID TO ESCAPE
WHEN REPLACING BRAKE PADS.
CHECK BRAKING EFFICIENCY.
IF THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE
LEVER IS TOO LONG, OR IN CASE OF FLUID LOSS, IT
MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN
THE SYSTEM.
Clutch system
Regolazione leva frizione
Perform the clutch adjustment when the engine

stops or the vehicle tends to drive forward with the
clutch lever actuated and the gear engaged, or if
the clutch "slips", causing the acceleration to delay
in relation to the number of engine revolutions. It
is possible to adjust the distance between the end
of the lever (1) and the grip (2), turning the adjuster
(3).
• Push the control lever (1) forwards and

turn the adjuster (3) until the lever (1)
is at the desired distance.
• Turning the adjuster clockwise moves
the lever (1) away from the handle (2).
In the event that the adjustment of the lever is not

sufficient, check that there is no air in the hydraulic
circuit or loss along the same; refer to the section
"braking system" for more information.
Headlight adjustment
NOTE
IN COMPLIANCE WITH LOCAL LEGISLATION, SPECIFIC PROCEDURES MUST BE FOLLOWED
WHEN ALIGNING THE LIGHTS.
MAIN - 85
Maintenance V100 E5
To quickly check if the headlamp is aimed correct-

ly, place the vehicle on a level surface 10 m (32.8
ft) from a vertical wall. Turn on the low beam light,
sit on the vehicle and check that the light beam
projected to the wall is a little below the horizontal
straight line of the headlight (about 9/10 of the total
height).
To carry out vertical adjustment of the light

beam:
• Place the vehicle in a vertical position;

• Adjust the adjusting screws (1) and (2),
located under the instrument panel, to
adjust the (1) left and (2) right low beam
headlamps. Turning the screw clock-
wise lowers the headlamp, and coun-
terclockwise raises the headlamp.
• Using a Phillips screwdriver, turn the

adjustment screw that can be reached
from under the top fairing to adjust the
high beam headlight. Turning the
screw clockwise lowers the headlamp,
and counterclockwise raises the head-
lamp.
NOTE
ONCE THE ADJUSTMENTS ARE FINISHED, CHECK THE VERTICAL ORIENTATION OF THE
LIGHT BEAM.
Anti-evaporation system
Removing system components

NOTE
IF THE FILTERING EFFECTIVENESS IS COMPROMISED, REPLACE THE COMPLETE CANISTER.
MAIN - 86
V100 E5 Maintenance

• Disconnect the connector (1) from the
SAS valve.
• Disconnect the connector (2) from the

coolant temperature sensor on the left
cylinder.
• Once the connectors are disconnec-

ted, release the wiring harness from its
fitting on the canister.
• Release the wiring harnesses from the

retainers on the canister indicated in
the figure.
MAIN - 87
Maintenance V100 E5
• Remove the two screws fixing the can-

ister to the frame.
• Lift the canister to allow easy access to

the SAS valve lines.
• Open the clamps and remove the two
pipes (3) on the right side of the SAS
valve.
• Open the clamp and remove the pipe

(4) from the canister.

(5) from the canister.
MAIN - 88
V100 E5 Maintenance
• Open the clamp and remove the

breather pipe (6) from the canister.

(7) from the left side of the SAS valve.
• Remove the canister from the vehicle.
• If it is necessary to replace the safety

valve (8), open the spring clamps (9),
disconnect the pipes (10) and proceed
with the replacement. During refitting,
make sure to observe the direction of
the valve (8).
MAIN - 89
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

V100 E5 Electrical system
Alternator belt removal
• First remove the fuel tank and the can-

ister.
• Remove the three fixing screws shown
in the figure.
• Remove the cover of the belt from the

vehicle.

in the figure.
• Remove the right head support brack-

et.
ELE SYS - 91
Electrical system V100 E5
• Loosen the lock nut of the set screw.
• Tighten the adjuster screw until it stops

with the lock nut.
• Remove the fixing screw of the adjust-

ment bracket.
• Unscrew almost completely the left fix-

ing screw of the alternator, but DO
NOT remove it.
ELE SYS - 92
• Press downwards the alternator so as

to release the belt tension.
• Remove the belt from the alternator
pulley then remove it from the vehicle.
Alternator belt installation
• Install the belt on the engine pulley,

then fit it on the alternator pulley.
NOTE
Fit the belt with the writing aligned as shown in the figure.
• Screw in the left-hand alternator fixing

screw, without tightening it.
ELE SYS - 93
• Screw in the fixing screw of the adjust-

ing bracket, without tightening it.
• Unscrew the adjusting screw to tem-

porarily tension the belt.
• Follow the belt tensioning procedure
described below, not including parts
related to component removal.
Alternator belt tensioning
• First remove the fuel tank and the can-

ister.
in the figure.
• Remove the cover of the belt from the

vehicle.
ELE SYS - 94

in the figure.
• Remove the right head support brack-

et.
• Using a digital frequency meter, meas-

ure the belt tensioning frequency by
vibrating it with your finger.
Characteristic
Alternator belt frequency
180 Hz
• Loosen the screws (1) and (2) fasten-

ing the alternator.
ELE SYS - 95
• Loosen the lock nut of the set screw.
• Act on the adjuster screw, screwing it

in to decrease the tensioning frequen-
cy or unscrewing it to increase it.
• Tighten the fixing screws (1) and (2) of

the alternator to the specified torque.
WARNING
It is essential to tighten the fixing screws to measure the
tensioning frequency correctly.

Fixing screw (1) 45 - 50 Nm (33.19 - 36.88 lb ft) Fixing
screw (2) 20 - 24 Nm (14.75 - 17.70 lb ft)
• Measure the tensioning frequency of

the alternator belt again.
Characteristic
Alternator belt frequency
180 Hz
ELE SYS - 96
• If the tension is correct, tighten the lock

nut of the adjuster screw.
• Otherwise, repeat the operations for
the belt tensioning.
• When the correct belt tension frequen-

cy is reached, install the RH head sup-
port bracket.
• Install the three fixing screws and tight-

en them to the specified torque.

Head mounting bracket fixing screw 50 ± 7.5 Nm
(36.88 ± 5.53 lb ft)
• Fit the cover of the belt on alternator.
ELE SYS - 97
• Tighten the three fixing screws of the

alternator belt cover.
• Refit the canister and the fuel tank on
the vehicle.
Components arrangement
ELE SYS - 98
KEY:
1. ECU
2. Starter relay and main fuses;
3. Secondary fuses;
4. Fuel pump;
5. Fuel level sensor;
6. Right-hand aerodynamic flap actuator;
7. Adjustable top fairing actuator;
8. Coolant temperature sensor;
9. Front right turn indicator;
10.Front ABS sensor;
11.Horn;
12.Right Lambda probe;
13.Right pipette/coil;
14.Starter motor;
15.PURGE valve;
16.IMU ECU;
17.Rear right turn indicator;
18.Licence plate lamp;
19.Alternator;
20.TFT instrument cluster;
21.Ignition switch assembly;
ELE SYS - 99
22.ABS Modulator;
23.Battery;
24.OBD5 port;
25.Rear light cluster;
26.Rear left turn indicator;
27.TPMS ECU;
28.GMP ECU;
29.Stand sensor;
30.Engine oil pressure sensor;
31.Left lambda probe;
32.Left pipette/coil;
33.Front left turn indicator;
34.Voltage regulator;
35.Front light cluster;
36.Left-hand aerofoil flap actuator;
37.USB port
38.USB socket (if provided);
39.Ohlins suspension ECU (V100 Mandello S).
Checks and inspections
GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS
THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC-

TORS; NOTE THAT THE DRAWING ALWAYS DEPICT THE CONNECTOR/COMPONENT VIEWED
FROM THE WIRING HARNESS SIDE, I.E. FROM THE SIDE ON WHICH THE CABLES LEADING
FROM THE MAIN WIRING HARNESS ENTER THE CONNECTOR/COMPONENT.
CAUTION
BEFORE STARTING ANY TROUBLESHOOTING PROCEDURES ON THE VEHICLE, CHECK THAT
THE BATTERY VOLTAGE IS ABOVE 12V.
CONNECTOR CHECK PROCEDURE
The procedure includes the following checks:
1. Observation and check of the connector correct
position on the component or on the coupling con-
nector, making sure that the locking catch is re-
leased.
2. Observation of the terminals on the connector:
no rust marks or dirt should be present and it is
important to check terminal correct positioning on
ELE SYS - 100

the connector (i.e., all terminals aligned at the

same depth) and terminal integrity (i.e., that termi-
nals are not loose, open/bent, etc.). For connec-
tors whose terminals are not visible (e.g. Marelli
control unit) use a metal cable of suitable diameter
and introduce it carefully in the connector slot at
the same depth as for the other terminals of the
connector.
CAUTION
IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE
THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PER-
FORMING EACH OF THE CHECKS INDICATED FOR TROU-
BLESHOOTING.
3. Pull cables gently from the back of the connector to check that the terminals are fitted correctly on
the connector and that the wires are fastened correctly to the terminals.
Checking electrical CONTINUITY
Purpose of check: the purpose of this check is ensure that there are no interruptions or excess re-
sistance (due to corroded terminals, for example) in the circuit under inspection.
Tester: set the tester selector to the "continuity" symbol and place the probes of the tested at the two
ends of the circuit: Normally, the tester will sound an audible signal to confirm continuity in the section
of circuit tested; Continuity may also be tested by setting the tester selector to the "Ohm" symbol and
checking that the resistance in the circuit is zero or of a few tenths of an Ohm.
WARNING: THE CIRCUIT MUST BE UNPOWERED DURING THIS TEST. IF THE CIRCUIT IS POW-
ERED, THE RESULTS OF THIS TEST ARE MEANINGLESS.
Checking GROUND CONNECTION
Purpose of check: the purpose of this check is to verify that a cable or circuit is correctly connected
to the ground (-) of the vehicle.
Tester: set the tester selector to the "continuity" symbol and place one of the tester probes on the
vehicle ground point (or on the battery negative pole) and the other probe on the cable under inspection:
Normally, the tester will sound an audible signal to confirm continuity in the section of circuit tested.
Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the
resistance in the circuit is zero or of a few tenths of an Ohm.
IMPORTANT: WHERE GROUND IS PROVIDED BY THE ECU, CHECK THAT THE ECU IS EFFEC-
TIVELY PROVIDING THE GROUND CONNECTION FOR THE CIRCUIT DURING THE TEST.
Checking VOLTAGE
Purpose of check: the purpose of this check is to determine if a cable is carrying voltage, in other
terms, to verify whether it powered by the battery or ECU.
Tester: set the tester selector to the "DC voltage" symbol and place the red tester probe on the cable
under inspection and the black tester probe on the vehicle ground point (or on the battery negative
pole).
ELE SYS - 101

CAUTION
IN THE CASE OF SPORADIC FAULTS, MOVE OR WIGGLE THE RELATIVE WIRING HARNESS
SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOT-
ING.
Immobiliser
The vehicle is equipped with an electronic engine disabling system that is activated automatically when
the ignition key is removed. Each key in the grip has an electronic device - transponder - which mod-
ulates the radio frequency signal emitted by a special aerial inside the switch when the vehicle is started.
The modulated signal is the "password" by which the appropriate central unit recognises the key and
only after this occurs, it allows the engine start-up.
The vehicle is delivered to the customer with two pre-programmed keys. The instrument cluster accepts
a maximum of four keys at the same time. Approximately ten seconds after the key is set to ON, the
instrument cluster requests a personal five-digit code to be entered.
On the leftmost value of the display, a variable value is shown that can be modified from 0 to 9, by using
the MODE selector. Press the centre of the MODE selector to confirm each of the five digits. Once
confirmed, the display shows the code in a fixed manner, this is so the user can check the code that
has been entered. To remove the screen showing the code that has been entered, carry out a KEY
OFF- KEY ON cycle. In the future you can always change the last code entered. This request message
is no longer displayed once the personal code is entered.
It is important to remember the personal code because:
• the vehicle can be started if the immobilizer system is faulty

• the instrument cluster need not be replaced should the ignition switch be changed
• new keys can be programmed
NOTE
IF THE PERSONA CODE IS NOT MEMORISED AND THE VEHICLE IS USED, THE MESSAGE DIS-
APPEARS AFTER 10 SECONDS BUT REAPPEARS WITH EACH KEY ON.
NOTE
THE FACTORY SET CODE IS COMPOSED OF FIVE ZEROES.
All the functions for changing, storing or resetting the immobilizer codes can be carried out by the dealer,
whereas some of the instrument cluster settings can also be carried out by the customer.
With the key set to "KEY OFF" the general alarm

warning light flashes to indicate activation of the
locking system.
ELE SYS - 102

If there is an immobilizer failure at ignition, the in-

strument cluster requests you to enter a user code.
If the code is entered correctly, the instrument
cluster signals the failure by displaying the word
SERVICE and the red general warning light turns
on.
Once the code has been correctly entered, the er-
ror will be displayed on the screen, and you can
still start the motorcycle.
CAUTION
PRESSING OR MOVING ANY CONTROL ON THE LEFT
SWITCH CLUSTER, IT IS POSSIBLE TO REMOVE THE ER-
ROR NOTIFICATION SCREEN, BUT THE SCREEN WILL BE
VISIBLE AGAIN AFTER ABOUT 10 SECONDS.
Change user code (Change user code)

This function may be used to modify the existing
code (you must be in possession of the code itself
in order to do this). The user code enables engine
start even in the event of an immobiliser system
fault. The user code is set by default as five zeros
(00000) on a new vehicle, and the message "IN-
SERT CODE" is shown on the display for ten
seconds.
This function allows you to change the code itself
and remove this message.
On the value to the leftmost of the display a value
from 0 to 9 will be shown (which can be modified
by moving the MODE selector upward or down-
ward). Press the centre of the "MODE" selector
briefly to confirm the selection. Repeat the opera-
tion for all the digits. Once the code is confirmed,
the new code is shown steadily on the display to
let the user verify that the code has been entered
correctly. Turn the ignition off and then on again to
unlock the instrument cluster. The last code set
may be modified again in future. Access the setting
mode again, enter the last user code used (OLD
CODE), then enter a new user code (NEW CODE)
as described previously.
ELE SYS - 103

Code recovery (Code recovery)

This function must be used should it be necessary
to change the user code when the user no longer
remembers the current code. Both keys stored in
the vehicle memory are needed to access this
function.
When the function is activated, by pressing briefly
on the middle of the MODE selector, the screen
"INSERT KEY 1" is displayed to signal the recog-
nition request of the first key. Insert the key. If the
correct key is recognised within twenty seconds,
the message "INSERT KEY 2" is shown on the
display. Insert the second key. If the second key is
also recognised within twenty seconds, the instru-
ment cluster resets the user code to the default
code (five zeros - 00000). Enter the new user code
following the "CHANGE USER CODE " procedure.
IMMOBILIZER ANTENNA
Function
detects the transponder code in the key and sends
it to the instrument cluster
Level in electrical circuit diagram:
Immobilizer
Position:
• on the vehicle: in the instrument cluster

• connector: two-way, grey, below the
right side steering sleeve
Electrical specifications
• 14 Ohm
Pin out
not significant
Diagnostic tool - Electrical errors

The instrument cluster errors are detected by means of the diagnostic tool. It is therefore necessary to
connect it to the vehicle.
Error code B0003 (ALARM IMMO B0003)
Error cause
ELE SYS - 104

• Occurs, when the transponder is working, but it is not within the recognised ones.
Identification
• General alarm warning continuously on (red) and indication "ALARM IMMO B0003" on the
display
Troubleshooting
• Store the new key

Error cause
• Occurs, when the key has no transponder or the transponder is damaged
Identification
display
Troubleshooting
• Replace the key and store it

Error cause
• Occurs when an electric interruption or a ground short circuit or voltage to the circuit have
been detected.
Identification
display
Troubleshooting
• Check the sensor connector on the wiring harness and the instrument panel connector.
Check that the antenna is connected, if OK remove it and check the continuity of the antenna
between the PIN of the connector (resistance between 10 - 100 Ohm), if not OK replace the
sensor; if OK reconnect the connector to the antenna and check from the wiring harness
side that there is continuity between the two PIN (resistance between 10-100 Ohm), if not
OK restore the wiring harness; if OK check continuity between the two PIN 2 and 3 of the
instrument panel, if not OK replace the instrument panel.

Error cause
• Occurs when a fault in the instrument panel has been detected
Identification
• General alarm warning continuously on (red) and indication "ALARM IMMO B0006"
ELE SYS - 105

Troubleshooting
• Replace the instrument cluster
Error code B0007 (ALARM 1 KEY STORED)

Error cause
• Occurs when the number of stored keys is less than two
Identification
• General alarm warning continuously on (red) and indication "ALARM 1 KEY STORED" on
the display
Troubleshooting
• Store the two keys again
System not programmed
Storing new keys

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

message will be visible. Press "OK"
and start programming the keys.
NOTE
IF THE IMMOBILIZER ANTENNA IS DISCONNECTED, YOU
WILL NOT BE ABLE TO START KEY PROGRAMMING.
ELE SYS - 106

• Enter the USER CODE to continue.

• If the code entered is correct, the first
key is stored.
• At this point, on the digital display of the motorcycle, after the automatic restart of the dy-
namic presentation screen, a message will appear with a countdown of 20 seconds to insert
the second key to be programmed.
• Set key to "OFF", insert the second key and set to "ON".
CAUTION
IF YOU DO NOT HAVE A SECOND KEY OR YOU DON'T WANT TO STORE ONE, THE DIAGNOSTIC
TOOL WILL SHOW AN ERROR SAYING "1 KEY STORED"
• The second key is stored and you will
be asked to enter the third key (if you
have one). The same operation will be
repeated to store the fourth key.
• To complete AND end the memorisa-
tion procedure, set key to "OFF".
• You should then test the correct func-
tioning of all keys stored.
Maintenance icon reset
The system displays the function as follows:
• After the maintenance interval thresh-

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

• Select the concerned model;
• Enter in the "INSTRUMENT CLUS-
TER" section;
• Select "SELF-DIAGNOSTIC";
• Select "ACTIVATIONS";
ELE SYS - 107

• Enable the command "SERVICE RE-

SET".
Infotainment
INFOTAINMENT
Key:
1. GMP ECU
2. OBD ECU
3. Ignition switch
4. Battery
5. Fuse
ELE SYS - 108

INSTRUMENT CLUSTER
Key:
1. TFT instrument cluster

2. Ignition switch
3. Battery
4. Main fuse
5. Fuse
ELE SYS - 109

HEATED HAND GRIPS - Only for V100 Mandello S

Key:
1. Instrument cluster
2. Right hand grip
3. Left hand grip
4. air temperature sensor
5. Immobilizer antenna
Battery recharge circuit
Key:
(1) Generator.
(2) Secondary fuse.
• Rear daylight running light

• Horn
• Licence plate lamp
(3) Sense connection.

(4) Ignition switch
(5) Main fuse .
(6) Battery.
The generator starts to recharge the battery only
with:
ELE SYS - 110

• Ignition switch set to ON,

• Battery voltage below 14.8 Volt,
• If voltage of at least 2 Volts is applied
to the Sense connection.
CAUTION
Do not leave the vehicle with the engine off and the ignition
key to "ON". The sophisticated on-board instruments have
a high current draw which, if left on with the engine switch-
ed off, will discharge the battery in a short time.
Recharge system voltage check
The following tools are required to test the func-

tionality of the charging system:
1. Ammeter clamp.
2. Voltmeter.
3. Fuse interrupted with a wire bridging be-
tween the two pins.
• Remove the rider saddle and the bat-

tery cover.
• Remove the 40 A main fuse.
• Restore the continuity of the circuit in-

serting, in the fuse holder, the previ-
ously prepared fuse (3).
ELE SYS - 111

• Position the ammeter clamp (1) on the

cable of the fuse (3).
• With the ignition switch in the ON po-
sition, but with the engine stopped,
there will be a continuous current draw
of 3.372A.
NOTE
Perform the measurements shown below with the lights
off.
The readings may vary from those shown depending on
the ambient temperature and the temperature of the in-
stallation itself; therefore, similar values, although not ex-
actly the same, are still significant to certify the correct
operation of the charging system.
• With the engine at idle speed the cur-

rent delivered (1) is 15.53 A and the
voltage on the battery (2) is 14.14 V.
• With the engine at 3,500 rpm the cur-

• With the engine at 5500 rpm the cur-

NOTE
When the voltage at the load reaches 14.82V, the generator
output current will be close to zero.
ELE SYS - 112

Start-up system check
Function
Communicates to the control unit the consent to
start the engine.
Operation / Operating principle
Pressing the start button closes the relative circuit,
bringing the ECU PIN 65 to zero voltage (closure
to ground).
Start-up enabling switch
Position:
• Button: on right hand light switch.
Electrical specifications:
• key released: open circuit

• key pressed: closed circuit
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
Key:
1. Ignition switch
ELE SYS - 113

2. Starter button
3. Starter Motor
4. 11MP ECU
5. Starter relay
6. Battery
7. Fuse
Lights list
HEADLAMP
Key:
1. Headlamp
2. Fog lights
3. Front left turn indicator
4. Front right turn indicator
6. Left light switch
7. Right light switch
8. Ignition switch
9. Battery
10.Fuse
ELE SYS - 114

TAILLIGHT
Key:
1. Taillight
2. Rear right turn indicator
3. Rear left turn indicator
4. Licence plate lamp
5. 11MP ECU
7. Ignition switch
8. Battery
9. Fuse
The 11MP control unit (5) controls the activation of the STOP light via pin 11.
Fuses
To check:
• Turn the ignition switch to "OFF" to avoid an accidental short circuit;

• Remove the passenger saddle to access the auxiliary fuses;
• Remove the driver saddle and the battery cover to access the main fuses;
• Remove the fuse box cover;
• Take out one fuse at a time and check if the filament is broken;
• Before replacing the fuse, investigate the cause of the problem and eliminate it;
ELE SYS - 115

• If the fuse is damaged, replace it with one of the same current rating.
NOTE
IF THE SPARE FUSE IS USED, REPLACE WITH ONE OF THE SAME TYPE IN THE CORRE-
SPONDING FITTING.
MAIN FUSES MSS V100

40A fuse Charging the battery
30A fuse Loads of the entire vehicle
spare fuses
They are located under the tank, in front of the E.C.U.
AUXILIARY FUSES (1)

A) 10A fuse Rear position, horn, licence plate light
B) 5A fuse Fog lights live positive lead (where provided)
C) 7.5A fuse ECU key-on positive, ABS key-on positive, instrument panel
key-on positive, RH light switch key-on positive, inertial plat-
form key-on positive, stand key-on positive, TMPS key-on pos-
itive (if provided), rear radar key-on positive (if provided), main
ignition relay
D) 7.5A fuse Key-on power for smart EC key-on positive (if provided)
E) 7.5A fuse GMP key-on positive (if provided), OBD key-on positive, anti-
theft system positive
F) 7.5A fuse Headlamp key-on positive
G) 3A fuse USB 1 and 2 key-on positive (2 if provided)
Q) Spare fuses
They are located on the tail fairing, under the passenger saddle
AUXILIARY FUSES (2)

H) 15A fuse Power supply for: Fan relay, ECU, fuel pump relay, RH and LH
lambda probe, RH and LH injectors, RH and LH coils, secon-
dary air valve, urge valve
I) 5A fuse Power supply for: anti-theft device provision, OBD2
L) 7.5A fuse Fan power feed
M) 7.5A fuse ECU permanent positive lead
N) fuse of 10A MGCA aerodynamic protection power supply
O) 5A fuse Instrument panel power supply (turn indicators)
P) 20A fuse ABS power feed
Q) Spare fuses
They are located on the tail fairing, under the passenger saddle
ELE SYS - 116

Control unit
ENGINE TONE WHEEL PROGRAMMING PRO-

CEDURE
• Using the PADS diagnostic tool, per-
form the "Reset wheel tooth values";
• Bring the engine to a temperature
above 80°;
Then proceed as described:

• In neutral position, with the side stand
extended/open and with the vehicle
absolutely immobile, quickly bring the
engine above 7000 RPM (it is not nec-
essary to stay there, it is sufficient to
exceed it);
• Close the throttle completely and wait
for the engine to go down to idle speed;
• Repeat this procedure three times.
The success of the procedure is confirmed by the

immediate turning off of the MIL light (in the pres-
ence of other errors the MIL light may remain on
but in any case stops flashing).
Switch off the panel and wait for at least one mi-
nute (Power Latch).
CAUTION
DURING THE ENGINE TONE WHEEL PROGRAMMING
PROCEDURE, THE VEHICLE'S SPEED MUST ALWAYS BE
0 km/h.
IN CERTAIN CASES, EVEN SMALL VIBRATIONS GENER-
ATED BY THE ENGINE (WITH THE ENGINE IN NEUTRAL
POSITION AND THE SIDE STAND EXTENDED/OPEN, THE
INSTRUMENT PANEL DOES NOT DETECT THE VEHICLE'S
SPEED), MAY CAUSE THE PROCEDURE TO FAIL, WHICH
ELE SYS - 117

MEANS IT HAS TO BE REPEATED. IN THIS CASE, REPEAT

THE PROCEDURE WITH THE SIDE STAND CLOSED AND
VEHICLE IN NEUTRAL ALWAYS PAYING EXTREME AT-
TENTION. FOR MORE SAFETY, POSSIBLY BLOCK THE
VEHICLE AGAINST A WALL.
CAUTION
PROGRAMMING OF THE TONE WHEEL TAKES PLACE
DURING THE RELEASE PHASE OF THE THROTTLE
(FROM 7000 rpm TO IDLE RPM). IN THIS DESCENDING
PHASE THE THROTTLE GRIP MUST REMAIN COMPLETE-
LY CLOSED.
ASC CONTROL UNIT (ELECTRONIC SUSPENSION CONTROL UNIT)
(if applicable)
ASC CONTROL UNIT - Diagnosis

Function
It manages the ASC system, the system safety checks and the self-diagnosis function.
ASC Control Unit
Position:
• on the vehicle: at the front, connected to the instrument cluster mount.

• connector: on 34 PIN connector control unit (24 of which are active)
Pin out:See CONNECTORS paragraph
DIAGNOSTIC TOOL:INFO
(screen page/example values with key ON)
• Hardware version / - (indicates the hardware version)

• BOOT version / -
• Software version / -
• Map identification / -
DIAGNOSTIC TOOL:ACTIVATIONS
• Suspension test - Softest setting - min damping / Minimum damping preload check
• Suspension test - Hardest setting - max damping / Maximum damping preload check
DIAGNOSTIC TOOL: ERRORS
ASC ELECTRONIC SUSPENSION ECU ERROR

Code Description / Symptoms
D08600 Invalid X-axis acceleration sensor signal
D08601 Invalid Y-axis acceleration sensor signal
D08602 Invalid Z-axis acceleration sensor signal
D08603 Invalid WX angular value sensor signal
D08604 Invalid WY angular value sensor signal
D08605 Invalid WZ angular value sensor signal
D08606 Invalid front wheel speed sensor signal
D08607 Invalid rear wheel speed sensor signal
D08608 Invalid front brake pressure sensor signal
D08609 Invalid rear brake pressure sensor signal
D0860A Invalid accelerator sensor signal
D0860B Invalid bank angle sensor signal
ELE SYS - 118


D0860C Invalid suspension mode sensor signal
D0860D Invalid front compression block HMI signal
D0860E Invalid front rebound block HMI signal
D0860F Invalid rear compression block HMI signal
D08610 Invalid rear rebound block HMI signal
D08611 Invalid steering damper block HMI signal
D08612 Invalid OBTI acceleration HMI signal
D08613 Invalid OBTI brake HMI signal
D08614 Invalid OBTI angle HMI signal
D08615 Invalid OBTI front stability HMI signal
D08616 Invalid OBTI rear stability HMI signal
D08617 Invalid OBTI steering damper HMI signal
D08618 Invalid engine RPM sensor signal
D08619 Invalid ignition signal
D08700 Communication interrupted with instrument cluster ECU (DSB1)
D08701 Communication interrupted with instrument cluster ECU (DSB2)
D08702 Communication interrupted with inertia measurement ECU (IMU1)
D08705 Communication interrupted with ABS ECU (ABS1)
D08706 Communication interrupted with ABS ECU (ABS3)
D08707 Interrupted communication with infotainment ECU (GMP1)
D08708 Communication interrupted with engine ECU (ECU1)
D08800 Can Bus-Off
ECU 11MP (ENGINE ECU)

The Marelli 11 MP ECU is a highly advanced Ride
By Wire injection system that controls the opening
and closing of the throttle bodies (via DC motors)
and independently manages the injection time and
ignition advance of the engine cylinders.
The 11MP allows very precise engine manage-
ment that complies with EURO 5 regulations, sup-
porting mapping selection, cruise control and
traction control.
During driving, the control unit receives the throttle
opening command via a two-track potentiometer
called the Demand (throttle knob). The control unit
will then manage the outputs of:
• Throttle opening;
• Injection time;
• Ignition advance.
There are two separate connectors; the larger (1)

is dedicated to engine management and the small-
er (2) to vehicle interface.
ELE SYS - 119

Removal
• Remove the driver's seat and battery

beforehand.
• Lift the slide (1) and disconnect the
connector (2).
• Lift the slide (3) and disconnect the

connector (4).
• Remove the ECU (5) by pulling it up-

wards.
NOTE
WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE
LIMIT STOP, THUS FACILITATING THE CONNECTOR'S INSERTION: THE CATCH SHOULD SNAP
INTO PLACE ONCE THE LIMIT STOP IS REACHED.
NOTE
If the 11MP control unit is replaced, it will self-adapt to the vehicle parameters. During the first
tens of kilometres of vehicle use, the control unit will learn the parameters necessary for the
regular operation of the engine and the vehicle itself.
CONTROL UNIT - Diagnosis
Function
It manages the Ride by wire system, the injection/ignition, the system safety checks and the self-diag-
nostic function
Each level in which the main component involves the control unit
Position:
ELE SYS - 120

• on the vehicle: under the driver's seat, between the tank and the battery.
Pin out:See CONNECTORS paragraph
(screen page/example values with key ON)
• Drawing number / - (identified inserted by the manufacturer)
• HW number/ - (indicates the Hardware number)
• Hardware version / -
• Mapping / - (indicates the mapping number)
• Software version / -
• Type approval number / -
• ISO code / -
• Marelli SW code / -
• Serial number (NIP)
• Author of the latest progr. / - (author of the latest programming)
• Internal code (IDEEKE) / -
• Internal code (IDVAG1) / -
• Hardware code / - (indicates the hardware code)
• VIN / - (vehicle identification number)
ADAPTIVE FUEL CORRECTION (EEPROM RESET)
Adaptive fuel correction aims to store the lambda correction when it corresponds to a stable steady
state.
It is divided into two tables for each cylinder, one for the cold engine and one for the warm engine; the
diagnostic tool will only display the adaptive parameter applied by the ECU at that precise moment (hot/
cold engine, throttle opening, engine revs).
The adaptive correction is deleted when the Adaptive Parameter Reset (EEPROM RESET) is carried
out via the diagnostic tool, or when a new mapping is loaded.
It is recommended to perform the EEPROM RESET on the occasion of:
• Air filter cleaning;
• Spark plug replacement;
• Valve clearance adjustment;
• Repairs to the intake or exhaust system.
DERATING STRATEGY
Using the engine oil temperature sensor, the 11MP control unit is able to monitor and control the
engine oil temperature through the DERATING strategy, preventing it from exceeding 150° C (302° F).
The DERATING strategy starts as soon as the engine oil exceeds 113° C (235.4° F) and involves a
progressive decrease in engine torque through a reduction in engine load and ignition advance (to avoid
detonation problems) from 7500 rpm.
Using the P.A.D.S. diagnostic tool, it is possible to check the torque reduction (up to -40%) present
at the time of connection.
ELE SYS - 121

RECOVERY STRATEGIES
Various recovery strategies, characterised by a progressively increasing level of impact on vehicle
driving, are provided to ensure maximum driving safety while minimising inconvenience for the customer
in the event of a breakdown.
Depending on the impact the failure will have on the safe running/integrity of the engine, the indication
on the instrument cluster may be more or less obvious:
Level 1: error recognised, but not of safety significance and not noticeable to the driver => No indication
on the instrument cluster
Level 2: Safety-insignificant error but noticeable to the driver => Fixed warning light and display of
URGENT SERVICE message on the instrument cluster.
Level 3: error impairing safety => Flashing warning light and display of the message URGENT SERV-
ICE on the instrument cluster.
Four Recovery are possible depending on the severity of the technical problem detected:
1. Recovery Degraded Torque: torque and maximum engine speed are reduced, so as to avoid critical
driving situations or engine damage. Such a recovery is, for example, applied when one of the tracks
of the TPS or the DEMAND SENSOR fails.
2. Recovery Limp Home: the ECU manages throttle position, advance and injection time in such a
way as to keep the engine at a constant idle speed, regardless of the action on the throttle knob. The
rider is thus able to drive the vehicle to the repair shop (e.g. in the event of failure of both DEMAND
SENSOR tracks).
3. Recovery dead throttle valve: the throttle valve motor is switched off, the valve then moves to the
rest position (which is slightly open). In turn, the ECU manages the advance and injection time so as
to keep the engine at an accelerated idle speed. This recovery is applied, for example, when both traces
of the TPS are faulty or when the MAP sensor reading is implausible (throttle body off).
4. Recovery engine stop: The control unit shuts down the engine when it detects its own internal error
or finds that the throttle cannot be set to the accelerated idle position.
DIAGNOSTIC TOOL - PARAMETERS:

Italian PADS description / English PADS description
• Engine speed / Engine RPM

• Temperatura aria / Air temperature
• Temperatura aria ante recovery / Air temperature before recovery
• Temperatura motore / Engine temperature
• Temperatura motore ante recovery / Engine temperature before recovery
• Temperatura motore all'avviamento / Engine temperature upon starting
• Segnale potenziometro posizione manopola (traccia A) / Handgrip position potentiometer
signal (trace A)
ELE SYS - 122

• Segnale potenziometro posizione manopola (traccia B) / Handgrip position potentiometer

signal (trace B)
• Apertura manopola acceleratore in percentuale / Accelerator handgrip opening in percent-
age
• Tensione farfalla destra potenziometro 1 / 1 potentiometer right throttle voltage
• Tensione farfalla destra potenziometro 2 / 2 potentiometer right throttle voltage
• Tensione farfalla sinistra potenziometro 1 / 1 potentiometer left throttle voltage
• Tensione farfalla sinistra potenziometro 2 / 2 potentiometer left throttle voltage
• Angolo farfalla destra potenziometro 1 / 1 potentiometer right throttle angle
• Angolo farfalla destra potenziometro 2 / 2 potentiometer right throttle angle
• Angolo farfalla sinistra potenziometro 1 / 1 potentiometer left throttle angle
• Angolo farfalla sinistra potenziometro 2 / 2 potentiometer left throttle angle
• Pressione aspirazione / Induction pressure
• Valore in tensione del sensore pressione / Pressure sensor value when excited
• Pressione stimata aspirazione / Intake estimated pressure
• Anticipo cilindro attuale / Actual cylinder advance
• Anticipo cilindro destro / RH cylinder ignition advance
• Anticipo cilindro sinistro / LH cylinder ignition advance
• Tempo iniezione cilindro destro / RH cylinder injection time
• Tempo iniezione cilindro sinistro / LH cylinder injection time
• Regime nominale di minimo / Rated idle speed
• Tensione batteria / Battery voltage
• Tensione sonda lambda destra / RH lambda sensor voltage
• Tensione sonda lambda sinistra / LH lambda sensor voltage
• Correzione lambda destra / Right lambda correction
• Correzione lambda sinistra / Left lambda correction
• Efficienza iniezione cilindri / Cylinder injection efficiency
• Correzione angolo farfalla / Throttle angle correction
• Portata caburante per ciclo motore / Fuel flow rate per engine cycle
• Correzione adattativa carburante cilindro destro / RH cylinder fuel adaptive correction
• Duty Cycle valvola aria secondaria / Secondary air valve duty cycle
• Posizione inferiore farfalla destra / Right throttle lower position
• Posizione inferiore farfalla sinistra / Left throttle lower position
• Velocità veicolo / Vehicle speed
• Tempo di Dwell bobina destra / Right coil Dwell time
• Tempo di Dwell bobina sinistra / Left coil Dwell time
• Marcia inserita / In gear
• Velocità ruota anteriore / Front wheel speed
ELE SYS - 123

• Circonferenza ruota posteriore / Rear wheel circumference

• Rapporto finale trasmissione / Transmission final ratio
• Correzione adattativa carburante cilindro sinistro / LH cylinder fuel adaptive correction
• Contatore errori blocchetto chiave / Ignition block key error counter
• Tensione sensore marce / Gear sensor voltage
• Valore riduzione di coppia / Torque reduction value
DIAGNOSTIC TOOL - STATUSES:

• Controllo sonda lambda destra / RH lambda sensor check

• Controllo sonda lambda sinistra / LH lambda sensor check
• Autoapprendimento farfalla destra / Right throttle Self-Learning
• Autoapprendimento farfalla sinistra / Left throttle Self-Learning
• Stato motore / Engine state
• Modo motore / Engine Mode
• Manopola / Knob
• Cambio in folle / Gear in neutral
• Rele' ventola / Fan relay
• Consenso da immobilizer / Enable from immobilizer
• Stato Ruota fonica / Phonic wheel status
• Cavalletto laterale / Side stand
• Droop sensor / Droop sensor
• Interruttore RUN/OFF / RUN/OFF switch
• Leva frizione / Clutch lever
• Segnale frizione / Clutch signal
• Abilitazione Accensione / Ignition enabling
• Sonda lambda destra / Right-hand lambda sensor
• Sonda lambda sinistra / Left-hand lambda sensor
• Attivazione leva quick shift / Quick Shift Lever Activation
• Stato del sistema cruise control / Cruise Control system status
• Switch qualificato leva freno anteriore / Front brake lever qualified switch
• Switch qualificato leva freno posteriore / Rear brake lever qualified switch
• Switch raw leva freno anteriore / Front brake lever raw switch
• Switch raw leva freno posteriore / Rear brake lever raw switch
• Indica lo stato del tasto relativo al cruise control sul volante / It indicates the status of cruise
control button on steering wheel
• Switch Cruise Control '+' / Cruise Control '+' switch
• Switch Cruise Control '-' / Cruise Control '-' switch
ELE SYS - 124

• Apprendimento ruota fonica / Phonic wheel learning

• Immobilizer sbloccato tramite codice / Immobilizer unlocked by code
• Codice o segnale immobilizer antenna ricevuto / Antenna immobilizer code or signal re-
ceived
• Codice Immobilizer / Immobilizer code
• Comunicazione con Immobilizer / Communication with immobilizer
DIAGNOSTIC TOOL - ACTIVATIONS:

• Attivazione bobina destra / RH coil actuation

• Attivazione bobina sinistra / LH coil actuation
• Rele' pompa benzina / Petrol pump relay
• Attivazione del contagiri / Rev.counter enabling
• Riscaldatore sonda lambda destra / Right lambda sensor heater
• Iniettore cilindro destro / Right cylinder injector
• Iniettore cilindro sinistro / Left cylinder injector
• Attivazione Elettroventola / Electro fan activation
• Riscaldatore sonda lambda sinistra / Left lambda sensor heater
• Attivazione spia MIL / MIL indicator activation
• Attivazione Valvola Solenoide Aria Secondaria / Activation of the secondary air Solenoid
valve
• Luce stop / Stop light
DIAGNOSTIC TOOL - SETTINGS:

• Azzeramento EEPROM centralina / Control unit EEPROM reset

• Azzeramento valori ruota fonica / Phonic wheel values reset
• Autoapprendimento farfalla / Throttle Self-Learning
• Scarico file dati memorizzati / Stored data file download
• Scrittura codice VIN / Write VIN
• Reset contatore errori blocchetto chiave / Key switch error counter reset
• Configurazione veicolo con equipaggiamento premium (Km) / Premium equipment vehicle
configuration (Km)
• Configurazione veicolo con equipaggiamento premium (Miglia) / Premium equipment vehi-
cle configuration (Miles)
• Configurazione Veicolo Base (Km) / Vehicle configuration basic (Km)
• Configurazione Veicolo Base (miglia) / Vehicle configuration basic (Miles)
• Attivazione cambio Quick Shift / Quick Shift transmission enabling
• Disattivazione cambio Quick Shift / Quick Shift transmission disabling
ELE SYS - 125

• Abilitazione sistema TPMS / TPMS system enabling

• Disabilitazione sistema TPMS / TPMS system disabling
• Abilitazione sistema RADAR BLIS / RADAR BLIS system enabling
• Disabilitazione sistema RADAR BLIS / RADAR BLIS system disabling
DIAGNOSTIC TOOL - ERRORS:
11MP ECU ERRORS ENGINE CONTROL UNIT

P0030 Right lambda heater circuit - Short circuit to negative
P0030 Right lambda heater circuit - Short circuit to positive
P0030 Right lambda heater circuit - Open circuit
P0050 Left lambda heater circuit - Short circuit to negative
P0050 Left lambda heater circuit - Short circuit to positive
P0050 Left lambda heater circuit - Open Circuit
P0105 Right cylinder air pressure sensor - Open Circuit or Short circuit to negative
P0105 Right cylinder air pressure sensor - Short circuit to positive
P0106 Right cylinder air pressure sensor - Below the minimum limit
P0106 Right cylinder air pressure sensor - Above the maximum limit
P0106 Right cylinder air pressure sensor
P0110 Air temperature sensor - Short circuit to negative
P0110 Air temperature sensor - Open Circuit or Short circuit to positive
P0111 Air temperature sensor - functional diagnosis (locked)
P0111 Air temperature sensor - functional diagnosis (intermittent)
P0114 Air temperature sensor - intermittent signal
P0115 Engine temperature sensor - Open Circuit or Short circuit to positive
P0115 Engine temperature sensor - Short circuit to negative
P0116 Engine temperature sensor - functional diagnosis (stuck)
P0116 Engine temperature sensor - functional diagnosis (intermittent)
P0119 Coolant temperature sensor - Intermittent signal
P0120 Potentiometer sensor 1 right throttle valve position - Short circuit to positive
P0120 Potentiometer sensor 1 right throttle valve position - Open Circuit or Short circuit to negative
P0121 Plausibility potentiometer 1 right throttle - signal not plausible
P0130 Right lambda probe - Short circuit to negative (polarised probe only)
P0130 Right lambda probe - Short circuit to positive
P0130 Right lambda probe - Open circuit (polarised probe only)
P0133 Right lambda probe (functional diagnosis) - Slow response
P0134 Right lambda probe (functional diagnosis) stuck - no switching from high
P0150 Left lambda probe - Open circuit (polarised probe only)
P0150 Left lambda sensor - Short circuit to negative (polarised probe only)
P0150 Left lambda sensor - Short circuit to positive
P0153 Left lambda probe (functional diagnosis) - slow response
P0154 Left lambda probe (functional diagnosis) stuck - no switching from high
P0171 Poor status for the right power supply system - Signal above the admissible range
P0172 Rich status for the right power supply system - Signal above the admissible range
P0174 Poor status for the left power supply system - Signal above the admissible range
P0175 Rich status for the left power supply system - Signal above the admissible range
P0196 Engine oil temperature sensor - functional diagnosis (stuck)
P0196 Engine oil temperature sensor - functional diagnosis (intermittent)
P0199 Oil temperature sensor - Intermittent signal
P0201 Right cylinder injector - Short circuit to negative
P0201 Right cylinder injector - Short circuit to positive
P0201 Right cylinder injector - Open Circuit
P0202 Left cylinder injector - Short circuit to negative
P0202 Left cylinder injector - Short circuit to positive
P0202 Left cylinder injector - Open Circuit
P0220 Potentiometer sensor 2 right throttle valve position - Short circuit to positive
P0220 Potentiometer sensor 2 right throttle valve position - Open Circuit or Short circuit to negative
P0221 Plausibility potentiometer 2 right throttle - signal not plausible
P0225 Track hand grip position sensor Pot.A - Short circuit to positive
P0225 Track hand grip position sensor Pot.A - Open circuit or Short circuit to negative
P0230 Fuel pump relay control - Short circuit to negative
P0230 Fuel pump relay control - Short circuit to positive
ELE SYS - 126


P0230 Fuel Pump Relay Control - Open Circuit
P0300 Random/multiple cylinder error 1000 detected
P0300 Random/multiple cylinder error 200 detected
P0301 Right cylinder error 1000 detected
P0301 Right cylinder error 200 detected
P0302 Left cylinder error 1000 detected
P0302 Left cylinder error 200 detected
P0336 Engine speed sensor - signal not plausible
P0351 Right coil circuit - Short circuit to positive
P0351 Right Coil Circuit - Open circuit or Short circuit to negative
P0352 Left coil circuit - Short circuit to positive
P0352 Left Coil Circuit - Open circuit or Short circuit to negative
P0410 Secondary air valve control - Short circuit to negative
P0410 Secondary air valve control - Short circuit to positive
P0410 Secondary air valve control - Open circuit
P0443 Bleed valve control circuit Evaporative emission system - Short circuit to positive
P0443 Bleed valve control circuit Evaporative emission system - Short circuit to negative
P0443 Bleed valve control circuit Evaporative emission system - Open circuit
P0480 Cooling fan control - Short circuit to negative
P0480 Cooling fan control - Short circuit to positive
P0480 Cooling Fan Control - Open circuit
P0500 Front wheel vehicle speed sensor/signal - Sensor electrically defective
P0500 Front wheel vehicle speed sensor/signal - Invalid electrical signal
P0500 Front wheel vehicle speed sensor/signal - Sensor signal not plausible
P0500 Front wheel vehicle speed sensor/signal - Invalid plausibility signal
P0505 RPM of idle control system - lower than expected
P0505 RPM of idle control system - higher than expected
P0512 Starter Engine button (functional while pressed) - signal not plausible
P0560 Battery voltage: Below minimum threshold
P0560 Battery voltage - above maximum limit
P0564 GCC button errors (On/Off, +, -,) - Signal not plausible
P0564 GCC button errors (On/Off, +, -,) - Stuck button error
P0569 Control "-" Plausibility - Closed contacts
P0569 Control "-" Plausibility - Open contacts
P0601 EEPROM Error - signal not plausible
P0604 RAM error - signal not plausible
P0605 ROM error - signal not plausible
P060B A/D converter - circuit not working
P060C Engine stop due to Safety - circuit not working
P0615 Starter relay - Short circuit to positive
P0615 Starter relay - Open circuit or Short circuit to negative
P0638 Right throttle valve position error - EPOS error
P0639 Left throttle valve position error - EPOS error
P0641 Sensor power supply 1 - Internal electronic fault
P0685 Main relay control - Short circuit to negative
P0685 Main relay control - Short circuit to positive
P0685 Main Relay Control - Open circuit
P0704 Clutch switch plausibility error - signal not plausible
P0914 Analogue operation sensor - short circuit to negative
P0914 Analogue operation sensor - Open circuit or Short circuit to positive
P0915 Analogue operation sensor - blocked or out of range
P1105 Left intake pressure sensor - Short circuit to positive
P1105 Left intake pressure sensor - Open circuit or Short circuit to negative
P1107 Left intake pressure sensor - below the minimum limit
P1107 Left intake pressure sensor - above the maximum limit
P1107 Left intake pressure sensor - signal not plausible
P1305 Stop light relay error - Short circuit to negative
P1305 Stop light relay error - Short circuit to positive
P1305 Stop light relay error - Open circuit
P1309 Flywheel learning error - signal not plausible
P1400 Left throttle valve Limp Home self-learning - LH test failed
P1401 Right throttle valve (opening) spring test self-learning - opening spring test failed
P1402 Right throttle valve lower mechanical stop self-learning - lower mechanical stop error
P1403 Rec. condition self-learning. Right throttle valve - test condition errors
ELE SYS - 127


P1404 Right throttle valve supply voltage self-learning - below the minimum limit
P1405 Right throttle valve spring test (re-closure) spring test self-learning - re-closure spring test failed
P1406 Left throttle valve Limp Home self-learning - LH test failed
P1407 Left throttle valve (opening) spring test self-learning - opening spring test failed
P1408 Left throttle valve minimum mechanical position self-learning - test failed
P1409 Left throttle valve recovery condition self-learning - test condition error
P1410 Left throttle valve supply voltage self-learning - below the minimum limit
P1411 Left throttle valve mechanical spring (re-closing) self-learning - test failed
P1412 Right throttle valve self-learning - Test not performed
P1413 Left throttle valve self-learning - Test not performed
P1414 Right throttle valve Self Learning Limp Home Diagnosis - circuit not working
P1415 Left throttle valve Limp Home self-learning diagnosis - circuit not working
P1560 Low Battery Voltage Error - Voltage Error
P1600 Right cylinder manifold small hole error - signal not plausible
P1601 Left cylinder manifold small hole error - signal not plausible
P1602 Right cylinder intake manifold pressure estimation error - pressure too low
P1602 Right cylinder intake manifold pressure estimation error - pressure too high
P1604 Left intake manifold pressure estimation error - pressure too low
P1604 Left intake manifold pressure estimation error - pressure too high
P1606 Incompatibility error between Software and Hardware
P1608 Data buffer full and triggered by special events
P1609 A-PRC functional error - Scheduling error
P1609 A-PRC functional error - CKSUM flash error
P1609 A-PRC functional error - Voltage error
P160C Safety level2 reset - circuit not working
P1615 ROM checksum test failure report performed on code 2&3 and calibration areas
P1650 Engine event configuration checksum calculation error - signal not plausible
P1753 Brake pedal switch 1 - Signal comparison error
P1754 Brake pedal switch 2 - Signal comparison error
P1760 Stand switch congruence - Signal comparison error
P1900 Quick Shift Sensor Electrical Diagnosis - Short circuit to positive
P1900 Quick Shift Sensor Electrical Diagnosis - Open circuit or Short circuit to negative
P1902 Quick Shift Sensor Functional Diagnosis - Signal blocked in down
P1902 Quick Shift Sensor Functional Diagnosis - Signal blocked in up
P1902 Quick Shift Sensor Functional Diagnosis - Signal not plausible
P1905 Acceleration sensor plausibility AX Sensorbox[3] - Signal failure
P1905 Acceleration sensor plausibility AX Sensorbox[3] - KO sensor
P1907 Acceleration sensor plausibility AY Sensorbox[4] - Signal failure
P1907 Acceleration sensor plausibility AY Sensorbox[4] - KO sensor
P1909 Oscillation Ωz sensor plausibility Sensorbox[1] - Signal failure
P1909 Oscillation Ωz sensor plausibility Sensorbox[1] - KO sensor
P1911 Oscillation Ωz sensor plausibility Sensorbox[2] - Signal failure
P1911 Oscillation Ωz sensor plausibility Sensorbox[2] - KO sensor
P2100 Right throttle valve H-Bridge - Short circuit to negative
P2100 Right throttle valve H-Bridge - Short circuit to positive
P2100 Right throttle valve H-Bridge - Open circuit
P2100 Right throttle valve H-Bridge - Overtemperature, current overload
P210A Left throttle valve pilot circuit - Short circuit to negative
P210A Left throttle valve pilot circuit - Short circuit to positive
P210A Left throttle valve pilot circuit - Open circuit
P210A Left throttle valve pilot circuit - overcurrent/high internal temperature
P2120 Potentiometer sensor 1 left throttle valve - Short circuit to positive
P2120 Potentiometer sensor 1 left throttle valve - Open circuit or Short circuit to negative
P2121 Potentiometer plausibility 1 left throttle valve - signal not plausible
P2125 Potentiometer sensor 2 left throttle valve - Short circuit to positive
P2125 Potentiometer sensor 2 left throttle valve - Open circuit or Short circuit to negative
P2126 Potentiometer plausibility 2 left throttle valve - signal not plausible
P2130 Track hand grip position sensor Pot.B - Short circuit to positive
P2130 Track hand grip position sensor Pot.B - Open circuit or Short circuit to negative
P2135 Right throttle valve position sensor congruency
P2138 Left throttle valve position sensors - signal not congruent
P2140 Track A-B hand grip position redundancy - signal not congruent
P2158 Rear wheel vehicle speed sensor/signal - Electrically defective sensor
P2158 Rear wheel vehicle speed sensor/signal - Invalid electrical signal
P2158 Rear wheel vehicle speed sensor/signal - Sensor signal not plausible
P2158 Rear wheel vehicle speed sensor/signal - Invalid plausibility signal
ELE SYS - 128


P2173 Left cylinder manifold pressure too low error - signal not plausible
P2175 Right cylinder manifold pressure too low error - signal not plausible
P2227 Barometric pressure sensor - generic hardware fault
P2227 Barometric pressure sensor - Plausibility at key on
U0001 CAN line diagnosis (NCM) Bus Off - bus off
U0002 Mute Node CAN Line - Mute Node
U0121 CAN line diagnosis ABS or CLF ECU - signal not plausible
U0121 CAN line diagnosis ABS or CLF ECU - Absent signal
U0125 Box sensor CAN line diagnosis - signal not plausible
U0125 Box sensor CAN line diagnostics - Absent signal
U0140 NQS CAN line diagnosis/Dashboard node absent - absent signal
U0426 Immobilizer error - signal not plausible
U1121 CAN line diagnosis ABS or CLF ECU Frame counter - Absent signal
U1140 NQS CAN line diagnosis/Dashboard package counter - Absent signal
INSTRUMENT CLUSTER ECU ERRORS

B0001 Oil sensor fault
B0002 Oil pressure fault
B0003 Immobilizer: Key code read but not recognised
B0004 Immobilizer: Key code reading error
B0005 Immobilizer: antenna electrical fault (open circuit or short circuit)
B0006 Immobilizer: internal error
B0007 Immobilizer: insufficient number of keys memorised
B0010 Engine overtemperature error
B0012 Fuel sensor disconnected
B0013 Fuel sensor configuration error
B0100 Can line reception error
B0110 Can line transmission error
B0111 Headlight sensor CAN line reception error
B0210 Front brake lever locked
B0211 Rear brake lever locked
B0301 Left turn indicators button locked
B0302 Right turn indicators button locked
B0303 Reset indicator button locked
B0304 MODE UP button locked
B0305 MODE DOWN button locked
B0306 MODE SET button locked
B0307 MODE RIGHT button locked
B0308 MODE RIDING button locked
B0309 CRUISE UP button locked
B0310 CRUISE DOWN button locked
B0311 CRUISE SET button locked
ABS ECU ERRORS

C1D90 Front wheel speed sensor - electrical fault
C1D91 Front wheel speed sensor - extrapolation fault
C1D92 Front wheel speed sensor - periodic fault
C1D93 Front wheel speed sensor - recognition start failure
C1D94 Front wheel speed sensor - phase length supervision fault
C1D95 Front wheel speed sensor - dual frequency control
C1D9A Front wheel pressure sensor
C1DA0 Rear wheel speed sensor - electric fault
C1DA1 Rear wheel speed sensor - extrapolation fault
C1DA2 Rear wheel speed sensor - periodic fault
C1DA3 Rear wheel speed sensor - recognition start failure
C1DA4 Rear wheel speed sensor - phase length supervision fault
C1DA5 Rear wheel speed sensor - dual frequency control
C1DD3 OSEK error
C1DF0 Defective pump
C1DF1 Pump connection error
C1DF2 Hardware fault
C1DF3 Voltage too low detected in the long term
C1DF4 Voltage too low
ELE SYS - 129


C1DF5 Hardware inside error
C1DF7 Voltage too high
C1E11 CAN BUS error
C1E59 Vehicle variant coding error
C1E5A ABS switch error
C1F13 IMU - Invalid or not plausible data error
C1F14 IMU - Incorrect Voltage
C1F15 IMU - Signal error, before ABS initialisation
C1F18 IMU - CAN communication loss with IMU
C1F19 IMU - Mismatch with IMU ID
U30CB Code check failed - undervoltage
TPMS ECU ERRORS

B0001 Oil sensor fault
B1000 Faulty receiver
B1011 Front wheel sensor dead battery
B1012 Front wheel high pressure
B1013 Front wheel low pressure
B1014 Front wheel pressure very low
B1015 Front wheel puncture
B1016 Missing front wheel sensor signal
B1017 Front wheel sensor not configured
B1021 Rear wheel sensor dead battery
B1022 Rear wheel high pressure
B1023 Rear wheel low pressure
B1024 Rear wheel pressure very low
B1025 Rear wheel puncture
B1026 Missing rear wheel sensor signal
B1027 Rear wheel sensor not configured
TPMS ECU (Tire Pressure Monitoring System)

- on V100 Mandello S only
Position:
• ECU: under the rider saddle

• Connector: on the control unit
Key:
1. TPMS ECU
2. Ignition switch
3. Battery
4. Fuse
ELE SYS - 130

CAV MODULE CONTROL UNIT

• Actuator motors electrical resistance:

14 Ohm
Position
• ECU: on the left side of the vehicle un-

der the side panelling, attached to the
left side radiator panelling.
• Connector: on the control unit.
Key:
1. CAV control unit

2. Electrical wind-shield
3. LH aerodynamic protection
4. RH aerodynamic protection
5. Heated saddle
6. Ignition switch
7. Battery
8. Fuse
ELE SYS - 131

ABS CONTROL UNIT

Position
• ECU: Fastened to the ABS modulator,

under the air filter box and expansion
tank.
• Connector: on the control unit.
ABS CONTROL UNIT

Key:
1. ABS control unit

2. Rear ABS sensor
3. Front ABS sensor
4. Ignition switch
5. Battery
6. Fuse
ELE SYS - 132

Battery
Function
Provides electrical power to vehicle.
Charging the battery
Position:
• on the vehicle: under the rider saddle

• connector: on the battery
Electrical specifications:12 V / 18 Ah
Pin out:
1. Positive pole (red): approx. 12.6 V

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

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

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

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

considering whether recovery mode is implemen-
ted
CAUTION
Do not leave the vehicle with the engine off and the ignition
key to "ON". The sophisticated on-board instruments have
a high current draw which, if left on with the engine switch-
ed off, will discharge the battery in a short time.
ELE SYS - 133

Phonic wheel sensor
PICK UP
Function
Provide the ECU with the crankshaft position and
thus the engine timing, to adjust the ignition timing
of the cylinders.
Position:
Pick up: Inside the timing housing, above the tone
wheel.
Features:
• Electrical resistance at 20 °C: 100-150

Ohm.
• Air gap distance: 0.5 mm.
• The positive half-wave (1) must pre-
cede the negative half-wave (2).
Key:
(1) Pick up
1. Signal.
2. Earth.
(2) 11MP ECU
Twistgrip position sensor
Function
Provides the throttle grip position signal to the ECU
to activate the throttle valve actuators accordingly.
Sends an electrical signal to the 11MP ECU, which
in turn relays the information to the throttle valve
actuators.
Position:
• Right hand grip (accelerator).
ELE SYS - 134

Key
(1) PURGE valve
1. Track power supply 1

2. Track 1 ground
3. Track 1 signal
4. Track power supply 2
5. Track 2 ground
6. Track 2 signal
(2) 11MP ECU

CAUTION
Intake pressure sensor
PRESSURE/Tmap AIR TEMPERATURE SEN-

SOR
Function
The Tmap sensor calculates the pressure and
temperature of the engine intake air and sends this
data to the control unit, which consequently ad-
justs the ignition timing and the correct amount of
fuel to achieve the correct stoichiometric ratio.
intake air pressure sensor
Position:
• on the vehicle: on the throttle bodies,

one for each throttle body.
• connector: on the sensor.
Key:
(1) RH cylinder Tmap:
1. Earth.
2. Intake air temperature signal.
3. Pressure sensor power supply.
4. Intake air pressure signal.
(2) LH cylinder Tmap:
ELE SYS - 135

1. Earth.
2. Intake air temperature signal.
3. Pressure sensor power supply.
4. Intake air pressure signal.
(3) 11MP ECU
Engine temperature sensor
ENGINE OIL TEMPERATURE SENSOR

Function
It is used to inform the ECU regarding the engine
oil temperature in order to optimize parameter
management.
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Position:
• Sensor: inside the "V" of the engine, on

the front side, under the thermostatic
valve
• Connector: on the sensor
Technical Characteristics
• Electrical resistance at 25 °C: 5000

Ohm
• Maximum temperature: 170°C
• Maximum temperature attainable for
short periods: 185°C
Key
(1) Engine oil temperature sensor
1. Signal.
2. Earth.
(2) 11MP ECU
ELE SYS - 136

COOLANT TEMPERATURE SENSOR

Function
It is used to inform the ECU regarding the coolant
temperature in order to optimize engine parameter
management.
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Position:
• Sensor: inside the "V" of the motor,

screwed onto the thermostatic valve
• Connector: on the sensor
Key
(1) Coolant temperature sensor
1. Earth.
2. /
3. Signal.
(2) 11MP ECU
RESISTANCE VALUES BASED ON THE ENGINE TEMPERATURE

Temperature Minimum resistance Nominal resistance Maximum resistance
0°C 7487 Ohm 8039 Ohm 8590 Ohm
20°C 2793 Ohm 2964 Ohm 3135 Ohm
60°C 533.6 Ohm 555.8 Ohm 578.0 Ohm
90°C 191.7 Ohm 197.5 Ohm 203.3 Ohm
Lambda sensor
Function
In charge of telling the control unit whether the
mixture is lean or rich
The 11MP control unit reads and interprets a volt-
age generated by the difference in oxygen content
between the exhaust fumes and the ambient.
ELE SYS - 137

It requires no external power but must reach a high

operating temperature (closed loop) to operate
properly: that is why there is a heating circuit in-
side.
Closed loop lambda control varies the mixture to
continuously oscillate the state of the probe be-
tween rich and lean and it is used throughout the
range of the emission cycle.
A stoichiometric air/fuel ratio allows the maximum
emission reduction efficiency of the catalyst; how-
ever, under certain operating conditions, the opti-
mum air/fuel ratio may deviate from the stoichio-
metric value. In particular, at full load, the ratio
must be very different to the rich value for reasons
of performance and reliability.
Lambda probe
Left lambda position:
• sensor: on the left exhaust manifold

• connector: front left-hand side, se-
cured to radiator support bracket
Right lambda position:
• sensor: on the right exhaust manifold

• connector: front right-hand side, se-
cured to radiator support bracket
• Heating circuit: 7-9Ω at ambient temp.

• Output signal to the control unit: 0 -
1000 mV
Left lambda pin out (1):
1. Sensor signal + (black wire)

2. Sensor signal - (grey wire)
3. Heater ground connection (white cable)
4. Heater power supply (white cable)
Right lambda pin out (2):
1. Sensor signal + (black wire)
ELE SYS - 138

2. Sensor signal - (grey wire)

3. Heater ground connection (white cable)
4. Heater power supply (white cable)
Fuse 15A (3)

Fuse 30A (4)
Injection relay (5)
Battery (6)
Injector
INJECTORS
Function
Ensure the correct amount of fuel in the correct
stage of the cycle.
When the coil is energized, the injector opens and
atomizes fuel into the intake duct.
Coils and injectors
Position:
Injectors: on the intake duct of the head, one for
the right head and one for the left.
Connectors: on injectors.
Features:
• 3-hole injector: ɑ = 12° β = 12°

• Resistance: 12.5 ± 5 % ohm
• Inductance: 8 ± 20 % mH
• Static flow rate: 4.35 ± 3% grams / sec-
ond
• Dynamic flow rate: 8.2 ± 4.5% mg /
pulse
ELE SYS - 139

Key:
(1) RH injector:
1. Power supply +Vbatt

2. Activation from the control unit
(2) LH injector:

2. Activation from the control unit
(3) 11MP ECU

(4) Injection relay
(5) Fuse
(6) Battery
Fuel pump
Function
Fuel pump: keeps pressure of the injectors supply
duct.
Fuel level sensor: provides the instrument panel
with information on the fuel level in the tank and
the reserve status.
The fuel level sensor varies its resistance accord-
ing to the position of the relative fuel float im-
mersed in the tank. The signal is read by the
instrument cluster that translates it in visual infor-
mation for the rider.
Level in electrical circuit diagram
Injection loads relay
Operating specifications
• Power supply voltage 12 V

• Operating pressure 4 bar
• Current consumption I ≤ 4.7 A
Position
• On the vehicle: on the tank.

• Connectors: on the upper part of the
tank, (1) fuel pump (2) fuel level sensor
ELE SYS - 140

Pin Out :
1. Not connected.
2. Earth.
3. Not connected.
4. Not connected.
5. Fuel pump relay power supply.
Electrical circuit
1. Fuel pump.
2. 11MP ECU.
3. Fuel pump relay.
4. Injection relay.
5. Fuse.
6. Battery.
Coil
Function
Spark generation
With inductive discharge
coils and injectors
Position:
• On the valve cover, integrated into the

spark plug cap.
• Connector: front part vehicle, between
the throttle bodies and the chassis.
ELE SYS - 141

• Primary circuit resistance (pin 1 and 3):

650 ± 50 mohm
• Secondary circuit resistance: 4 ± 0.5
Kohm
Right coil pin out (1):
1. Power supply (+Vbatt)

2. Secondary circuit ground connection
3. Activation from the 11MP control unit
Left coil pin out (2):
1. Power supply (+Vbatt)

2. Secondary circuit ground connection
3. Activation from the 11MP control unit
Key:
1. Right cylinder coil.

2. Left cylinder coil.
3. 11MP ECU
4. Injection relay.
5. Fuse.
6. Battery.
CAUTION
Throttle body
Function
To send the throttle position to the injection control
unit and to activate the throttle itself based on the
request from the control unit
All the unit internal components (potentiometer
and electric motor) are contactless; therefore, no
electrical diagnostic is possible for the throttle
body, but for the circuits connected to it only.
ELE SYS - 142

Throttle and handgrip sensor control (Demand)

Position:
• on the vehicle: under the air filter box

• connector: on the throttle body
RH cylinder throttle body Pin Out (1):
1. TPS 1 signal
2. TPS power supply
3. Throttle body engine positive
4. TPS 2 signal
5. Throttle body engine ground
6. TPS ground
Left cylinder throttle body Pin Out (2):
1. TPS 1 signal
2. TPS power supply
3. Throttle body engine positive
4. TPS 2 signal
5. Throttle body engine ground
6. TPS ground
THROTTLE VALVE OPENING ANGLE

The angle of rotation of the accelerator is coupled with a torque request, which in turn determines that
controller the choice of the 11MP ECU regarding the opening angle of the throttle valves. In doing so,
the ECU will also take into account other key parameters such as the gear engaged, the number of
engine revolutions and the engine mapping chosen.
Depending on the actual position of the throttle valves and the number of engine revolutions, the quantity
of fuel and the ignition advance to be applied will be determined.
The intake air amount is calculated by cross-referencing the TPS and TMAP signals. The injection time
and ignition advance are determined according to the engine load and the number of revolutions
(TPS signal and PICK UP signal).
The intake pressure is continuously monitored and if it deviates from the set reference values, the ECU
will apply a throttle valve angle correction. This is to obtain the alignment of the actual pressure values
(TMAP) with the reference values (mapped tables).
The idle speed is managed by the 11MP ECU by adjusting the:
• Ignition advance;
• Throttle bodies opening.
THROTTLE VALVE OPENING ANGLE CORRECTION

The throttle valve opening angle correction strategy is only applied at idle speed and after the cranking
phase.
ELE SYS - 143

In fact, the throttle valve correction starts operating when the lambda probe check starts. From the
throttle correction value it is possible to determine whether the engine has ventilation problems (in the
case of corrections during closure) or fouled bodies (in the case of corrections during).
A negative correction ˂ - 0.6 ° indicates low vacuum in the manifold, which may be generated by:
• A leakage of air,
• Poor sealing of exhaust valves,
• Timing system error.
A positive correction ˂ + 0.6 ° indicates too much vacuum in the manifold, which may be generated
by:
• dirty and fouled throttle bodies.
Engine oil pressure sensor
ENGINE OIL PRESSURE SENSOR

Function
Indicates the instrument cluster if there is enough
oil pressure 0.33 bar (4.8 PSI) in the engine.
Switch normally open. With oil pressure lower than
0.33 bar (4.8 PSI), closed circuit.
Low fuel and oil pressure.
Position
• Sensor: on the crankcase, under the

left head.
• Connector: on the sensor.
• Engine off: closed circuit (continuity).

• With engine started: open circuit (infin-
ite resistance).
Key
1. Oil pressure sensor.

2. 11MP ECU
ELE SYS - 144

Neutral sensor
GEAR SENSOR
Function
It is used to indicate to the ECU which gear is en-
gaged.
Each gear engaged has a sensor position, which
in turn will have a higher output voltage as the gear
engaged increases.
Position:
• On the cover of the box of the gearbox,

under the selector shaft.
Output voltage:
• First gear: 0.625 V ± 0.1 V

• Second gear: 1.375 V ± 0.1 V
• Third gear: 2.125 V ± 0.1 V
• Fourth gear: 2,875 ± 0.1 V
• Fifth gear: 3.625 V ± 0.1 V
• Sixth gear: 4.375 V ± 0.1 V
• NEUTRAL: 1 V ± 0.09 V
Key
(1) Gear sensor
1. Gear signal.
2. Neutral signal.
3. Earth.
4. Power supply.
(2) 11MP ECU
ELE SYS - 145

Clutch lever sensor
Function
Indicates the clutch lever position to the control
unit.
If a gear is engaged but the clutch is engaged,
meaning with the circuit closed to ground, there is
consent to start the vehicle.
Start enable switches
Position:
• Switch: under the clutch lever.
• Clutch lever pulled: closed circuit (con-

tinuity)
• Clutch lever released: open circuit (in-
finite resistance).
CAUTION
Key:
(1) Clutch lever switch.
• (A) Lever pulled.

• (B) Lever released.
(2) Rear brake lever switch.
• (A) Lever pulled.

• (B) Lever released.
(3) 11MP ECU.

NOTE
The front brake switch is not provided. Operation of the
front brake lever results in pressure changes detected by
the ABS control unit pressure sensor which, via CAN,
communicates with the 11 MP control unit.
ELE SYS - 146

Side stand sensor
Function
indicates to the control unit the position of the side
stand
If the gear is engaged and the side stand is unfol-
ded, and therefore the circuit is open, the control
unit does not enable vehicle start-up or shuts off
the engine if it is rotating
Start enable switches
Position:
• sensor: on the stand support, under the

rider's left footrest
Stand pin out (1):
1. Fuel system
2. Output A
3. Ground
4. Output B
• Stand up: closed circuit (continuity)

• Stand down: open circuit (infinite re-
sistance)
ELE SYS - 147

Electric fan circuit
RADIATOR ELECTRIC FAN

Key:
1. Electric fan
2. Electric fan relay
3. 11MP ECU
4. Injection relay
5. Fuse
6. Battery
SAS valve actuator
Function
Quickly warms up the catalytic converter and
keeps the combustion rich in some critical condi-
tions .
The valve coil is energized to open the air passage
from the filter housing to the exhaust manifolds.
Secondary air system
Position:
ELE SYS - 148

• (1) The PURGE valve: under the bat-

tery compartment, fixed to the canister
support.
• (2) Secondary air valve: Under the bat-
tery compartment, on the right side of
the vehicle.
• Connectors: On the relative valves.
PURGE valve electrical resistance at 20 °C: 24 ±
3 Ohm
Secondary air valve electrical resistance at 20 °C:
21.5 Ohm
Key
(1) PURGE valve

2. Ground
(2) Secondary air valve

2. Ground
(3) 11MP ECU

(4) Fuse
(5) Injection relay
(6) Battery
CAUTION
Quick shift
Function:
To indicate to the control unit the request for as-
sisted gear shift.
Operation / Operating principle:
Two normally open switches that are closed to
ground when the shift lever is operated (both at
upshift and downshift).
ELE SYS - 149

Electrical circuit diagram - Level in electrical

circuit diagram:
• Electronic gearbox.
Position:
• On the gearbox lever gear.
• Switch normally open.
Key:
(1) Quick shift
1. Power supply (+ 5 Volt)

2. Signal
3. Ground
(2) 11MP ECU
Inertial sensor platform (sensor box)

Inertia platform
Position:
• On the rear wheel arch, near the can-

ister
Inertial platform Pin out:
1. Ground
2. CAN line signal_Low
3. CAN line signal_High
4. Fuel system
ELE SYS - 150

Electrical circuit:
Key:
1. Inertia platform
2. Fuse
3. Ignition switch
4. Main fuse
5. Battery
Suspension valves
SUSPENSION CONTROL UNIT - only V100 Mandello S

Key:
1. Suspension control unit

2. Rear shock absorber compression adjuster
3. Rear shock absorber extension adjuster
4. Right stanchion compression adjuster
5. Left stanchion extension adjuster
6. Ignition switch
7. Battery
8. Fuse
ELE SYS - 151

Can line
Function
Allows the communication between:
• 11MP ECU;
• TFT instrument cluster;
• Front headlamp;
• Suspension control unit;
• CAV control unit.

A CAN line (Controller Area Network) is a connection between different electronic devices of a vehicle
organised like a computer network (internet). The CAN network significantly simplifies the layout of the
electrical system and its overall ground. With this communication line, needless duplication of several
sensors present on the motorbike has been obviated. The sensor signals are shared by the two elec-
tronic elaboration units (instrument panel and control unit).
• Cable number reduction: The CAN line travels through a twisted cable to several nodes.
• These nodes can also isolate the errors without causing a system breakdown (FaultsCon-
fination).
• Immunity to interference: the signal travels through two cables and the signal reading is
differential (voltage difference between the two signals on both cables). If the two signals
are disturbed by an external factor, their difference remains unaltered.
ELE SYS - 152

• Communication speed: messages travel at a speed of 250 kbps (data arrive at nodes every
20 ms, i.e. 50 times/second).
CAN PROTOCOL (CONT. NETWORK AREA)

The communication protocol is CSMA/CD (Carrier Sense Multiple Access w/ Collision Detection).
In order to transmit, every nod must first check that the BUS (the connection among all devices) is free
before attempting to send a message with BUS (Carrier Sense).
If during this period there is no activity on BUS, every nod has the same chance to send a message
(Multiple Access). If two nodes start transmitting simultaneously, the nodes recognise the "colli-
sion" (Collision Detection) and initiate an exchange action based on message priority (messages remain
unaltered during exchange and there is no delay for high priority messages).
CAN protocol is based on messages and not on addresses. The message itself is divided into several
parts (frames), each of which has a meaning: message priority, data contained, error detection, recep-
tion confirmation, etc.
Every network nod receives all the messages sent through the BUS (with reception confirmation or error
messages) and each nod decides if the message is to be processed or rejected. Besides, every nod
can request information from the other nodes (RTR = Remote Transmit Request).
• CAN Line
• All the control units connected: Electri-

cal resistance value, when measured
between pins 1 and 2 of the OBD port
= 60 ± 6 Ohm
• Only instrument cluster disconnected:
Electrical resistance value, when
measured between pins 1 and 2 of the
OBD port = 120 ± 12 Ohm
• Only 11MP control unit disconnected:
Electrical resistance value, when
measured between pins 1 and 2 of the
OBD port = 120 ± 12 Ohm
ELE SYS - 153

ELE SYS - 154

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle V100 E5
Vehicle preparation
CAUTION
TO CARRY OUT THE MAINTENANCE OPERATIONS AND IF THERE IS THE NEED TO RAISE THE
VEHICLE, USE A PANTOGRAPH LIFT PLACED IN CORRESPONDENCE WITH THE OIL SUMP.IN
ORDER TO AVOID DAMAGES, PLACE A PROTECTION BETWEEN THE OIL SUMP AND THE LIFT.
To remove the engine from the vehicle, first perform the following operations:
• Place a pantograph jack under the engine and support the rear part of the vehicle with a
suitable stand or a workshop lift. Check the stability of the vehicle to prevent it from falling
and causing personal injuries.
• Disconnect the battery and remove: the radiator, fuel tank, air filter housing, swingarm, car-
dan shaft, ECU.
• Remove the clutch actuator and the rear shock absorber preload adjuster from the clutch
crankcase.
Removing the engine from the vehicle
• Cut the tape fastening the engine wir-

ing harness to the frame.
NOTE
During refitting, you can use plastic clamps to secure the
wiring harness in position.
• Pass the wiring harness under the

frame pipe.
ENG VE - 156
V100 E5 Engine from vehicle
• Remove the connector (1) from its re-

tainer on the internal side of the rear
wheel housing and disconnect it.
CAUTION
MAKE SURE TO RECONNECT THE CONNECTOR (1) DUR-

ING REFITTING, OTHERWISE IT WILL NOT BE POSSIBLE
TO START THE ENGINE.
• Cut the clamp (2).
• Disconnect the water temperature sen-

sor (3).
• Remove from the canister support the

wiring harnesses indicated in the fig-
ure.
ENG VE - 157
• Unscrew the fixing nut (4) and remove

the PURGE valve from its support.
• Unscrew the fixing nut (5) of the engine

ground cable.
• Unscrew the fixing nut of the rear brake

hose clamp.
• Remove the protective cap (6).

• Remove the fixing nut (7) of the starter
motor supply cable, then remove the
cable from the starter motor.
ENG VE - 158
• Cut the plastic clamp shown in the fig-

ure, on both sides of the vehicle.
• Remove the 4 cable gland clips and re-

move the side covers of the radiator.
• Repeat on the opposite side.
• Pass the wiring harnesses through the

frame to prevent them from getting
damaged during the engine removal.
On both sides.
• Unscrew the three fixing screws (8) of

the head support (9).
During refitting, tighten the fixing screws to the

prescribed torque.

Head support fixing screw 50 ± 7.5 Nm (36.88 ± 5.53
lb ft)
ENG VE - 159
• Remove the head support bracket (9)

from the frame.
Repeat the removal operations for the bracket on

the opposite side.
• Remove the screws fixing the engine

to the front frame.

prescribed torque.

Screw fixing the engine to the frame 50 ± 7.5 Nm
(36.88 ± 5.53 lb ft)
• Remove the lock nut of the engine sup-

port pin.
During refitting, tighten the lock nut to the prescri-

bed torque.

Engine pin lock nut 86 ± 13 Nm (63.43 ± 9.59 lb ft)
• Remove the engine support pin from

the left side of the vehicle.
CAUTION
MAKE SURE THE ENGINE AND THE FRAME ARE STABLE.
ENG VE - 160
• Remove the engine from the frame by

pulling downward. Take extra care not
to damage any components during re-
moval.
ENG VE - 161
INDEX OF TOPICS
ENGINE ENG
V100 E5 Engine
TO CONSULT THE CHAPTER ABOUT THE ENGINE AND ITS COMPONENTS PLEASE REFER TO
THE APPROPRIATE MANUAL: "MSS Engine Guzzi V100"
ENG - 163
INDEX OF TOPICS
POWER SUPPLY P SUPP

V100 E5 Power supply
Fuel pump
FUEL TANK
1 Screws fastening the fuel tank to M6 4 10 Nm (7.38 lbf ft) -
frame
2 Ring nut fastening the fuel pump to - 1 20 Nm (14.75 lbf ft) -
the fuel tank
3 Nuts fixing the fuel level probe to the M4 5 1 Nm (0.74 lb ft) -
fuel tank
Removing
NOTE
The fuel pump can be removed even if the tank is mounted on the vehicle. The procedure is the
same as that described below, just remove the tank cover.
• Disconnect the connector of the fuel
pump's wiring harness.
P SUPP - 165
Power supply V100 E5
• Remove the safety tab (1) from the fuel

pipe.
• Press the external ring (2) and remove

the pipe (3) from the fuel pump.
• Unscrew and remove the ring nut from

the tank.
• Extract the pump from the tank and re-

trieve the gasket (4).
P SUPP - 166
CAUTION
During refitting, the pump connector must be turned to-
ward the rear side of the tank.
Injection
Removing the throttle body
To access the throttle bodies, the battery must be

disconnected and the following components re-
moved:
• top fairing
• front fairing cover
• left and right side fairing
• tank cover
• fuel tank
• Air filter box
Unscrew the fixing screw of the pipe metal retain-

ing calmp to the fuel tank.
Remove the fixing screw of the metal retaining

calmp.
P SUPP - 167
Unscrew the right intake duct fixing screws.
Remove the right intake duct.
Unscrew the left intake duct fixing screws.
Remove the left intake duct.
P SUPP - 168
Disconnect the two throttle body ECU connectors

by pulling the relative tab.
Disconnect the two throttle body ECU connectors.
P SUPP - 169
Perform the following operations for both throttle

bodies.
Loosen the throttle body retaining calmp from the
engine sleeve.
Lift up the throttle body and remove the retaining

calmp.
Disconnect the air temperature/pressure sensor

connector.
Remove the vacuum hose.
P SUPP - 170
Remove the throttle body.
Installing the throttle body
THROTTLE BODIES
Pos. Description Type Quantity Torque Note
1 Injector mounting fixing screw M6 2 11 ÷ 13 Nm (8.11 ÷ 9.59 -
lbf ft)
2 Air temperature/pressure sensor fas- M6 2 11 ÷ 13 Nm (8.11 ÷ 9.59 -
tening screw lbf ft)
3 Throttle body fastening screw M6 4 9 ÷ 11 Nm (6.64 ÷ 8.11 -
lbf ft)
P SUPP - 171
Perform the following operations for both throttle

bodies.
Position the throttle body near the engine sleeve.
Insert the vacuum tube.
Connect the air temperature/pressure sensor con-

nector.
Place the throttle body retaining calmp on the en-

gine sleeve.
Insert the throttle body on the engine sleeve.
P SUPP - 172
Screw the throttle body retaining calmp to the en-

gine sleeve.
Connect the two throttle body ECU connectors by

locking them with the appropriate tab.
Position the intake ducts on the throttle bodies.
Tighten intake duct fixing screws.
P SUPP - 173
Screw in the fixing screw of the pipe metal retain-

ing calmp to the fuel tank.
Proceed to reassemble the following components:
• Air filter box

• fuel tank
• tank cover
• left and right side fairing
• front fairing cover
• top fairing
• Reconnect the battery.
P SUPP - 174
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions V100 E5
Front
Handlebar
HANDLEBAR-CONTROLS
1 Screws fastening the lower U-bolts to M10 2 50 Nm (36.88 lbf ft) Loctite 243
the upper steering yoke
2 Screws fastening the lower U-bolt M8 4 25 Nm (18.44 lbf ft) -
clamp to the handlebar
3 Screws fastening the anti-vibration M6 1+1 10 Nm (7.38 lbf ft) -
weights to the handlebar
4 Screws fastening the light switch to M5 1+1 4 Nm (2.95 lbf ft) Pre-fitted on the
handlebar light switch
5 Clutch pump U-bolt fastening screws M6 2 10 Nm (7.38 lbf ft) -
6 Front brake master cylinder U-bolt M6 2 10 Nm (7.38 lbf ft) -
fixing screws
7 Screw fastening the electronic throt- M4 1 4 Nm (1.62 lbf ft) Pre-fitted on the
tle control to handlebar throttle control
SUSP - 176
V100 E5 Suspensions
Removing
• First remove the rear-view mirrors.

• Remove the anti-vibration weight from
the handlebar, on both sides.
During refitting, tighten the anti-vibration weight to


Screw fastening the anti-vibration weight 10 Nm
(7.38 lbf ft)
• Remove the threaded bushing from the

handlebar, on both sides.

cable gland on the right stanchion.
• Open the rubber clamp.
SUSP - 177
Suspensions V100 E5
• Loosen the screw fastening the throttle

control.
• Remove the throttle control from the

handlebar and place it on the vehicle,
taking care not to damage the body-
work.
WARNING
It is not possible to replace only the throttle control grip as

it is integrated with the throttle control. If necessary, you
must replace the throttle control unit.
• Loosen the screw fastening the right

switch.
• Slide the switch off the handlebar, pay-

ing attention to the throttle control, the
wiring harnesses are secured together
with clamps.
SUSP - 178
V100 E5 Suspensions
• Support the front brake pump and un-

screw the two fixing screws (1) of the
fixing U-bolt (2).
• Remove the front brake pump from the

handlebar and place it on the tank, tak-
ing care not to tension the pipe or dam-
age the bodywork.
• Remove the rubber clamp from the left

side wiring harnesses.
• Remove the screw (3) fixing the top of

the left handle.
SUSP - 179
Suspensions V100 E5
• Remove the lower fixing screw (4) of

the left knob.
• Remove the left hand handle from the

handlebar and place it on the vehicle,
taking care not to damage the body-
work.
DURING REFITTING, MAKE SURE TO INSERT THE FIXING

SCREWS OF THE HANDLE IN THE RELEVANT THREADED
HOLES OF THE HANDLEBAR.

cable gland on the left stanchion.
• Loosen the fixing screw (6) of the left

light switch and remove it from the han-
dlebar; place it on the vehicle, taking
care not to damage the bodywork.
SUSP - 180
V100 E5 Suspensions
• Support the clutch pump and unscrew

the two screws (7) of the fixing U-bolt
(8).
• Remove the clutch pump from the han-

dlebar and place it on the tank, taking
care not to tension the pipe or damage
the bodywork.
• Unscrew the four fixing screws (9) of

the handlebar.
During refitting, first tighten the front fixing screws

and then the rear, all to the prescribed torque.

Handlebar fixing screw 25 Nm (14.44 lbf ft)
• Remove the U-bolt (10) of the handle-

bar, then remove the handlebar itself
from the vehicle.
CAUTION
ALWAYS REPLACE A DAMAGED AND/OR BENT HANDLE-
BAR AS ITS STRUCTURAL STRENGTH IS COMPRO-
MISED. NEVER ATTEMPT TO READJUST A BENT HAN-
DLEBAR, EVEN IF IT IS ONLY SLIGHTLY BENT.
SUSP - 181
Suspensions V100 E5
Front fork
FRONT FORK
1 Screws fastening the calliper mount- M6 4 10 ± 1.5 Nm (7.38 ± 1.10 -
ing bracket to the wheel axle lb ft)
SUSP - 182
V100 E5 Suspensions
STEERING
ening torque 30 Nm
+/- 5 Nm (22.13 +/-
3.69 lbf ft)
the headstock
Removing the fork legs
• To remove the front fork, install a work-

shop stand to the rear wheel and place
a pantograph jack under the engine to
lift the front wheel off the ground.
Check the stability of the vehicle.
• First remove the side fairings, the front
mudguard, the brake callipers and the
front wheel.
• Only for OHLINS fork: Disconnect the
connectors of the sensors on the stan-
chion caps.
To avoid damaging the vehicle, place a protection between

the jack and the sump oil.
• Disconnect the connector (1) from both

stanchion caps.
NOTE
Operation necessary only for OHLINS forks .
SUSP - 183
Suspensions V100 E5
TO AVOID DAMAGING THE CONNECTOR, PRESS THE

TAB (2) ON THE INDICATED POINT AND THEN CAREFUL-
LY REMOVE THE CONNECTOR.
PAY SPECIFIC ATTENTION WHEN DISCONNECTING THE

CONNECTORS, TO AVOID DAMAGING THEM, WHICH
WOULD COMPROMISE THE OPERATION OF THE VEHI-
CLE.
• Cut the clamp that fastens the ABS

sensor cable.
• Undo the screw (1) fastening the ABS

sensor cable gland.
• Release the ABS sensor cable from

the right hand calliper mounting brack-
et.
SUSP - 184
V100 E5 Suspensions
• Loosen the cable gland clamp from the

fork stanchion.
• Loosen the screw (2) of the upper

steering plate.
During refitting, tighten the screw to the prescribed

torque.

Upper steering plate screw 25 ± 2.5 Nm (18.44 ± 1.84
lbf ft)
• Support the fork stanchion and loosen

the two screws (3) of the lower steering
plate.
During refitting, tighten the screws to the prescri-

bed torque.

Lower steering plate screw 25 ± 2.5 Nm (18.44 ± 1.84
lbf ft)
• Slide off the stanchion downward and

remove it from the vehicle.
• Repeat the operation for the stem on
the opposite side.
SUSP - 185
Suspensions V100 E5
INSTALLATION
• Follow the removal procedure in re-

verse order; be careful to tighten the
retainers to the specified tightening tor-
ques.
NOTE
DURING REFITTING, INSERT THE FORK STANCHIONS IN
THE STEERING PLATES SO AS TO OBTAIN 12 mm BE-
TWEEN THE UPPER STEERING PLATE AND THE UPPER
EDGE OF THE FORK STANCHION (MEASURED UNDER
THE SLEEVE CAP).
Draining oil
V100 Mandello S
NOTE
THE FOLLOWING OPERATIONS ARE FOR OHLINS FORKS WITH ELECTRONIC ADJUSTMENTS.
• Set the pre-loading spring to the mini-
mum position.
• Unscrew the upper cap from the sleeve

using a specific Öhlins tool.
Specific tooling
SUSP - 186
V100 E5 Suspensions
• Loosen the cap using a wrench in order

to release the upper nut on the spring
retaining ring.
• Unscrew the upper adjustment cap us-
ing the special Ohlins tool.
Specific tooling
• Remove the complete cap.
• Unscrew the nut and remove it, exert-

ing slight pressure on the pre-loading
spring.
• Remove the pre-loading spring retain-

ing ring.
SUSP - 187
Suspensions V100 E5
• Remove the pre-loading spring.
• Empty the fork oil into a special con-

tainer, taking care not to let the pre-
loading tube come out.
Disassembling the fork
V100 Mandello
NOTE
THE FOLLOWING OPERATIONS REFER TO THE KAYABA FORKS WITH MECHANICAL AD-
JUSTMENTS.
NOTE
THE STEMS ARE NOT THE SAME, THEREFORE THEY REQUIRE SEPARATE REMOVAL PRO-
CEDURES.
THE FOLLOWING OPERATIONS APPLY WHEN
REMOVING THE RIGHT HAND STEM
• Taking care not to damage it, secure

the fork vertically in a vice, using the
appropriate protection devices.
• Unscrew the upper cap (1).
Specific tooling
SUSP - 188
V100 E5 Suspensions
• Using the special tool (2), fastened to

the pre-loading pipe (3), compress the
spring and, with the assistance of a
second operator, insert the separator
plate (4) under the cap retaining nut
(5).
Specific tooling
020888Y Pre-load tube clamp
• Ensure that the cap (1) cannot rotate,
and then loosen the nut (5).
• Unscrew and remove the cap (1).
• Extract the shaft (6) and remove it.
SUSP - 189
Suspensions V100 E5
• After removing the locking plate and

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

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

sufficient capacity, extending the stan-
chion several times in order to ensure
the oil is drained completely.


the sleeve horizontally in a vice, using
the appropriate protection devices.
• Extract the dust guard (9).
Specific tooling
SUSP - 190
V100 E5 Suspensions
• Remove the seeger ring (10) from in-

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

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

the plunger fastening screw (11), tak-
ing care not to lose the copper washer
(12).
• Remove the complete plunger (13).
SUSP - 191
Suspensions V100 E5
• Observing the indicated sequence, ex-

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

REMOVING THE RIGHT HAND STEM

the fork vertically in a vice, using the
appropriate protection devices.
• Unscrew the upper cap (1).
Specific tooling
• Ensure that the cap (1) cannot rotate,
and then loosen the special nut (2).
• Unscrew and remove the cap (1).
SUSP - 192
V100 E5 Suspensions
• Unscrew the special nut (2) and re-

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

sufficient capacity, extending the stan-
chion several times in order to ensure
the oil is drained completely.


the sleeve horizontally in a vice, using
the appropriate protection devices.
• Extract the dust guard (4).
Specific tooling
SUSP - 193
Suspensions V100 E5
• Remove the seeger ring (5) from inside

the sleeve.
• Pull the stem repeatedly towards your-

self in order to remove it from the
sleeve.

tract and remove the slider bushing (6),
the guide bushing (7), the ring (8), the
oil seal (9), the seeger ring (5) and the
dust guard (4).
V100 Mandello S
NOTE
• Remove the pre-loading tube.
SUSP - 194
V100 E5 Suspensions
• Remove the wheel holder shaft (1) and

the sleeve (2).
• Clamp the sleeve in a vice and, by lev-

ering it alternately at various points,
remove the anti-dust seal (3) from the
sleeve (2).
• Remove the retaining ring (4).
• Remove the shaft seal (5) by levering

it alternately at various points.
CAUTION
PROTECT THE EDGE OF THE SLEEVE IN ORDER TO
AVOID RUINING IT WHILE REMOVING THE SHAFT SEAL
(5).
Replace the following components with new ones:

- shaft seal (5)
- anti-dust seal (3)
CAUTION
SUSP - 195
Suspensions V100 E5
PROCEED WITH EXTREME CAUTION IN ORDER TO PREVENT FOREIGN BODIES FROM EN-
TERING THE SLEEVE OR THE WHEEL HOLDER SHAFT. DO NOT REUSE THE OIL THAT WAS
DRAINED EARLIER
Checking the components
V100 Mandello
NOTE
JUSTMENTS.
stanchion
Check that the sliding surface is not scratched or scored.
Any scoring can be removed by sanding with damp sandpaper (grain 1).
If the scratches are deep, replace the stanchion .
Using a dial gauge, check than any bending of the stanchion is below the limit value.
If it is over the limit, replace the stanchion .
CAUTION
A BENT STANCHION SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE
WEAKENED MAKING THE VEHICLE DANGEROUS TO USE.
Characteristic
Bending limit:
0.2 mm (0.00787 in)
Sleeve
Check for damage and/or cracks; if it is damaged, replace it.
Spring
Check for damage and/or cracks; If it is damaged, replace it.
Check the condition of the following components:

• slider bushing;
• guide bushing;
• plunger.
If there is evidence of excessive wear or damage, replace the component concerned.

CAUTION
REMOVE ANY IMPURITIES FROM THE BUSHINGS, BEING CAREFUL NOT TO SCRATCH THEIR
SURFACES.
Replace the following components with new ones:
• Oil seal.
• Dust guard.
• - O-ring on the cap.
V100 Mandello S
NOTE
SUSP - 196
V100 E5 Suspensions
stanchion
Check that the sliding surface is not scratched or scored.
Any scoring can be removed by sanding with damp sandpaper (grain 1).
If the scratches are deep, replace the stanchion .
Using a dial gauge, check than any bending of the stanchion is below the limit value.
If it is over the limit, replace the stanchion .
CAUTION
A BENT STANCHION SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE
WEAKENED MAKING THE VEHICLE DANGEROUS TO USE.
Characteristic
Bending limit:
0.2 mm (0.00787 in)
Sleeve
Check for damage and/or cracks; if it is damaged, replace it.
Spring
Check for damage and/or cracks; If it is damaged, replace it.
Reassembling the fork
V100 Mandello
NOTE
JUSTMENTS.
CAUTION
THE STEMS ARE NOT THE SAME, THEREFORE THEY REQUIRE SEPARATE MOUNTING PRO-
CEDURES.
MOUNTING THE RIGHT HAND STEM.

tract and remove the dust guard (1),
the seeger ring (2), the oil seal (3), the
ring (4), the guide bushing (5) and the
slider bushing (6).
SUSP - 197
Suspensions V100 E5
• Insert the complete plunger (7).
• Secure the stem in a vice and, after in-

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

striking hammer, insert oil seal into its
housing (3).
Specific tooling
AP8140189 Tool for fitting oil seal for 43 mm
(1.69 in) diameter hole
AP8140146 Weight
SUSP - 198
V100 E5 Suspensions
• Position the seeger ring (2) inside the

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

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

surface.
• Fill the stem with the quantity of oil in-
dicated in the "Refilling oil" section.
• Insert the spring (10), making sure that

it is aligned correctly The end where
the spirals are more compressed
should be facing upwards
SUSP - 199
Suspensions V100 E5
• Insert the pre-load tube (11), making

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

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

pre-load pipe (11) and the plunger sup-
port shaft (14), with the assistance of a
second operator, raise the plunger so
that it is possible to insert the plate (15)
under the cap locking nut.
Specific tooling
020888S Pre-load tube clamp
AP8140150 Bored shaft for bleeding plunger
air
• Insert the shaft (16) into the plunger.
SUSP - 200
V100 E5 Suspensions
• Before positioning the cap, adjust the

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

far as it will go.
CAUTION
CHECK THE O-RING PRESENT ON THE FILLING CAP AND
REPLACE IF DAMAGED.
• Ensure that the cap cannot rotate, and

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

the pre-defined torque.
SUSP - 201
Suspensions V100 E5

MOUNTING THE LEFT HAND STEM

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

striking hammer, insert oil seal into its
housing (3).
Specific tooling
AP8140146 Weight
• Position the seeger ring (2) inside the

sleeve.
SUSP - 202
V100 E5 Suspensions
• Insert the dust guard (1) into its hous-

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

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

as far as it will go.
SUSP - 203
Suspensions V100 E5
• Insert the cap (9) and tighten it as far

as it will go.
CAUTION
CHECK THE O-RING PRESENT ON THE FILLING CAP AND
REPLACE IF DAMAGED.
• Ensure that the cap cannot rotate, and

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

the pre-defined torque.
V100 Mandello S
NOTE
• Install the following components on the
wheel holder stanchion (1) in the order
given: dust gaiter (3), retainer ring (4)
and oil seal (5).
SUSP - 204
V100 E5 Suspensions
• Fix the sleeve in a vice, taking care not

to damage the sleeve.
• Insert the stanchion (1) into the sleeve
(2).
• Position the two halves of the special

tool on the shaft (1) behind shaft seal
(5), together with the respective buffer.
• Grip the special tool and push the shaft
seal (5) into its housing on the sleeve
(2).
• Remove the tool.
Specific tooling
AP8140146 Weight
• Insert the retaining ring (4) into its
housing on the sleeve (2).
• Position the two halves of the special

tool on the shaft behind anti-dust seal
(3), together with the respective buffer.
• Grip the special tool and push the anti-
dust seal (3) into its housing on the
sleeve (2).
• Grasp the shaft and move it slowly, in
alternating directions a few times.
CAUTION
THE SHAFT MUST SLIDE FREELY WITHIN THE SLEEVE,
WITHOUT OBSTRUCTIONS.
SUSP - 205
Suspensions V100 E5
Specific tooling
AP8140146 Weight
Filling oil
V100 Mandello
NOTE
JUSTMENTS.
RIGHT-HAND STANCHION FILLING.
• Place the fork stanchion in a vice and

lock it in a vertical position.
• Fill the stanchion with the specified oil
quantity.
WARNING
OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR
BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.
THE FORK MUST BE PERFECTLY UPRIGHT IN ORDER TO

MEASURE THE CORRECT OIL LEVEL.
Characteristic
Quantity of oil for RH STEM
503 cc (30.70 cu in)
• Check the oil level from the rim of the

sleeve.
Characteristic
Oil level (from sleeve rim, without the spring
and with the pump all the way lowered)
97 mm (3.82 in)
SUSP - 206
V100 E5 Suspensions
LEFT-HAND STANCHION FILLING.
• Place the fork stanchion in a vice and

lock it in a vertical position.
• Fill the stanchion with the specified oil
quantity.
WARNING
OPERATE THE PLUNGER MULTIPLE TIMES UNTIL AIR
BUBBLES MAY BE SEEN ON THE SURFACE OF THE OIL.
THE FORK MUST BE PERFECTLY UPRIGHT IN ORDER TO

MEASURE THE CORRECT OIL LEVEL.
Characteristic
Quantity of oil for LH stem
378 cc (23.01 cu in)
• Check the oil level from the rim of the

sleeve.
Characteristic
Oil level (from sleeve rim, without the spring
and with the pump all the way lowered)
95 mm (3.74 in)
V100 Mandello S
NOTE
• Place the sleeve upright in a vice fitted
with protection shoes.
• Compress the sleeve in the stanchion.
Place a support under the stanchion in
order to leave it compressed.
• Pour part of the fork oil into the sleeve.
• Wait a few 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.
SUSP - 207
Suspensions V100 E5
THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER

TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL
MUST BE THE SAME IN BOTH STANCHIONS.
Specific tooling
Oil level: 160 mm (6.30 in) (from the edge of the
sleeve, without spring or pre-fill pipe).
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
Fork oil
460 ± 4 cc (28.07 ± 0.24 cu in)
• Insert the pre-load tube in the stanchion making sure that it is aligned correctly.
• Insert the spring.

CAUTION
PROCEED WITH CAUTION WHEN INSERTING THE
SPRING AND ENSURE THAT THE PART WHERE THE SPI-
RAL IS MORE COMPRESSED IS FACING DOWNWARDS.
SUSP - 208
V100 E5 Suspensions
• Position the ring nut on the preload

spring and keeping it compressed,
screw the lock nut on the pumping el-
ement
• Tighten the nut as much as possible.

• Insert the cover and tighten until it
stops.
• Using the special Ohlins tool, tighten

the cap to the prescribed torque.
Upper steering yoke
Removal
• Unscrew the four fixing screws (1) and

remove the U-bolt (2) of the handlebar.
During refitting, first tighten the front fixing screws

and then the rear, all to the prescribed torque.

Handlebar fixing screw 25 Nm (14.44 lbf ft)
SUSP - 209
Suspensions V100 E5
• Place the handlebar on the tank. To

avoid damage to the bodywork, place
a protective cloth on the tank before
placing the handlebar.
• Loosen the screw (3) of the steering

plate, on both sides.

bed torque.

Upper steering plate screw 25 ± 2.5 Nm (18.44 ± 1.84
lbf ft)
• Remove the plug (4) of the steering

plate.
During refitting, tighten the plug to the prescribed

torque.

Upper steering plate plug 100 Nm (73,76 lbf ft)
• Remove the steering plate from the ve-

hicle.
NOTE
For the "MANDELLO S" version, before removing the up-
per steering plate, it is necessary to disconnect the wiring
harnesses from the forks.
Steering bottom yoke
SUSP - 210
V100 E5 Suspensions
Removing
• To remove the lower steering plate, in-

stall a workshop stand to the rear
wheel and place a pantograph jack un-
der the engine to lift the front wheel off
the ground. Check the stability of the
vehicle.
• First remove the upper steering plate
and both stanchions of the front fork.

NOTE
It is possible to remove the lower steering plate also with
the fork stanchions fitted.
• Retrieve the safety washer (1).
• Remove the four fixing screws (2) and

remove the plastic (3) from the lower
steering plate.
SUSP - 211
Suspensions V100 E5
• Using the specific tool, unscrew the

counter-lock ring (4).
Specific tooling
020966Y Steering adjustment socket
Remove the counter-lock ring (4) and the rubber

spacer (5).
• Using the specific tool, unscrew and

remove the ring nut (6) of the steering
headstock.
Specific tooling
• Retrieve the dust seal ring (7).
SUSP - 212
V100 E5 Suspensions
• Remove the shim washer (8) of the up-

per bearing.
• Remove the internal ring (9) of the up-

per bearing.
• Remove the balls of the upper bearing

(10).
Remove the lower steering plate from the vehicle.
SUSP - 213
Suspensions V100 E5
• Remove the balls of the lower bearing

(11) from the steering plate.
Steering bearing
STEERING
ening torque 30 Nm
+/- 5 Nm (22.13 +/-
3.69 lbf ft)
the headstock
SUSP - 214
V100 E5 Suspensions
Adjusting play
To adjust the steering play, follow the procedure described below:
• Place the vehicle so that the front wheel is off the ground.
• Carry out a handlebar rotation test, using a dynamometer at the hand grip external end.
• The handlebar resistance to rotation must be of 250 +/- 100 g (0.55 +/- 0.22 lb) in both
directions.
• Adjust if clearance is detected.
NOTE
THE STEERING COLUMN RESISTANCE TO ROTATION MUST BE PERFORMED IN THE TWO
OPPOSITE ROTATION DIRECTIONS.
• Remove the handlebars and upper
steering triple clamp.
Then proceed as described:
• Remove the steering safety plate (1).
• Remove the upper steering ring nut (2)

using the special tool.
Specific tooling
• Remove the rubber shim (3).
SUSP - 215
Suspensions V100 E5
• Unscrew the lower ring nut (4) using

the special tool.
Repeat the steering assembly tightening proce-

dure in the correct manner as described:
• Pre-tighten the ring nut (4) to 60 Nm

(44.25 lbf ft).
• Turn the handlebar to the left and right
as far as it will go to seat the bearings.
• Unscrew the ring nut and tighten it
again to 30 +/- 5 Nm (22.13 +/- 3.69 lbf
ft).
Specific tooling
• Insert the rubber shim (2) and then manually screw the counter-lock ring (3) until it is in
contact with the shim itself. Make sure that the slots of the counter-lock ring (3) are aligned
with those of the ring nut (4).
• Fit the safety washer (1).
• Check that the handlebar resistance to rotation is 250 + / - 100 g (0.55 + / - 0.22 lb) in both
directions.
Disassembling
Install a workshop stand to the rear wheel and

place a pantograph jack under the engine in order
to lift the front wheel from the ground. Check the
stability of the vehicle.

SUSP - 216
V100 E5 Suspensions
• Remove the lower steering plate.

• Using a generic bearing extractor, re-
move the outside seat of the upper
steering bearing.
• Using a generic bearing extractor, re-

move the outside seat of the lower
steering bearing.
• Remove the inner ring (1), together

with the balls, of the lower bearing from
the steering headstock pipe.
• Using a workshop heating gun, heat
the internal seat (2) of the bearing and
then remove it from steering headstock
pipe.
• Retrieve the dust seal ring (3).
Assembling
• Working on the bench, pre-fit on the

steering headstock pipe the dust seal
ring (3), the internal seat (2) and the
inner ring (3) with the balls of the lower
steering bearing.
Lubricate the inserted seat with grease for bearings.
SUSP - 217
Suspensions V100 E5
• Using the specific tool, completely in-

sert the external seat of the upper bear-
ing.
Specific tooling
• Using the specific tool, completely in-
sert the external seat of the lower bear-
ing.
Specific tooling
• Insert the lower steering plate in the
headstock, together with the bearing.
• Use a bearing grease to lubricate the

upper steering bearing inner ring (4),
together with the balls.
• Support the lower steering plate and
insert the inner ring (4) inside the steer-
ing headstock.
SUSP - 218
V100 E5 Suspensions
• Lubricate the internal seat (5) of the

upper steering bearing with bearing
grease.
insert the internal seat (5) inside the
steering headstock.

insert the dust seal ring (6) on the
steering headstock.

insert the rubber dust seal ring (7) on
the steering headstock.

insert the ring nut (8) on the steering
headstock and bring it to the end with
the dust seal ring (7).
SUSP - 219
Suspensions V100 E5
• Using the specific tool, pre-tighten the

ring nut (8) to the torque of 60 Nm
(44.25 lbf ft).
• Turn the handlebar to the right and left
until the end of the stroke, to allow the
bearings to settle.
• Unscrew the ring nut (8) and tighten it
to a torque of 30 ± 5 Nm (22.23 ± 3.68
lbf ft).
• Turn the handlebar to the right and left
several times through its full travel and
make sure that the rotation is smooth
and free of jams.
Specific tooling
• Insert the rubber shim (9) on the steer-
ing headstock.
• Screw the counter-lock ring (10) until it
is in contact with the shim (9).
• Align the grooves of the counter-lock

ring (10) with those of the ring nut (8).
SUSP - 220
V100 E5 Suspensions
• Insert the safety plate (11) on the ring

nuts of the steering headstock.
• Refit the previously removed compo-
nents.
Rear
Shock absorbers
REAR SHOCK ABSORBER

1 Upper shock absorber fixing screw M10 1 50 ± 7.5 Nm (36.87 ± -
5.53 lb ft)
2 Lower shock absorber clamping M10 1 50 ± 7.5 Nm (36.87 ± -
screw 5.53 lb ft)
3 Fixing screw for preload tank to M6 2 10 ± 2 Nm (7.37 ± 1.47 -
bracket lb ft)
SUSP - 221
Suspensions V100 E5
Removing
Properly support the vehicle by means of a pan-

tograph.
Unscrew the fixing screws of the preload tank to

the support bracket.
Remove the preload tank.
Position the preload tank so that it is not in the way

of subsequent operations; protect the support area
properly.
SUSP - 222
V100 E5 Suspensions
While holding the rear nut (1), unscrew the screw

(2).
Remove the screw (2).
Retrieve the nut (1).
While holding the rear nut (3), unscrew the screw

(4).
SUSP - 223
Suspensions V100 E5
Remove the screw (4).
Retrieve the nut (3).
Remove the damper complete with the preload

tank.
FOR "MANDELLO S" VERSION

Before removing the damper with the preload tank
as described above, the electrical connectors of
the wiring harness from the electronic suspension
ECU must be disconnected.
SUSP - 224
V100 E5 Suspensions
Proceed as follows:
• remove the passenger and driver's

seat;
• remove the battery cover;
• disconnect and remove the battery;
• disconnect and remove the engine
ECU;
• remove the engine ECU bracket;
Remove the right side panel and remove the inner

side fairing underneath.
Disconnect the first wire harness connector from

the suspension ECU.
Remove the rubber clamp.
SUSP - 225
Suspensions V100 E5
Remove the rear brake oil tank by unscrewing the

fixing screw.
Remove the fixing rubber calmp from the rear

brake hose.
Remove the fixing metal calmp from the rear brake

hose.
Unscrew and remove the saddle screw so that it

can be detached from the chassis.
SUSP - 226
V100 E5 Suspensions
Cut the fixing calmp from the electrical wiring har-

nesses.
Remove the second ECU suspension wire har-

ness connector from the saddle.
Disconnect the second connector.
Installing
Position the shock absorber complete with preload

tank in its seat.
SUSP - 227
Suspensions V100 E5
Insert the rear nut (3).
Holding the rear nut (3), tighten the screw (4) to

Insert the rear nut (1).
Holding the rear nut (1), tighten the screw (2) to

SUSP - 228
V100 E5 Suspensions
Position the preload tank on the support bracket

and tighten the fixing screws to the prescribed tor-
que.
NOTE
FOR THE "MANDELLO S" VERSION, PROCEED WITH THE
INSTALLATION OF THE ELECTRICAL WIRING BY PER-
FORMING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL.
SUSP - 229
INDEX OF TOPICS
CHASSIS CHAS
V100 E5 Chassis
FOR MAINTENANCE/REPAIR WORK AND WHERE THERE

IS A NEED TO LIFT THE VEHICLE WHEELS OFF THE
GROUND, INSTALL A WORKSHOP STAND AT THE REAR
WHEEL AND PLACE A PANTOGRAPH JACK UNDER THE
OIL SUMP. PLACE A GUARD BETWEEN THE JACK AND
THE OIL SUMP TO PREVENT DAMAGE TO THE OIL SUMP.
FINALLY, MAKE SURE THAT THE VEHICLE IS STABLE
BEFORE CARRYING OUT ANY OPERATION.
Wheels
REPLACEMENT PROCEDURE OF THE TPMS SENSOR - VALVE

Remove the relevant wheel from the vehicle.
NOTE
The following procedure applies to the rear tyre, but is also applicable to the front tyre.
Remove the tyre using a tyre changer.
CAUTION
The bead breaking of the tyre must take place at a distance
of at least 90° from the inflation valve.
CAUTION
The positioning of the levers for the removal of the tyre
must be at a distance of at least 10 cm (3.93 in) from the
inflation valve.
CHAS - 231
Chassis V100 E5
Completely remove the tyre from the rim.
Remove the screw (1) that fastens the TPMS sen-

sor to the valve.
Remove the retaining nut (2) and slide off the valve
(3) from inside the rim.
Fit the new valve kit for TPMS (3) - code

2D000689 for tubeless wheels.
CHAS - 232
V100 E5 Chassis
Insert and tighten the valve retaining nut (2) to the

prescribed torque.

Valve retaining nut 4.7 ± 0.25 Nm (3.47 ± 0.18 lb ft)
Install and tighten to the prescribed torque the

screw (1) that fastens the TPMS sensor to the
valve.

Sensor retaining screw 1.3 ± 0.05 Nm (0.96 ± 0.037 lb
ft)
Reassemble the tyre using a tyre changer.

Lubricate the edges of the tyre with grease to aid
insertion into the seat.
Once the tire has been inserted in its seat, inflate

the tyre to the following pressure:
Rear tyre: 2.8 bar (280 KPa) (40.61 PSI).
Front tyre: 2.5 bar (250 KPa) (36.26 PSI).
Once the wheels have been reassembled on the vehicle, the following operations are required using
the P.A.D.S. diagnostic tool.
• Connect the P.A.D. S. to the vehicle and find the model "V100 Mandello";
• select the section "TYRE PRESSURE MONITORING - TPMS"
CHAS - 233
Chassis V100 E5
• select the "SELF-DIAGNOSIS" function
• Select the "ADJUSTMENTS" tab
• select "vehicle configuration" and press "OK"
• select "front wheel TPMS learning" and press "OK"
CHAS - 234
V100 E5 Chassis
• When required by P.A.D.S., deflate the front tyre, until the learning is complete.
WARNING
THE DEFLATION / LEARNING OPERATION MUST BE PERFORMED WITHIN A MAXIMUM 90
SECONDS.
CAUTION
TO BE ABLE TO PERFORM THE CALIBRATION, THE SENSOR MUST DETECT A DECREASE IN
TYRE INFLATION PRESSURE.
ONCE THE LEARNING IS COMPLETE, THE TYRE PRESSURE MUST BE BROUGHT BACK TO
THE NOMINAL VALUE. EVEN IF THE INITIAL PRESSURE IS ABOVE THE VALUE, IT WILL STILL
BE REQUIRED TO ADJUST THE INFLATION PRESSURE TO THE CORRECT VALUE.
• Repeat the learning operations for the rear wheel also, selecting "Rear wheel TPMS learn-
ing".
• After both learning procedures have been performed, wait a few minutes for the sensors to
align with the vehicle ECU. Any errors present will pass to the "STORED" status and can
be cancelled.
• The current tyre pressure and temperature data will be displayed by selecting the "PARAM-
ETERS AND STATUS" tab.
CAUTION
If the pressure is 5.10 bar and temperature is 205 °C, it means that the sensor is not calibrated.
If a condition of this type occurs, it is necessary to carry out the TPMS learning procedure again.
CHAS - 235
Chassis V100 E5
Front wheel
FRONT WHEEL
1 Nut fastening the front wheel axle M25x1.5 1 80 Nm (59.01 lbf ft)
2 Brake disc fixing screw M6 6+6 30 Nm (22.13 lbf ft) Loctite 243
3 ABS sensor fixing screw M5 1 6 Nm (4.46 lbf ft) -
CHAS - 236
V100 E5 Chassis
Removal
REMOVAL
To remove the front wheel, install a workshop
stand to the rear wheel and place a pantograph
jack under the engine to lift the front wheel off the
ground. Check the stability of the vehicle.

• First remove the front mudguard.

• Release the ABS sensor cable from
the 4 retainers of the brake pipe.
• Remove the two fixing screws (1) and

remove the brake calliper (2) from the
vehicle; repeat for the opposite side.
• Remove the plastic clamp (3).
CHAS - 237
Chassis V100 E5
• Remove the fixing screw and remove

the ABS sensor (4) from its housing on
the right hand calliper mounting brack-
et.
• Unscrew the nut of the wheel axle (5)

and recover the relative washer (6).
• Loosen the screws of the right foot.
• Loosen the screws of the left foot.
CHAS - 238
V100 E5 Chassis
• Slide off the wheel axle from the front

suspension.
• Remove the front wheel from the vehi-

cle.
• Remove the spacer (7) on the right side

of the wheel.
REMOVAL OF EXTERNAL WHEEL COMPO-

NENTS
After removing the front wheel, operating from the
right side:
• Remove the six fixing screws (8) and

remove the tone wheel (9) from the
wheel.
CHAS - 239
Chassis V100 E5
• Remove the right-hand brake disc (10).
• Working on the opposite side, unscrew

the six fixing screws (11) and remove
the left-hand brake disc (12).
REMOVAL OF INTERNAL WHEEL COMPO-

NENTS
• Remove the dust guard (13).
Remove the bearing using a generic extractor,

proceeding as follows:
• Insert the collar (A) into the bearing,

and screw the pin (B) into the bearing
until the collar is securely fastened to
the bearing.
• Insert the thrust bushing (C) and nut
(D) onto the collar (A).
• Hold the collar (A) while tightening the
nut (D) to push the bearing out of its
seat.
NOTE
CHAS - 240
V100 E5 Chassis
REPEAT THE OPERATION DESCRIBED ABOVE, TO RE-

MOVE THE BEARING ON THE OPPOSITE SIDE OF THE
WHEEL.
• Once the first bearing has been removed, retrieve the inner spacer from the wheel hub
before removing the second bearing.
Checking
FRONT WHEEL BEARINGS

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

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

Radial: none.
If one or both bearings do not fall within the control parameters:
• Replace both wheel bearings.
ALWAYS REPLACE BOTH BEARINGS.

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

ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE.
CHAS - 241
Chassis V100 E5
WHEEL AXLE
• Use a dial gauge to measure the ec-

centricity of the wheel axle. Replace
the wheel axle if the eccentricity meas-
ured exceeds the specified limit.
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
• Use a dial gauge to check that the ra-

dial (A) and axial (B) eccentricity of the
wheel do not exceed the specified lim-
its. Excessive eccentricity is usually
caused by worn or damaged bearings.
If eccentricity is not within the indicated
limits after replacing the bearings, re-
place the wheel.
Characteristic
Maximum radial and axial eccentricity:
0.8 mm (0.031 in)
Installing
INSTALLATION OF INTERNAL WHEEL COM-

PONENTS
• Insert the bearing into the wheel hub

and bring it to the stop using the special
equipment.
Specific tooling
020359Y 42 x 47 mm Adaptor
CHAS - 242
V100 E5 Chassis
• Insert the inner spacer the wheel hub,

and repeat the insertion of the bearing
on the opposite side.
• Insert the dust seal (13) and bring it
flush with the wheel hub.
• Repeat the operation for the dust seal
on the opposite side.
INSTALLATION OF EXTERNAL WHEEL COM-

PONENTS
• Install the left brake disc (12) on the

rim.
• Gradually screw in the six attachment
screws (11) following the sequence A-
B-C-D-E-F and tighten them to the
specified torque.

Brake disc fixing screw 30 ± 4.5 Nm (22.13 ± 3.32 lb
ft)
• Working on the opposite side, fit the

brake disc right (10) and the tone wheel
(9) on the rim.
• Gradually screw in the six attachment
screws (8) following the sequence A-B-
C-D-E-F and tighten them to the speci-
fied torque.

ft)
• Fit the spacer (7) on the right side of

the wheel.
CHAS - 243
Chassis V100 E5
FRONT WHEEL INSTALLATION
• Install the front wheel on the vehicle

and insert the wheel axle into the fork
feet.
• Tighten the screws of the right foot to


Calliper mounting bracket screw 10 Nm (7.38 lbf
ft)
• Install the washer (6) and the nut (5) on

the wheel axle.
• Tighten the nut (5) to the prescribed
torque.

Wheel axle nut 80 ±12 Nm (59 ± 8.85 lb ft)
• Tighten the screws of the left foot to the

prescribed torque.

Calliper mounting bracket screw 10 Nm (7.38 lbf
ft)
CHAS - 244
V100 E5 Chassis
• Reinsert the ABS sensor (4) in its seat

and tighten the fixing screw.
• Fit the brake calliper (2) on the brake

disc and tighten the fixing screws (1) to
• Repeat for the brake calliper on the op-
posite side.

Brake calliper fixing screw 50 ± 5 Nm (36.88 ± 3.69
lbf ft)
• Refit the plastic clamp (3) and reposi-

tion the ABS cable in the four retainers
on the brake pipe.
• Perform several rotations to check that
the wheel moves freely and smoothly.
• Refit the front mudguard.
• Remove the pantograph jack and the
rear stand.
CHAS - 245
Chassis V100 E5
Rear wheel
REAR WHEEL
1 Rear wheel nut M60x2 1 260 ± 39 Nm (191.75 ± -
28.76 lb ft)
2 Rear brake disc fixing screw M8 5 30 ± 4.5 Nm (22.12 ± Screws with pre-ap-
3.32 lb ft) plied threadlocker
Rimozione
• Install a workshop stand to the rear

wheel, so as to keep it raised off the
ground.
• Remove the exhaust end first.
CHAS - 246
V100 E5 Chassis
• Open the safety circlip (1).
• Remove the safety circlip (1) from the

hole on the wheel hub and remove it
from the vehicle.
• Unscrew the nut (2) from the hub.
During refitting, tighten the nut (2) to the prescribed

torque.
• Remove the rear wheel from the vehi-

cle.
During refitting, make sure to correctly insert the pins of

the flange of the brake disc in the corresponding holes of
the rim.
CHAS - 247
Chassis V100 E5
Checking
• Check the wheel for damage to the mating surfaces with the wheel hub and fixing nut. Also
check that there are no signs of damage and/or for cracks along the spokes and the duct of
the rim.
Swinging arm
SWINGARM
1 Swingarm pin M16 x 1.5 1 65 ± 9.5 Nm (47.94 ± -
7.01 lb ft)
2 Swingarm pivot screw M8 1 28 ± 4 Nm (20.65 ± 2.95 -
lbf ft)
- Rear shock absorber lower fixing M10 1 50 ± 7.5 Nm (36.88 ± -
screw 5.53 lb ft)
CHAS - 248
V100 E5 Chassis
Removing
• First remove the bevel gear.

• Cut the plastic clamp (1) from the dust
guard cap.
• Holding the nut (2), unscrew the lower

fixing screw (3) of the rear shock ab-
sorber.
During refitting, tighten the fixing screw to the pre-

scribed torque.

Rear shock absorber lower fixing screw 50 ± 7.5
Nm (36.88 ± 5.53 lb ft)

the rear shock absorber.
• Disconnect the rear shock absorber
from the swingarm.
• Remove the wiring harnesses and the

rear brake hose from the cable gland,
as indicated in the figure.
CHAS - 249
Chassis V100 E5
• Loosen the screw (4) of the swingarm

pivot.
During refitting, tighten the screw of the swingarm

pivot to the prescribed torque.

Swingarm pivot screw 28 ± 4 Nm (20.65 ± 2.95 lbf ft)
• Unscrew the swingarm pivot (5).
During refitting, tighten the pin of the swingarm to


Swingarm pin 65 ± 9.5 Nm (47.94 ± 7.01 lb ft)
• Support the swingarm and remove the

pin (5).
• Remove the swingarm from the vehi-

cle, sliding the cardan shaft (6) inside.
Cardan shaft
CHAS - 250
V100 E5 Chassis
Removing
• First remove the rear wheel, the bevel

gear and the swingarm.
• Using a suitable tool, apply force on the
gearbox output shaft (1) in order to re-
lease the cardan shaft (2) from the
gearbox output shaft spline.
Checking
Carefully check:
The splines (1) of the cardan shaft must be intact,
without grainings or dents.
Check that the joint (2) is not hardened or exces-
sively loose, in which case the complete cardan
shaft must be replaced.
In the figure are shown two worn toothing profiles:
• Profile (3) shows acceptable wear, the

cardan shaft should not be replaced.
• Profile (4) shows unacceptable wear,
the cardan shaft must be replaced.
CHAS - 251
Chassis V100 E5
Bevel gears
BEVEL GEAR
1 Bevel gear fixing screws M10 3 45 ± 6.5 Nm (33.19 ± -
4.79 lb ft)
CHAS - 252
V100 E5 Chassis
REAR WHEEL TRANSMISSION - COMPONENTS

1 Fixing screw for rear gearbox cover M8x1 11 25 Nm (18.43 lb ft) Screws with pre-ap-
plied threadlocker
2 Pinion fixing ring nut - 1 140 Nm (103.25 lb ft) With Loctite 243
3 Flanged nut fixing pinion M20x1 1 100 Nm (73.75 lb ft) With Loctite 243
4 Pinion fastening cap M14x1 1 50 Nm (36.87 lb ft) With Loctite 243
5 Oil drainage plug M10x1.5 1 30 Nm (22.1 lb ft) -
6 Oil load cap M12x1.5 1 25 Nm (18.43 lb ft) -
CAUTION
SINCE THE BEVEL GEAR IS A SAFETY COMPONENT, IT IS STRICTLY FORBIDDEN TO PER-
FORM ANY PINION/SPROCKET CLEARANCE ADJUSTMENTS FOR THE ENTIRE DURATION OF
THE COMPONENT'S SERVICE LIFE. IF THE CLEARANCE IS NOT WITHIN THE REQUIRED TOL-
ERANCE, THE ENTIRE BOX WILL HAVE TO BE REPLACED.
IF OIL LEAKAGES ARE DETECTED ON THE SPROCKET SIDE, REPLACE THE OIL SEALS AC-
CORDING TO THE DESCRIPTION BELOW.
Removing
• Place a pantograph jack under the en-

gine to lift the rear wheel, and secure
the vehicle so that it is stable and can-
not fall.
• First remove the wheel and the rear
brake disc.
• Remove the fixing screw (1) of the ABS
sensor (2).

• Remove the ABS sensor (2) from the

bevel gear.
CHAS - 253
Chassis V100 E5
• Remove the upper fastener screw (3).
• Remove the two lower fixing screws

(4).
• Remove the bevel gear from the rear

swingarm.
Removal
CAUTION
CARRY OUT OIL DRAINING AND PROCEED WITH THE REMOVAL OF THE BREATHER BEFORE
DISASSEMBLING THE GEARBOX.
NOTE
THE PICTURES OF THE SPECIFIC TOOL, CODE 021066Y, AND THE POSITIONING OF THE
GEARBOX ARE INDICATIVE; HOWEVER, THE FOLLOWING PROCEDURE IS CORRECT.
CHAS - 254
V100 E5 Chassis
Place the specific tool in a vice and secure it prop-

erly.
Specific tooling
Place the complete gearbox on the specific tool.
CHAS - 255
Chassis V100 E5
Use the screws to secure the complete gearbox to

the swingarm and lock the gearbox to the specific
tool.
Pay attention because the lower screws are equip-

ped with a locking nut.
Insert the supplied flange with the specific tool on

the sprocket hub, bringing it into contact with the
case cover.
CHAS - 256
V100 E5 Chassis
Screw the specific tool arm onto the flange.
Heat the sleeve seat using an air heater.
Unscrew the pinion fixing cap.
CHAS - 257
Chassis V100 E5
Remove the shim underneath the cap.
Reheat the sleeve seat using an air heater.
Unscrew the pinion fixing flanged nut.
Remove the flanged nut.
CHAS - 258
V100 E5 Chassis
Extract the sleeve.
Heat the seat of the ring nut using an air heater.
To remove the ring nut, use the specific tool by

inserting the relevant bolts into the holes in the ring
nut.
Specific tooling
Make sure to bring the specific tool to a stop on the

ring nut.
CHAS - 259
Chassis V100 E5
Using the specific tool, unscrew the ring nut.
Remove the ring nut.
Separate the ring nut from the specific tool.
Remove the o-ring from the pinion.
CHAS - 260
V100 E5 Chassis
Remove the oil seal from the ring nut.
Remove the sealing ring from the ring nut by tap-

ping with a suitable punch.
Unscrew the arm of the specific tool to release the

flange.
Remove the supplied flange with the specific tool

from the sprocket hub.
CHAS - 261
Chassis V100 E5
Unscrew the fixing screws of the gearbox cover.
Using a rubber hammer, slightly separate the cov-

er from the case so that the shims can be removed.
Remove the first shim.
Remove the second shim.
CHAS - 262
V100 E5 Chassis
Remove the complete sprocket hub with the cover

from the gearbox.
Remove the o-ring from the sprocket hub.
Position the complete sprocket hub with gearbox

cover in a suitable press, using suitable supports.
WARNING
BEFORE USING THE PRESS, ENSURE THAT THE SUP-
PORTS USED REST EVENLY ON THE SURFACE OF THE
COVER IN ORDER TO PREVENT DAMAGE TO COMPO-
NENTS.
CHAS - 263
Chassis V100 E5
Operate the press in order to disassemble the

case cover from the sprocket hub.
WARNING
NOTE
BEFORE USING THE PRESS TO DISASSEMBLE THE
SPROCKET HUB FROM THE COVER, IT IS RECOMMEN-
DED THAT THE INVOLVED AREA BE HEATED WITH AN
AIR HEATER IN ORDER TO FACILITATE DECOUPLING.
Remove the sealing ring from the gearbox cover.
Remove the gearbox from the specific tool and the

vice.
Remove the sealing ring from the case by tapping
with a suitable punch.
Using the specific tool, remove the roller bearing

from the gearbox.
Specific tooling
punch
CHAS - 264
V100 E5 Chassis
Checking
• After assembly of the box, it is necessary to check the play between the pinion and the
crown. Clamp in a vice and install a dial gauge by means of a suitable support. The dial
gauge tester must be placed the outer end of a tooth positioned at 90°.
Characteristic
Maximum clearance allowed
0.08-0.2 mm (0.059-0.147 in)
• If the measured play is not compliant with the permitted values, proceed to the correction
by selecting and replacing an adequate rear sprocket axle thickness.
Assembling
Using the specific tool, insert a new roller bearing

in the gearbox, making sure to bring it up to its
stop.
WARNING
WHEN REASSEMBLING, ALWAYS REPLACE THE ROLL-
ER BEARING WITH A NEW ONE.
Specific tooling
punch
Turn the gearbox upside down and apply grease

between the roller bearing and the seal ring seat.
Position a new sealing ring, making sure to bring
it up to its stop using the special tool mentioned
above.
WHEN REASSEMBLING, ALWAYS REPLACE THE SEAL-
ING RING WITH A NEW ONE.
Insert a new sealing ring in the gearbox cover,

making sure to bring it up to its stop using a rubber
hammer.
CHAS - 265
Chassis V100 E5
Insert the gearbox cover on the sprocket hub.

Position the complete sprocket hub with gearbox
cover in a suitable press, using suitable supports.
WARNING
BEFORE USING THE PRESS, ENSURE THAT THE SUP-
PORTS USED REST EVENLY ON THE SURFACE OF THE
COVER IN ORDER TO PREVENT DAMAGE TO COMPO-
NENTS.
Operate the press in order to assemble the case

cover from the sprocket hub.
Insert a new o-ring on the sprocket hub.
Lubricate the bevel gear teeth during assembly.
CHAS - 266
V100 E5 Chassis
Place the first shim on the mating surface with the

cover, aligning it with the profile of the case itself.
Place the second shim with the inscription on the

upper side.
Insert the complete sprocket hub with the cover

into the gearbox.
CHAS - 267
Chassis V100 E5
Insert all fixing screws on the case cover.
Tighten the screws to the prescribed torque, ob-

serving a crosswise sequence.
Place the specific tool in a vice and secure it prop-

erly.
Specific tooling
Place the complete gearbox on the specific tool.

Use the screws to secure the complete gearbox to
the swingarm and lock the gearbox to the specific
tool.
Pay attention because the lower screws are equip-
ped with a locking nut.
Insert a new o-ring on the pinion, lubricating it be-
fore assembly.
CHECK THAT THE NEW O-RING IS COMPLETELY SEATED
AROUND ITS PERIMETER.
CHAS - 268
V100 E5 Chassis
Insert a new sealing ring inside the ring nut, mak-

ing sure to bring it up to its stop.
Insert a new oil seal in the ring nut.
Insert the supplied flange with the specific tool on

the sprocket hub, bringing it into contact with the
case cover.
Screw the specific tool arm onto the flange.
CHAS - 269
Chassis V100 E5
Clean the ring nut perfectly before assembly.

Use the specific tool by inserting the relevant bolts
in the holes of the ring nut.
Specific tooling
Using the tool, insert the ring nut on the pinion.
Using the specific tool, tighten the ring nut to the

prescribed torque.
CHAS - 270
V100 E5 Chassis
Insert the sleeve.
Insert the flanged nut.
Tighten the pinion fixing flange nut to the prescri-

bed torque.
Insert the shim with the chamfer facing the cap.
CHAS - 271
Chassis V100 E5
Make sure the shim is correctly positioned in its

seat.
Insert the pinion fixing cap.
Tighten the pinion fixing cap to the prescribed tor-

que.
Unscrew the arm of the specific tool to release the

flange.
CHAS - 272
V100 E5 Chassis
Remove the supplied flange with the specific tool

from the sprocket hub.
Installing
• Install the bevel gear on the swingarm,

taking care to properly insert the car-
dan shaft in its splines.
• Insert the two lower fixing screws (4)

and tighten them to the prescribed tor-
que.

Bevel gear fixing screw 45 ± 6.5 Nm (33.19 ± 4.79 lb
ft)
• Insert the upper fixing screw (3) and

tighten it to the prescribed torque.

Bevel gear fixing screw 45 ± 6.5 Nm (33.19 ± 4.79 lb
ft)
CHAS - 273
Chassis V100 E5
• Insert the ABS sensor (2) in the corre-

sponding seat on the bevel gear.
• Tighten the fixing screw (1) of the ABS

sensor (2).
• Top up the oil following the instructions in the "Maintenance / Transmission oil / Replace-
ment" chapter
See also
Replacement
Stand
CHAS - 274
V100 E5 Chassis
STAND
1 Nut for fastening the stand to the M8 1 25 ± 3.5 Nm (18.44 ± -
stand plate 2.58 lb ft)
2 Stand switch lock pin M6 1 10 ± 2 Nm (7.38 ± 1.48 Pre-applied Loct.
lb ft) 243
3 Pin fastening the spring to the stand M8 1 25 ± 5 Nm (18.44 ± 3.69 Pre-applied Loct.
plate lb ft) 243
4 Pin fastening the spring to the stand M6 1 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
5 Stand switch fixing nut M6 1 10 ± 2 Nm (7.38 ± 1.48 -
lb ft)
6 Stand sensor cable guard fixing M5 2 5.5 ± 1 Nm (4.06 ± 0.74 Pre-applied Loct.
screws lb ft) 243
7 Screws fastening the stand plate to M8 2 25 ± 3.5 Nm (18.44 ± -
the engine crankcase 2.58 lb ft)
Side stand
REMOVAL
• First remove the left rider footrest plate.

• Remove the two fixing screws and re-
move the protection of the stand
switch.
• Cut the plastic clamp.
• Remove the nut (1).
• Remove the switch from the side

stand.
CHAS - 275
Chassis V100 E5
• Remove the two fastening screws (2).

prescribed torque.

Side stand fixing screw 25 ± 3.5 Nm (14.75 ± 2.58 lb
ft)
• Remove the stand and the correspond-

ing support from the vehicle.
Exhaust
CHAS - 276
V100 E5 Chassis
SILENCER
1 Screw fastening outer silencer sup- M8 1 25 ± 5 Nm (18.43 ± 3.68 -
port bracket lb ft)
2 Upper silencer fixing screw to the M6 2 10 ± 2 Nm (7.37 ± 1.47 -
footrest lb ft)
3 Lower silencer fixing screw to the M8 1 25 ± 5 Nm (18.43 ± 3.68 -
footrest lb ft)
4 Fixing screw for silencer manifold M6 2 10 ± 2 Nm (7.37 ± 1.47 Screw with pre-ap-
protection lb ft) plied threadlocker
5 Fastening the silencer to the exhaust Pipe clamp 1 25 ± 5 Nm (18.43 ± 3.68 -
manifold lb ft)
6 Heat shield protection fastening M6 2 10 ± 2 Nm (7.37 ± 1.47 Screw with pre-ap-
screws lb ft) plied threadlocker
7 Heat shield protection fixing Pipe clamp 4 3 ± 0.6 Nm (2.21 ± 0.44 -
lb ft)
8 Lambda probe fastener M12x1.25 2 25 ± 5 Nm (18.43 ± 3.68 -
lb ft)
9 Exhaust manifold flange fastening M8 4 25 ± 5 Nm (18.43 ± 3.68 -
nuts lb ft)
10 Fixing screw for silencer support out- M6 2 10 ± 2 Nm (7.37 ± 1.47 -
er bracket lb ft)
11 Lower fixing screw for exhaust mani- M8 1 25 ± 5 Nm (18.43 ± 3.68 -
fold lb ft)
Removing the tail pipe
REMOVAL
• Undo the two fixing screws (1) and re-

move the heat shield (2).

prescribed torque.

Heat shield fixing screw (1) 10 Nm (7.38 lbf ft)
• Unscrew the clamp fastening the ter-

minal to exhaust pipe.
During refitting, tighten the clamp to the prescribed

torque.

Exhaust terminal clamp 25 Nm (18.44 lbf ft)
CHAS - 277
Chassis V100 E5
• Remove the screw and its fixing lock

nut used to fasten the terminal to the
frame.

scribed torque.

Support bracket terminal fastener 25 Nm (18.44 lbf
ft)
• Remove the exhaust terminal from the

vehicle.
Removing the exhaust manifold
EXHAUST MANIFOLD HEAT SHIELD

Unscrew the lower fixing screw of the heat shield.
NOTE
THESE OPERATIONS ARE ALSO VALID FOR THE HEAT
SHIELD ON THE OPPOSITE SIDE.
Unscrew the upper calmp located inside the heat

shield.
CHAS - 278
V100 E5 Chassis
Unscrew the lower calmp located inside the heat

shield.
Remove the heat shield from the exhaust manifold

by loosening the metal calmps.
When reassembling, loosen the calmps and place

the heat shield on the manifold.
Tighten the upper and lower clamps and the fixing
screw to the prescribed torque.
WARNING
DURING REASSEMBLY, USE NEW METAL CLAMPS.
• Remove the exhaust end first.

• Disconnect the lambda probe connec-
tor (1) on both sides.
CHAS - 279
Chassis V100 E5
• Remove the two nuts (2) of the exhaust

flange, on both heads.
During refitting, tighten the nuts to the prescribed

torque.

Exhaust flange fixing nut 25 ± 4 Nm (14.75 ± 2.95 lbf
ft)
• Remove the lower fastener screw (3).
During refitting, tighten the screw (3) to the pre-

scribed torque.
NOTE
Once tightened to torque, the fastening screw (3) must
project by of 5 -10 mm from the exhaust support. This is to
compensate for the metal deformations due to heat.

Lower screw fastening the exhaust manifold 25
± 4 Nm (14.75 ± 2.95 lbf ft)
• Remove the entire exhaust system

from the vehicle.
• Retrieve the copper gasket (4) from

both heads.
DURING REFITTING, USE NEW COPPER GASKETS.
CHAS - 280
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system V100 E5
FRONT BRAKE MASTER CYLINDER

1 Screws fixing brake pump clamp to M6 2 10 ± 1.5 Nm (7.38 ± 1.11 -
the handlebar lb ft)
FRONT BRAKE CALLIPER

1 Screws fastening front brake calliper M10x1.25 2+2 50 ± 5 Nm (36.88 ± 3.69 -
lb ft)
BRAK SYS - 282

V100 E5 Braking system
REAR BRAKE MASTER CYLINDER

1 Rear brake rod lock nut M6 1 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
2 Rear brake pump fastening screws M6 2 10 ± 1.5 Nm (7.38 ± 1.11 -
lb ft)
3 Brake oil tank fixing screw M6 1 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
4 Brake switch fixing screw M5 1 6 ± 1 Nm (4.23 ± 0.74 lb -
ft)
5 Rear brake lever rod screw M6 1 8 ± 1 Nm (5.90 ± 0.74 lbf -
ft)
6 Spring coupling pin for brake lever M5 2 6 ± 1 Nm (4.43 ± 0.74 lbf -
ft)
7 Brake switch cable gland M4 2 3 ± 0.5 Nm (2.21 ± 0.37 -
lbf ft)
8 Rear brake lever fixing pin M8 1 25 ± 3.5 Nm (18.44 ± -
2.58 lbf ft)
REAR BRAKE CALLIPER

1 Rear brake calliper fixing screws M10 2 50 ± 5 Nm (36.88 ± 3.69 -
lb ft)
Interventions rules
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
BRAK SYS - 283

ABS
ABS CONTROL UNIT

Key:
1. ABS control unit

2. Rear ABS sensor
3. Front ABS sensor
4. Ignition switch
5. Battery
6. Fuse
Modulator
REMOVAL
• Drain the brake system completely.

• First remove the fuel tank, the air filter
housing, the radiator and the expan-
sion tank.
• Unscrew the fittings of the brake pipes
from the ABS modulator.
BRAK SYS - 284

• Remove the joints and collect the seal-

ing washers from each pipe.
DURING REFITTING, USE NEW SEALING WASHERS.
• Remove the jig (1) for pipe positioning

from the ABS modulator.
• Remove the lower fixing nut (2).
• Remove the ground cable (3) from the

lower fixing of the modulator.
BRAK SYS - 285

• Remove the lateral fastener screw (4).
• Remove the ABS modulator from its

seat.
• Press the safety tab and push the con-
nector locking lever (5) forward.
• Disconnect the modulator connector.
• Remove the modulator from the vehi-

cle.
INSTALLATION
• Install the new modulator unit, complete with ABS control unit, completely pre-filled with
brake fluid and with the connection mounting holes closed with protective plugs
• To keep the brake fluid in the ABS control unit, first remove the protective plugs from the
feed holes to the brake callipers, then connect the corresponding pipes
BRAK SYS - 286

• Once the brake calliper pipes are connected, remove the protective caps from the inlet ports
from the brake pumps and connect the respective pipes to the ABS modulator
• Remove the plugs of the brake pump tanks and fill them with new brake fluid
CAUTION
PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED AT
THE END OF THE CHAPTER.
• Fill the reservoirs and refit the caps
• Check the stroke and sensitivity of the front brake lever and the rear brake pedal
• If the brake pedal or lever stroke is too long after carrying out the bleeding procedure, check
the braking system for leaks and, if none are found, bleed the system using the diagnostic
tool, as described.
• Disconnect the flexible bleeder pipes and re-tighten the bleeder screws, applying the correct
torque
ABS CONTROL UNIT CONNECTOR INSERTION PROCEDURE
• Check the initial position of the connection clip lever.
• When the connector is fully inserted,

the distance between the connector
and the ABS control unit must be 7.5
mm (0.29 in).
BRAK SYS - 287

• If the initial position of the connector

and the driving lever is not that shown
in fig. 1, the connector will not be prop-
erly coupled and the distance meas-
ured will be greater (12 mm approx.
(0.47 in)). In this case repeat the oper-
ation as described in the two previous
points.
WE RECOMMEND CREATING A TEMPLATE IN

ORDER TO ENSURE THAT THE CONNECTOR
IS INSERTED CORRECTLY.
Component maintenance
• The vehicle is equipped with two-chan-

nel ABS that operates both on the front
wheel and on the rear wheel. To do
this, the system uses sensors and tone
wheels on both wheels; the one on the
rear wheel is integrated inside the bev-
el gear and does not require mainte-
nance.
• It is important to check periodically and
all times that the front wheel is refitted,
the front sensor (1) or tone wheel (2)
are replaced and that the distance is
consistent over all 360°. Use a thick-
ness gauge to check the distance be-
tween sensor (1) and tone wheel (2) at
three points at a 120° span.
CAUTION
IF THE READINGS SHOULD RETURN A VALUE OUTSIDE
OF THE FIELD OF TOLERANCE, REPLACE THE SENSOR
AND/OR THE PHONIC WHEEL AND REPEAT THE CHECK
IN ORDER TO ENSURE THAT THE VALUES FALL WITHIN
THE FIELD OF TOLERANCE.
BRAK SYS - 288

Characteristic
Distance between tone wheel and front sensor
0.5 - 1.50 mm (0.020 - 0.059 in)
TONE WHEEL CLEANING
• It is important to check regularly that the front tone wheel is clean. If this is not the case,
carefully remove any dirt using a cloth or a brush. Avoid using solvents or abrasive sub-
stances and do not direct air or water jets directly on the tone wheel.
REPLACING THE PHONIC WHEEL SENSOR
• Disconnect the front phonic wheel sensor connector from the main wiring harness. Unscrew
and remove the screws and remove the phonic wheel sensor
CAUTION
BEFORE REFITTING, ENSURE THAT THE CONTACT SURFACES BETWEEN THE SENSOR AND
THEIR SEATS ARE FREE OF IMPERFECTIONS AND PERFECTLY CLEAN.
ALWAYS CHECK THE DISTANCE BETWEEN THE SENSOR AND THE PHONIC WHEEL.
Rear brake calliper
Removal
• Connect the bleed bottle to the calliper

bleeder screw and open it.
• Fully depress the rear brake lever and
secure it in place with a locking device
to prevent brake fluid from flowing out
of the open circuit.
• Close the calliper bleeder screw and
remove the bleeder bottle.
• Unscrew the rear brake pipe union
screw.
• Remove the screw from the brake pipe

fitting and retrieve the two sealing
washers.
BRAK SYS - 289

• Remove the two rear brake calliper fix-

ing screws (1).

prescribed torque.
NOTE
TO REMOVE THE BRAKE CALLIPER, IS NOT NECESSARY
TO REMOVE THE REAR WHEEL.

lbf ft)
• Remove the rear brake calliper from

the vehicle.
NOTE
TO REMOVE THE BRAKE CALLIPER, IS NOT NECESSARY
TO REMOVE THE REAR WHEEL.
Installing
• Completely insert the piston inside the

calliper, so as to widen the brake pads.
• Install the brake calliper on the vehicle,
inserting the brake disc inside.
NOTE
FOR THE INSTALLATION OF THE BRAKE CALLIPER, IT IS
NOT NECESSARY TO REMOVE THE REAR WHEEL.
• Install the two fixing screws (1) and

tighten them to the specified torque.
NOTE
FOR THE INSTALLATION OF THE BRAKE CALLIPER, IT IS
NOT NECESSARY TO REMOVE THE REAR WHEEL.

lbf ft)
BRAK SYS - 290

• Insert the screw and the associated

seal washers in the brake pipe fitting,
in the order shown in the figure.
• Install the brake pipe on calliper and

tighten the special screw of the fitting.
• Remove the brake oil tank cap and fill it with new brake fluid.
CAUTION
• Top up the oil tank and refit the cap.
• Check the stroke and sensitivity of the brake pedal.
• If, after bleeding, the pedal travel is too long, check the brake system for leaks and, if all is
well, bleed using the diagnostic tool as described.
• Disconnect the flexible bleeder pipes and re-tighten the bleeder screws, applying the correct
torque.
Front brake calliper
Removal
NOTE
THE FOLLOWING PROCEDURE IS TO BE CONSIDERED VALID FOR BOTH FRONT BRAKE CAL-
LIPERS.
BRAK SYS - 291

• Using a rubber pipe, connect a con-

tainer to the bleed screw (1) and loosen
it to allow the fluid to flow.
• Press thoroughly the brake lever and
lock it in position, in order to prevent
fluid leakages from the brake pipe.
• Tighten the bleed screw (1) and re-
move the container.
• Remove the special screw (2) from the

brake calliper and collect the sealing
washers (3)
• Remove the fixing screws (4) and re-

move the brake calliper from the vehi-
cle.
Installing
NOTE
THE FOLLOWING PROCEDURE IS TO BE CONSIDERED VALID FOR BOTH FRONT BRAKE CAL-
LIPERS.
• Insert the brake calliper (5) on the disc
and tighten the fixing screws (4) to the
prescribed torque.

lbf ft)
BRAK SYS - 292

• Insert the special screw (2) in the brake

pipe couplings using new sealing
washers (3).
• Install the screw / joints assembly on

the brake calliper and tighten the spe-
cial screw (2).
• Remove the clamp from the front brake lever.

• Remove the brake fluid reservoir cap and fill it with new brake fluid
CAUTION
• Top up the fluid reservoir and refit the cap
• Check the stroke and sensitivity of the brake lever
• If, after bleeding, the lever stroke is too long, check that there are no leaks in the braking
system. If there are no leaks, proceed with bleeding operations using the diagnostic tool.
• Detach the hoses and tighten the bleed screws.
Rear brake disc
BRAK SYS - 293

Removal
• First remove the rear wheel.
• Remove the two screws (1) fastening
the rear brake calliper.

prescribed torque.

Rear brake calliper fixing screw 50 ± 5 Nm (36.88 ±
3.69 lbf ft)
• Remove the brake calliper from the

swingarm and fasten it to the vehicle,
so as not tighten the oil pipe and the
wiring harness of the ABS sensor.
• Remove the rear brake disc together

with the flange from the rear wheel hub.
• Unscrew the fixing screws (2) and re-

move the brake disc (3) from the sup-
port flange (4).
WHEN REFITTING, MAKE SURE THAT THE MARKINGS ON

THE BRAKE DISC ARE FACING UPWARD.
Disc Inspection
REAR
CAUTION
BRAK SYS - 294

THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI-
FICATIONS OF THE SYSTEM.
• The following operations must be car-
ried out with brake disc fitted on the
wheel.
• Check the disc for wear by measuring
the minimum thickness with a micro-
meter in different points. If the mini-
mum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.
Disc thickness minimum value: 4 mm (0.16 in)
Front brake disc
Removal
THE OPERATIONS REFER TO ONE BRAKE

DIS, BUT ARE VALID FOR BOTH.
• First remove the front wheel.

• Working on the right side, unscrew the
six fixing screws (1) and remove the
tone wheel (2) from the wheel.
• Remove the right hand front brake disc

(3) from the wheel.
Disc Inspection
FRONT
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
BRAK SYS - 295

• The following operations must be car-

ried out with the brake discs fitted on
the wheel; they refer to a single disc,
but are valid for both.
• Check the disc for wear by measuring
the minimum thickness with a micro-
meter in different points. If the mini-
mum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.
Disc thickness minimum value: 4 mm (0.16 in)
• Using a dial gauge, check that the max-

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

with respect to the wheel centre line.
Installing
THE OPERATIONS REFER TO ONE BRAKE

DIS, BUT ARE VALID FOR BOTH.
• Position the brake disc (3) on the wheel

hub, making sure that the markings on
the brake disc face outwards. Also
check the correct direction of rotation,
indicated by the arrow stamped on the
disc.
• Fit the tone wheel (2) on the brake disc

and install the six fixing screws (1).
• Progressively tighten the fixing screws
(1) following the A-B-C-D-E-F se-
quence and bring them to the specified
tightening torque.

ft)
BRAK SYS - 296

Front brake pads
Removal
THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT
SIDE).
ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS.
REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE
STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE-
HICLE ITSELF.
CAUTION
THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER, BUT APPLY TO BOTH.
To remove the front brake pads proceed as de-
scribed:
• Remove the cotter pin (1) from the pin.
• Unscrew the pin (2) and remove it from

the calliper.
• Remove the spring (3) from the brake

calliper.
BRAK SYS - 297

• Remove the external pad (4) from the

calliper.
• Remove the internal pad (5) from the

calliper.
DO NOT OPERATE THE BRAKE LEVER ONCE THE BRAKE

PADS HAVE BEEN REMOVED, AS THIS MAY FORCE THE
PISTONS OUT FROM THEIR SEATS AND ALLOW BRAKE
FLUID TO ESCAPE.
Installing
THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT
SIDE).
ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS.
REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE
STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE-
HICLE ITSELF.
CAUTION
THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER, BUT APPLY TO BOTH.
• Fit the internal pad (5) in the calliper,
making sure that the support arm is
facing the lower part.
BRAK SYS - 298

• Install the external pad (4) in the cal-

liper, making sure that the support arm
is facing the upper part.
• Install the spring (3) in the calliper.
• Insert the fixing pin (2) in the calliper,

ensuring that it passes over the spring
and that it is correctly inserted pad
bushes.
• Once correctly inserted, tighten it firm-
ly.
• Insert the cotter pin (1) on the pin.

• When installation is complete, press
the brake lever several times to release
the pistons from the calliper and bring
the pads into position.
Rear brake pads
BRAK SYS - 299

Removal
• Press the brake calliper, from the out-

side, to retract the piston.
• Remove the cotter pins (1) from the

pin.
Remove the pin (2) from the brake calliper.
• Remove the external brake pad (3)

from the calliper.
BRAK SYS - 300

• Remove the internal brake pad (4) from

the calliper.
Installing
• Insert the internal pad (4) in the calliper

and lock it in position by inserting the
pin (2) in the relative eyelet of the pad.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY

ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
• Insert the external pad (3) in the brake

calliper and insert completely the pin
(2), bringing it to the end with the brake
calliper.
• Insert the two cotter pins (1) on the pin.

• When installation is complete, press
the brake lever several times to release
the pistons from the calliper and bring
the pads into position.
BRAK SYS - 301

MAKE SURE THAT THE FRONT PART OF THE

PADS IS INSERTED CORRECTLY IN ITS SEAT
ON THE BRAKE CALLIPER SUPPORT.
Bleeding the braking system
PREPARATION OF THE VEHICLE
• Place the vehicle on a flat surface and

in vertical position.
• Protect the areas around the front and/
or rear brake fluid tanks, avoiding un-
der any circumstances that the fluid
comes into contact with the bodywork
and/or painted parts of the vehicle.
• The use of a pneumatic bleeding de-
vice facilitates these operations, espe-
cially when, in addition to just bleeding,
the brake fluid also needs to be
changed.
Front
TRADITIONAL BLEEDING SYSTEM
WARNING
BLEED BOTH FRONT BRAKE CALLIPERS
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake and by poor braking.
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING THE BRAKE CALLIPERS AND RESTORING THE BREAKING SYSTEM TO ITS REG-
ULAR USE CONDITIONS, SO THAT THE HYDRAULIC CIRCUIT IS AIR PURGED.
BRAK SYS - 302

NOTE
THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY, BUT ARE
VALID FOR BOTH. THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE PURGING
THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF
BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN
THE RESERVOIR.
• Unscrew the two screws (1) and re-
move the cap (2).
• Remove the protective rubber (3).
• Refill the tank with brake fluid.

CAUTION
DURING BLEEDING OPERATIONS, CONSTANTLY TOP UP
THE TANK SO THAT IT NEVER RUNS EMPTY. OTHERWISE
AIR WILL ENTER THE CIRCUIT AND THE BLEEDING OP-
ERATION WILL HAVE TO BE STARTED ALL OVER AGAIN.
• Remove the rubber cap from the bleed

valve.
BRAK SYS - 303

• Insert an 8 mm spanner on the bleed-

ing valve and attach a rubber hose (4)
to the valve connection.
• Connect the other end of the rubber
hose to a suitably sized container.
• FULLY press and release the front

brake lever quickly for several times.
• After four / five complete cycles, hold
the front brake lever fully depressed.
• Keeping the front brake lever de-

pressed, open the brake calliper bleed-
ing valve. This will drain the brake fluid
inside the container.
• Close the bleeding valve BEFORE re-
leasing the front brake lever.
• Repeat the "braking" and bleeding cy-
cles until the fluid coming out of the
calliper is free of air bubbles.
• Test the lever stroke and ensure that

the pressure does not feel "spongy". In
this case, air is still present in the cir-
cuit, which must be removed by re-
peating the above steps.
• After completing operations, tighten
the bleeding valve and remove the rub-
ber hose and spanner.
• Replace the rubber cap.
BRAK SYS - 304

• Top up the tank with brake fluid to the

correct level.
• Replace the protective rubber, the tank
cap and tighten the two fixing screws.
BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT

If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the
brakes using this type of procedure.
• With the diagnostic tool properly connected, select the function "FRONT BLEEDING" in the
section "SETTINGS".
• The pump starts running.
• While the pump is performing a rotation cycle, operate and release the front brake lever until
the message diagnostic tool cycle completion is received.
• This procedure allows the air to circulate and accumulate.
• Once the procedure with diagnostic tool is finished, perform again the REGULAR PURGING
to remove the air from the system completely.
Rear
TRADITIONAL BLEEDING SYSTEM
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake and by poor braking.
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING THE BRAKE CALLIPER TO RESTORE THE BRAKING SYSTEM TO ITS REGULAR
USE CONDITIONS, SO THAT THE HYDRAULIC CIRCUIT IS AIR PURGED.
NOTE
THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE PURGING THE HYDRAULIC
SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK
THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
BRAK SYS - 305

Rear brake circuit
• Unscrew the cap (1) of the rear brake

fluid tank.

CAUTION
DURING BLEEDING OPERATIONS, CONSTANTLY TOP UP
THE TANK SO THAT IT NEVER RUNS EMPTY. OTHERWISE
AIR WILL ENTER THE CIRCUIT AND THE BLEEDING OP-
ERATION WILL HAVE TO BE STARTED ALL OVER AGAIN.

valve.
BRAK SYS - 306

• Insert an 8 mm spanner on the bleed-

ing valve and attach a rubber hose (3)
to the valve connection.
• Connect the other end of the rubber
hose to a suitably sized container.
• FULLY press and release the rear

brake pedal quickly for several times.
• After four / five complete cycles, hold
the rear brake pedal fully depressed.
• Holding the rear brake pedal de-

pressed, open the brake calliper bleed-
ing valve. This will drain the brake fluid
inside the container.
• Close the bleeding valve BEFORE re-
leasing the rear brake pedal.
• Repeat the "braking" and bleeding cy-
cles until the fluid coming out of the
calliper is free of air bubbles.
• Test the pedal stroke and ensure that

the pressure does not feel "spongy". In
this case, air is still present in the cir-
cuit, which must be removed by re-
peating the above steps.
• After completing operations, tighten
the bleeding valve and remove the rub-
ber hose and spanner.
• Replace the rubber cap.
BRAK SYS - 307


correct level.
• Replace the protective rubber and
screw the tank cap back on.
BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT

If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the
brakes using this type of procedure.
• With the diagnostic tool properly connected, select the function "REAR BLEEDING" in the
section "SETTINGS".
• The pump starts running.
• While the pump is performing a rotation cycle, operate and release the rear brake pedal until
the message of diagnostic tool cycle completion is received.
• This procedure allows the air to circulate and accumulate.
• Once the procedure with diagnostic tool is finished, perform again the REGULAR PURGING
to remove the air from the system completely.
Changing the brake fluid

WARNING
WHEN CHANGING BRAKE FLUID, USE A PNEUMATIC PUMP FOR BLEEDING BRAKE SYSTEMS.
THE BRAKE FLUID MUST ALWAYS BE REPLACED IN EACH BRAKE CALLIPER OF THE VEHI-
CLE AND IN BOTH CIRCUITS.
• Place the vehicle on a flat surface and
in vertical position.
• Protect the areas around the front and
rear brake fluid tanks, avoiding under
any circumstances that the fluid comes
into contact with the bodywork and/or
painted parts of the vehicle.
BRAK SYS - 308

Front brake circuit

NOTE
THE OPERATIONS CONCERNING THE FRONT BRAKE CIRCUIT REFER TO ONLY ONE BRAKE
CALLIPER, BUT ARE VALID AND MUST BE CARRIED OUT ON BOTH.
• Unscrew the two screws (1) and re-
move the cap (2).
BRAK SYS - 309


valve.
• Insert an 8 mm spanner on the bleed

valve and attach the rubber hose (3),
from the pneumatic pump, to the valve
connection.
• Operate the pneumatic pump for

bleeding and open the bleeding valve
of the brake calliper.
• Repeat the steps until the fluid coming
out of the brake calliper is light-col-
oured; then close the bleed valve and
stop the pneumatic pump.
• Once the pump is stopped, remove the
rubber hose and spanner from the
brake calliper.
CAUTION
CONSTANTLY CHECK THAT THE LIQUID INSIDE THE
TANK NEVER FALLS BELOW THE MINIMUM LEVEL. TOP
UP WHEN NECESSARY, USING THE RECOMMENDED
PRODUCT.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC
956 DOT4
BRAK SYS - 310

• Check the brake lever stroke and that

the pressure does not feel "spongy".
Otherwise, it means that there is air in
the circuit and it must be bled.
• Once the operations are finished, re-

place the rubber cap on the bleeding
valve.

correct level.
• Replace the protective rubber and the
tank cap and tighten the fixing screws.
Rear brake circuit
• Unscrew the cap (1) of the rear brake

fluid tank.
BRAK SYS - 311


valve.
• Insert an 8 mm spanner on the bleed

valve and attach the rubber hose (3),
from the pneumatic pump, to the valve
connection.
BRAK SYS - 312

• Operate the pneumatic pump for

bleeding and open the bleeding valve
of the brake calliper.
• Repeat the steps until the fluid coming
out of the brake calliper is light-col-
oured; then close the bleed valve and
stop the pneumatic pump.
• Once the pump is stopped, remove the
rubber hose and spanner from the
brake calliper.
CAUTION
CONSTANTLY CHECK THAT THE LIQUID INSIDE THE
TANK NEVER FALLS BELOW THE MINIMUM LEVEL. TOP
UP WHEN NECESSARY, USING THE RECOMMENDED
PRODUCT.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC
956 DOT4
• Check the brake pedal stroke and that

the pressure does not feel "spongy".
Otherwise, it means that there is air in
the circuit and it must be bled.
• Once the operations are finished, re-

place the rubber cap on the bleeding
valve.
BRAK SYS - 313


correct level.
• Replace the protective rubber and
screw the tank cap back on.
Front brake pump
Removal
• Place a container under the pump to

collect the brake fluid.
• Remove the union screw from the pipe.
• Retrieve the two sealing washers.
• Remove the two fixing screws from the

front brake master cylinder.

bed torque.

Screw fastening front brake master cylinder 10
Nm (7.38 lbf ft)
BRAK SYS - 314

• Remove the U-bolt and front brake

master cylinder from the vehicle.
Rear brake pump
Rimozione

• Remove the union screw (1) and re-
trieve the sealing washers (2).
• Remove the fixing screw (3) of the rear

brake fluid tank.
• Remove the two screws (4) fixing the

brake pump to the right-hand rider foot-
rest mounting plate.
BRAK SYS - 315

• Remove the rear brake pump from the

vehicle.
REAR BRAKE FLUID RESERVOIR REMOVAL

• Remove the metal clamp (1) and re-
move the rubber pipe (2) from the tank
(3).
• Remove the fixing screw (4) and re-
move the tank (3) from the vehicle.
Brake system lines
Removal
FRONT BRAKE PUMP PIPE - MODULATOR
• Open the upper rubber clamp (1) and

release the brake pipe from the pipe
grommet on the right fork stanchion.
• Remove the two pipe grommets from

the frame.
BRAK SYS - 316

• Unscrew the front brake pump connec-

tor.
• Remove the connector from the front

brake pump and collect the sealing
washers.
• Unscrew the connector from the mod-

ulator.
• Remove the connector from the mod-

ulator and collect the sealing washers.
BRAK SYS - 317

• Remove the brake pipe from the vehi-

cle as shown in the figure.
MODULATOR PIPE / RIGHT FRONT BRAKE

CALLIPER
• Remove the four pipe grommets from

the front brake pipe.

ulator.

BRAK SYS - 318

• Unscrew the connector from the brake

calliper.

brake calliper and collect the three
sealing washers.
NOTE
DURING REASSEMBLY, THE PIPE FROM THE MODULA-
TOR (2) GOES OVER THE CALLIPER COMMUNICATING
PIPE (3).

cle as shown in the figure.
FRONT BRAKE CALLIPERS CONNECTING

PIPE
• Remove the hose guide (1) from the

front mudguard.
BRAK SYS - 319

• Unscrew the connector from the brake

calliper.

brake calliper and collect the three
sealing washers.
NOTE
DURING REASSEMBLY, THE PIPE FROM THE MODULA-
TOR (2) GOES OVER THE CALLIPER COMMUNICATING
PIPE (3).
• Unscrew the connector from the front

left brake calliper.

left brake calliper and collect the three
sealing washers.
BRAK SYS - 320

• Remove from the vehicle the front

brake calliper connection pipe, as
shown in the figure
REAR BRAKE PUMP PIPE - MODULATOR
• Unscrew the connector of the rear

brake pump.
• Remove the connector of the rear

brake pump and retrieve the two seal-
ing washers.

ulator.
BRAK SYS - 321


• Release the rigid pipe from the lower

clip (1) used to fasten it to the frame.
• Release the rigid pipe from the upper

clip (2) used to fasten it to the frame,
located next to the throttle bodies.

cle, pulling it upward, as shown in the
figure.
BRAK SYS - 322

MODULATOR PIPE - REAR BRAKE CALLIPER
• Unscrew the modulator connector.

• Unscrew the rear brake calliper con-

nector.
• Remove the coupling from the rear

brake calliper and collect the sealing
washers.
BRAK SYS - 323

• Remove the screw fixing the pipe

grommet to the clutch housing.
• Release the rigid pipe from the lower

• Release the rigid pipe from the upper

• Cut the plastic clamp (3) and release

the hose guides (4) from the rear brake
pipe, leaving them fastened to the ABS
sensor cable.
BRAK SYS - 324

• Remove the brake pipe from the swing-

arm, passing it between the shock ab-
sorber and the mudguard, as shown in
the figure.

figure.
BRAK SYS - 325

INDEX OF TOPICS
CLUTCH SYSTEM CLU SYS

V100 E5 Clutch system
Removing the clutch master cylinder
CLUTCH PIPE
REMOVAL
• Drain the fluid completely from the

clutch control circuit.
• Unscrew the coupling of the clutch
master cylinder.
• Remove the connector from the clutch

master cylinder and collect the sealing
washers.
• Unscrew the control cylinder connec-

tor.
• Remove the connector from the clutch

control cylinder and collect the sealing
washers.
CLU SYS - 327

Clutch system V100 E5
• Remove the two pipe grommets from

the left beam of the frame.
• Pass the clutch pipe between the en-

gine and the frame, as illustrated in the
figure.
• Remove the clutch pipe from the vehi-

figure.
During refitting, make sure you pass the clutch pipe be-
tween the frame and the conduit of the electric system, as
shown in the figure.
FITTING
To refit, follow the removal procedures in reverse, bleeding the system after assembly is complete.
CLU SYS - 328

V100 E5 Clutch system
Removing the clutch slave cylinder
• Remove the union screw (1) and re-

trieve the sealing washers (2).
• Remove the two fixing screws (3) of the

rear shock absorber preload adjuster.

prescribed torque.

Preload adjuster fixing screw 10 ± 2 Nm (7.38 ± 1.48
lb ft)
• Remove the clutch cylinder (5) from the

clutch housing.
AFTER REFITTING, BLEED THE HYDRAULIC CIRCUIT OF

THE CLUTCH.
CLU SYS - 329

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

V100 E5 Cooling system
Coolant replacement
PERFORM THE INDICATED OPERATIONS WHEN THE ENGINE IS COLD.

• Place the vehicle upright and prepare
a container of adequate size under the
oil sump.
• Remove the filler plug of the expansion

tank.
• Remove the filler plug the radiator.
• Place a container of adequate dimen-

sions under the radiator.
• Remove the radiator drain plug and al-
low the fluid from the radiator to drain
into the container.
COOL SYS - 331

Cooling system V100 E5
• Remove the pipe from the "indicator

light" fitting on the water pump.
• Remove the bleed screw and allow the

coolant to drain completely from the
water pump.
Cooling circuit filling
• Insert the bleed screw on the water

pump using a NEW sealing washer
and tighten it to the specified torque.
• Refit the pipe on the "indicator light" fit-

ting of the water pump.
COOL SYS - 332

• Insert the drain screw of the radiator

with a NEW sealing washer and tighten
it to the specified torque.
• Refill the radiator with the Anti-freeze

liquid specified.
NOTE
Refill the radiator up to the lower edge of the filler plug.
• Install and tighten the radiator cap

properly.
COOL SYS - 333

• Fill the expansion tank with the speci-

fied anti-freeze liquid up to the MAX
mark.
• Fit the expansion tank cap.

• Start the engine and let it idle until the
radiator fan starts.
NOTE
THE COOLING SYSTEM OF V100 IS SELF-BLEEDING.
ONCE THE RADIATOR AND EXPANSION TANK ARE FIL-
LED CORRECTLY AND THE ENGINE IS RUNNING UNTIL
THE RADIATOR FAN COMES STARTS, NO FURTHER AC-
TION IS REQUIRED TO PURGE THE CIRCUIT.
Characteristic
Radiator cooling fan start-up
101° C
Radiator cooling fan shut-off
98° C
• Switch off the engine and top up the coolant level in the expansion tank.
Removing the radiator

• First remove the side fairings.
• Remove the screw fixing the horn.
COOL SYS - 334

• Disconnect the connectors and re-

move the horn from the vehicle.
• Remove the cap from the radiator.
• Place a container under the radiator,

remove the drain plug and completely
drain the coolant from the radiator.
• Unscrew the two upper fixing screws of

the radiator side fairing.
COOL SYS - 335

• Release the fairing from the relative re-

tainer to the radiator, sliding it down-
ward.
• Disconnect the turn indicator connec-

tor and remove the side fairing from the
vehicle.
• Repeat the operations for the fairing of
the side opposite side.
• Unscrew the two fixing screws (1) of

the fairing support (2) and remove the
support from the radiator, leaving it fas-
tened to the wiring harnesses.
• Repeat the operations described
above for the opposite side.
• Remove the radiator upper fixing

screw.
COOL SYS - 336

• Remove the second lower screw fas-

tening the radiator. (The first fastens
the horn and has been removed previ-
ously.)
• Open the metal clamp (3) and remove

the pipe that connects the radiator to
the expansion tank.
DURING REFITTING, USE A NEW CLAMP.
• Open the spring clamp (4) and remove

the breather pipe from the radiator.
• Loosen the metal clamp (5) and re-

move the left pipe from the radiator.
COOL SYS - 337

• Disconnect the electrical fan connector

(6) and pull the wiring harness out of
the vehicle.
• Loosen the metal clamp (7) and re-

move the right pipe from the radiator.
• Remove the radiator from the vehicle,

sliding it downward and by extracting it
laterally.
Removing the expansion tank

• First remove the side fairings and the
fuel tank.
• Place a container under the radiator,
remove the drain plug and drain the
coolant until the expansion tank is
empty.
NOTE
TO REMOVE THE EXPANSION TANK IS NOT NECESSARY
TO REMOVE THE RADIATOR.
COOL SYS - 338

• Open the metal clamp and remove the

pipe that connects the radiator to the
expansion tank.
DURING REFITTING, USE A NEW CLAMP.
• Remove the fixing screw.
• Lift the rear part of the expansion tank

to remove it from its housing on the
ABS modulator.
• Pass the load cap between the frame

beams.
COOL SYS - 339

• Remove the expansion tank from the

vehicle.
Thermostatic valve
Removing
• Preventively remove:
1. The top fairing;

2. The side fairings;
3. The fuel tank;
4. The air filter housing;
5. The throttle bodies.
• Open the filler cap and remove the ra-

diator bleed screw (shown in the fig-
ure), so that the coolant is completely
drained from the circuit.
• Disconnect the coolant temperature

sensor connector (1).
COOL SYS - 340

• Remove the front fixing screw (2) and

retrieve the corresponding cup wash-
er.
• Remove the two rear fixing screws (3)

and retrieve the relative cup washers.
• Remove the metal clamps (4) from the

sleeves connecting the valve to the ra-
diator.
• Disconnect the sleeves (5) from the

thermostatic valve.
COOL SYS - 341

• Remove the thermostatic valve as-

sembly from the vehicle.
• Remove the plate (6) from the thermo-

static valve
• Remove the O-ring (7).
REPLACE THE O RING UPON EACH REMOVAL.
COOL SYS - 342

• Remove the fitting (9).
• Remove the thermostatic valve (10)

from the valve body.
Installing
• Follow the removal operations but in

reverse order; be careful to carry out
the tightening of the fixing screws in
two different stages:
WARNING
BEFORE PLACING THE THERMOSTATIC VALVE ASSEM-

BLY, APPLY A THIN LAYER OF THREEBOND TO THE
CRANKCASE ALONG THE O-RING MATING SURFACE OF
THE THERMOSTATIC VALVE.

Pre-tightening 5 ± 1 Nm (3.69 ± 0.74 lbf ft) Final tight-
ening 12 ± 1 Nm (8.85 ± 0.74 lbf ft)
COOL SYS - 343

• Install:
1. The throttle bodies;

2. The air filter housing;
3. The fuel tank;
4. The side fairings;
5. The top fairing.
• Fill the cooling circuit following the pro-

cedure shown in the chapter: "Coolant
change".
COOL SYS - 344

INDEX OF TOPICS
BODYWORK BODYW
Bodywork V100 E5
Seat
• Rest the vehicle on its stand.

• Insert the key in the saddle lock located
on the left-hand side fairing.
• Turn the key clockwise to release the
passenger saddle from the lock.
• Lift the front part of the passenger sad-

dle and bring it toward the rear of the
vehicle to remove it.
• Now it is possible to access the storage
compartment of the vehicle.
• Lift the rear part of the rider saddle,

bring it toward the rear of the vehicle to
release it from the relative supports
and then remove it from the vehicle.
• Once the driver and passenger sad-
dles are removed, you will have access
to the vehicle's battery.
Refitting the saddles:
• Move the rider saddle rider in its posi-

tion, taking care to insert the central
fastener and the two front fasteners in
the relative seats.
BODYW - 346
V100 E5 Bodywork
• Insert the rear fastener of the passen-

ger saddle in its support on the vehicle.
• Keeping the saddle in position, press
downward the front part to engage the
lock.
Instrument panel
REMOVAL
• First remove the front light cluster.

• Remove the LH fixing screws of the
adjustable frame windshield.
• Remove the RH fixing screws of the

adjustable windshield frame.
• Remove the windshield frame (1) from

the instrument support.
NOTE
During refitting, make sure to insert the centring pins (2)
in their seats of the instrument panel.
BODYW - 347
Bodywork V100 E5
• Release the connector from the instru-

ment support.
• Disconnect the connector of the wiring

harness of the adjustable windshield,
then remove the frame of the wind-
shield itself from the vehicle.
• Disconnect the connector of the instru-

ment panel wiring harness.
• Unscrew the three fixing screws of the

instrument panel and retrieve the rela-
tive washers.
BODYW - 348
V100 E5 Bodywork
• Remove the instrument panel from the

three rubber bushings and remove it
from the vehicle.
Headlight assy.
FRONTAL SPOILER REMOVAL
• First remove the top fairing and the

side fairings.
• Remove the left-hand fixing screw.
• Remove the right-hand fixing screw.
• Remove the spoiler from its housing.

NOTE
During refitting, make sure to insert the pegs (1) in their
seats on the vehicle.
BODYW - 349
Bodywork V100 E5
• Disconnect the wiring harness connec-

tor and remove the spoiler from the
vehicle.
FRONT HEADLAMP REMOVAL
• Remove the front spoiler.

• Remove the two upper fixing screws.
• Remove the two lower fixing screws.
• Remove the headlamp from its hous-

ing.
• Remove the safety (1) from the con-
nector to release it.
BODYW - 350
V100 E5 Bodywork
• Disconnect the connector from the

headlamp.
• Remove the headlamp from the vehi-

cle.
Horn
REMOVAL
• Remove the fixing screw of the horn/

lower radiator support.
• Disconnect the two connectors and re-

move the horn from the vehicle.
BODYW - 351
Bodywork V100 E5
Turn indicators
REMOVING FRONT TURN INDICATORS
• First remove the side fairings.

• Unscrew the two upper fixing screws of
the radiator side fairing.
• Release the fairing from the relative re-

tainer to the radiator, sliding it down-
ward.
• Disconnect the turn indicator connec-

tor and remove the side fairing from the
vehicle.
• Repeat the operations for the fairing of
the side opposite side.
• Remove the nut (1) and the fixing

screw (2).
BODYW - 352
V100 E5 Bodywork
• Release the retaining claw (3) from the

inside of the radiator side fairing.
• Remove the turn indicator (4) from the

radiator side fairing.
• Repeat the removal operations for the
turn indicator on the opposite side.
REAR TURN INDICATORS REMOVAL
• Remove the four fixing screws (1) of

the lower cover (2) of the licence plate
support.
• Remove the cover (2) from the vehicle.
BODYW - 353
Bodywork V100 E5
• Disconnect the connectors of the turn

indicators.
NOTE
THE RED AND BLUE WIRING HARNESS OF THE VEHICLE
IS CONNECTED TO THE RIGHT TURN INDICATOR.
• Remove the fixing screw (3), holding

the nut from the rear.
• Remove the turn indicator (4) from the

vehicle by sliding the wiring harness
inside the licence plate support.
• Repeat the operation for the turn indi-
cator on the opposite side.
Headlight fairing
REMOVAL
• Remove the four screws fixing the

windshield and retrieve the relative
washers.
BODYW - 354
V100 E5 Bodywork
• Remove the windshield from the vehi-

cle.
• Remove the five fixing screws of the

lower front fairing element.
• Remove the front lower fairing from the

vehicle, pulling it downward.
• Unscrew the two fixing screws of the

right internal cover of the top fairing.
BODYW - 355
Bodywork V100 E5
• Remove the right internal cover from

the vehicle.
• Repeat the operation for the left cover.
• Remove the four fixing screws of the

upper front fairing.
• Lifting with the hands the points indi-

cated in the figure, release the front
upper fairing (1) from the side fairings
(2).
• Remove the front upper fairing from the

vehicle sliding it upward.
BODYW - 356
V100 E5 Bodywork
• Retrieve the top fairing side moulding,

on both sides.
Disassembling the lock
REMOVAL
• First remove the left fairing.

• Remove the screw (1) and the washer
(2) fastening the lock lever.
• Lift the lever from the lock pawl lock

and remove it.
NOTE
When removing, pay attention to the spring that is pre-loa-
ded.
• Remove the spring from the pawl.
BODYW - 357
Bodywork V100 E5
• Remove the pawl extracting it from the

external side from the fairing.
• Remove the plate (3).
• Remove the clip fixing the pawl.
FITTING
• Insert the pawl in the left side fairing,

taking care to insert the guide (4) into
its seat of the fairing.
BODYW - 358
V100 E5 Bodywork
• Install the plate (3), taking care to insert

the centring holes in the relative guides
on the fairing.
• Install the fastening clips of the pawl.
• Install the spring on the pawl, taking

care to insert the lower pin in its seat
on the pawl.
• Insert the upper pin of the spring in the

corresponding hole on the lever.
• Turn the lever to preload the spring and
then insert the lever into its seat on the
pawl.
BODYW - 359
Bodywork V100 E5
• Install the washer (2) and tighten the

fixing screw (1).
Taillight assy.
REMOVAL
• First remove the rear handle, the stor-

age compartment and the panels of the
tail fairing.
• Remove the rear screw (1) on both
sides.

holder.
BODYW - 360
V100 E5 Bodywork

the rear light cluster.
• Remove the rear light cluster from its

seat.
Disconnect the connector (5) and remove the light

cluster from the vehicle.
License plate light
REMOVAL

support.
BODYW - 361
Bodywork V100 E5
• Disconnect the license plate light con-

nector (3).
• Remove the two fixing screws (4) and

extract the license plate light (5) from
the license plate support.
Rider footrest plate
RIGHT FOOTREST PLATE REMOVAL
• Remove the two rear brake pump fas-

tener screws (1).
BODYW - 362
V100 E5 Bodywork
• Remove the pump from the footrest

plate and fix it to the vehicle.
• Remove the upper fixing screw (2) and

retrieve the washer (3).

scribed torque.

Footrest plate fixing screw 25 ± 3.5 Nm (14.75 ± 2.58
lb ft)
• Remove the two lower fixing screws (4)

and retrieve the relative washers (5).

prescribed torque.

lb ft)
• Retrieve the bushings (6) from the low-

er fasteners of the footrest.
BODYW - 363
Bodywork V100 E5
• Remove the screw (7) fixing the stop

sensor to the footrest plate.

scribed torque.
• Remove the right footrest plate from

the vehicle.
REMOVING THE REAR BRAKE LEVER
• Remove the O. R. (1) from the fork of

the rear brake actuator.
• Remove the safety pin (2) from the rear

brake actuator fork.
• Remove the rear brake actuator from
the brake lever.
BODYW - 364
V100 E5 Bodywork
• Release the return spring (3) of the lev-

er from the right footrest bracket.
• Remove the spring (3) from the rear
brake lever.
• Remove the screw / pin (4) fastening

the rear brake lever.
During refitting, tighten the pin to the prescribed

torque.
• Retrieve the pin (4), the two O. R. (5)

and the washer (6).
LEFT FOOTREST PLATE REMOVAL
• Remove the fixing screw (1) holding

the nut (2).

scribed torque.

lb ft)
BODYW - 365
Bodywork V100 E5
• Remove the screw (1) and retrieve the

washer (3).
• Remove the fixing screw (4) and re-

trieve the washer (5).

scribed torque.

lb ft)
• Once the fixing screw is removed (4),

retrieve the bushing (6) placed be-
tween the footrest and the engine
block.
• Remove the upper fixing screw (7) and

retrieve the washer (8).

scribed torque.

lb ft)
BODYW - 366
V100 E5 Bodywork
• Rotate the footrest to reach the trans-

mission (9) of the gearbox lever and
remove the safety clip (10).
• Remove the transmission (9) from the

gearbox lever and remove the left foot-
rest plate (11) from the vehicle.
REMOVING THE GEAR SHIFT LEVER
• Unscrew the screw / fixing pin (1), hold-

ing the nut (2).
During refitting, tighten the pin to the prescribed

torque.
• Retrieve the nut (2) and the washer (3).
BODYW - 367
Bodywork V100 E5
• Remove the gear lever from the foot-

rest plate.
• Retrieve the pin (1), the O. R. (4) and
the washer (5).
Passenger footrest plate
LEFT FOOTREST PLATE REMOVAL

prescribed torque.

lb ft)
• Remove the left footrest plate from the

vehicle.
RIGHT FOOTREST PLATE REMOVAL
• Holding the nut (1), unscrew the fixing

screw (2) of the exhaust end.
BODYW - 368
V100 E5 Bodywork

prescribed torque.

lb ft)
• Remove the right footrest plate from

the vehicle.
Footrest
NOTE
The following procedure is valid for both rider and passenger footrests and can be performed
also with footrest plates fitted on the vehicle.
REMOVAL
• Remove the cotter pin (1).
• Collect the washer (2).
BODYW - 369
Bodywork V100 E5
• Remove the pin (3) and remove the

footrest from the footrest support plate.
• Retrieve the return spring (4) from the

footrest.
REMOVING THE NON-SLIP RUBBER
• Remove the two screws (1)
• Remove the non-slip rubber (2) from

the footrest.
BODYW - 370
V100 E5 Bodywork
• Remove the fastening plate (3) from

the anti-slip rubber (2).
NOTE
The left rubbers are marked with "L" and the right with "R"
and can be fitted both for the rider and for the passenger.
Side body panels
REMOVAL
The operations described below refer to the left
side fairing, but are valid for the right side fairing
as well, excluding the operations concerning the
saddle lock.
• First remove the rider saddle.

• Remove the two expansion caps.
• Release the fairing from the tank mov-

ing it toward the rear of the vehicle.
• Release the saddle opening cable from

the support, by lifting it up.
BODYW - 371
Bodywork V100 E5
• Remove the cable from the operating

lever, then remove the fairing from the
vehicle.
Glove-box
REMOVAL
• First remove the rear handle.

• Remove the five fixing screws.
NOTE
To remove the storage compartment it not is necessary to
remove the tail fairing panels.
• Lift the storage compartment from the

tail fairing.
• Disconnect the USB port connector

and remove the compartment from the
vehicle.
BODYW - 372
V100 E5 Bodywork
Side fairings
REMOVAL
• First remove the top fairing.

then remove the cover of the tank (1)
from the vehicle.
NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO THE
REMOVAL OF ONLY ONE SIDE PANELLING, BUT ARE
VALID FOR BOTH.
• Remove the expansion cap on the in-

side of the fairing.
• Remove the fixing screws indicated in

the figure.
• Remove the upper fixing screw.
BODYW - 373
Bodywork V100 E5
• Remove the lower fastening screw.
• Remove the three rear fixing screws.
• Release the front fasteners by pulling

the side fairing outward.
• Move the fairing toward the rear to re-

lease it from the fuel tank.
BODYW - 374
V100 E5 Bodywork
• Disconnect the connector of the aero-

dynamic guard's wiring harness, then
remove the fairing from the vehicle.
AERODYNAMIC FLAP REMOVAL

Disconnect the battery and remove:
• top fairing
• front fairing cover;
• right and left instrument cluster;
• driver and passenger seat;
• fuel tank cover;
• left and right side fairing.
NOTE
THE FOLLOWING PROCEDURE IS ALSO VALID FOR THE
FLAP ON THE OTHER SIDE OF THE VEHICLE.
Unscrew the 9 fixing screws of the inner cover.
Remove the complete inner cover with the sup-

ports and actuator.
BODYW - 375
Bodywork V100 E5
Please note that there are washers on the 2 flap

fixing screws.
Turn the fairing and remove the flap.
If necessary, remove the mushroom-shaped

grommets from the fairing.
Place the complete inner cover with supports and

actuator on a steady surface.
BODYW - 376
V100 E5 Bodywork
Unscrew the fixing screws of the first plate.
Remove the first plate.
Unscrew the fixing screws of the second plate.
Remove the second plate.
BODYW - 377
Bodywork V100 E5
Remove the fixing cir-clip of the actuator connect-

ing rod.
Remove the actuator connecting rod from the

bracket.
Remove the mount.
Unscrew the fixing screws for the actuator assem-

bly from the additional support.
BODYW - 378
V100 E5 Bodywork
Remove the actuator assembly.
Unscrew the fixing screws for the actuator assem-

bly from the actuator bracket.
Remove the actuator assembly.
FITTING
For reassembly, carry out the operations descri-
bed for removal in reverse order, paying particular
attention to the mounting of the plates.
These in fact have a tooth that must be correctly
positioned in its slot on the inner cover.
BODYW - 379
Bodywork V100 E5
Once the flap has been inserted, before refitting

the inner cover, grease the seat for the 2 washers
properly.
Place the 2 washers on their respective seats on

the flap, then proceed to fixing the inner cover.
Fairing mounting panels
REMOVING THE RIGHT HAND UNDER-FAIR-

ING
• First remove the right side fairing.

BODYW - 380
V100 E5 Bodywork
• Remove the expansion cap (3).
• Move the under-fairing forward to re-

move it from the tail fairing.
BODYW - 381
Bodywork V100 E5
• Disconnect the connector (6).
• Operating from the internal side, re-

move the clip fastening the connector
(6) to the under-fairing.
• Cut the plastic clamp (7) as shown in

the figure.
• Remove the connector (8) from the un-

der-fairing.
BODYW - 382
V100 E5 Bodywork
• Press the fixing clip (9) with the clamps

and remove it from the under-fairing.
• Remove the right under-fairing from

the vehicle.
REMOVING THE LEFT HAND UNDER-FAIRING
• First remove the left side fairing.

BODYW - 383
Bodywork V100 E5
• Move the under-fairing forward to re-

move it from the tail fairing.
BODYW - 384
V100 E5 Bodywork
• Remove the connector (6) from its sup-

port on the under-fairing.
• Operating from the internal side, re-

move the clip (7) fastening the connec-
tor to the under-fairing.
• Remove the left under-fairing from the

vehicle.
License plate holder
REMOVAL
• First remove the tail fairing, the storage

compartment and the rear light cluster.
• Disconnect the connectors of the li-
cence plate light and of the rear turn
indicators.
• Remove the four fixing screws (1).
BODYW - 385
Bodywork V100 E5
• Remove the license plate holder (2)

from the vehicle.
Air box

• Loosen the two clamps (1) of the throt-
tle body manifolds.
• Open the clamp and disconnect the left

breather pipe (2) from the filter box.
• Remove the left fixing screw of the filter

box.
BODYW - 386
V100 E5 Bodywork
• Open the clamp and disconnect the

right breather pipe (3) from the filter
box.
• Remove the right fixing screw of the fil-

ter box.
• Remove the filter box from the vehicle

by extracting it upward.
DURING REASSEMBLY, ENSURE THE CORRECT INSER-

TION OF THE AIR FILTER HOUSING MANIFOLDS ON THE
THROTTLE BODIES.
• To remove the air filter inside the filter box, carry out the procedure described in paragraph
"air filter" in the "maintenance" chapter.
See also
Air filter
BODYW - 387
Bodywork V100 E5
Fuel tank
FUEL TANK COVER

REMOVAL
• First remove the rider saddle and the

side fairings.
• Open the tank plug.
• Remove the three external fixing
screws (1).
• Remove the internal fixing screw (2).
• Remove the tank cap from the tank it-

self.
• - Remove the two rear fixing screws.
BODYW - 388
V100 E5 Bodywork
• Remove the two fixing screws on the

right side of the tank.
• Remove the two fixing screws on the

left side of the tank.
• Remove the tank cover from the vehi-

cle, lifting it upward.
FUEL TANK
REMOVAL
• Remove the tank cover.

• Open the spring clamp (1) on both
sides.
CAUTION
BEFORE REMOVING THE TANK, EMPTY IT OF ALL GAS-
OLINE
BODYW - 389
Bodywork V100 E5
• Remove the vent pipe (2), on both

sides.
• Remove the safety tab from the fuel

pipe quick coupling.
• Press the fuel coupling on the sides

and simultaneously extract the pipe
from the coupling.
• Disconnect the connector of the fuel

pump / fuel level sensor wiring har-
ness.
BODYW - 390
V100 E5 Bodywork
• Remove the left-hand fixing screw.
• Remove the right-hand fixing screw.
• Remove the tank from the vehicle pull-

ing it upward.
FUEL LEVEL SENSOR

NOTE
The fuel level sensor can be removed even if the tank is mounted on the vehicle. The procedure
is the same as that described below, just remove the tank cover.
REMOVAL
• Disconnect the connector.
BODYW - 391
Bodywork V100 E5
• Remove the fixing nuts (1) of the flange

(2).
• Remove the flange (2) from the sensor

(3).
• Remove the sensor (3) from the tank

and retrieve the gasket (4).
Rear wheelhouse
REMOVAL
• Preventively remove: The battery, the

control unit, the tail fairing, the storage
compartment, the rear light cluster and
• Unscrew the screw fixing the rear
brake oil tank.
BODYW - 392
V100 E5 Bodywork
• Remove the internal fixing screw (1),

which can be reached from inside the
battery compartment.
• Remove the wiring harnesses from the

two cable glands shown in the figure.
• Extract the secondary fuse boxes from

the relative supports on the wheel arch.

BODYW - 393
Bodywork V100 E5

• Move the cover of the rear frame, in or-

der to remove the right fixing screw (4)
of the wheel arch.
• Move the cover of the rear frame, in or-

der to remove the left fixing screw (5)
of the wheel arch.
• Remove the lower fixing screw (6) on

the right side of the wheel arch.
BODYW - 394
V100 E5 Bodywork
• Remove the two rear screws (7).
• Lower the wheel arch and place it on

the rear wheel.
• Disconnect the connectors (8) and (9).
• Extract the starter relay (10) from its

support on the wheel arch.
• Extract the main fuse (11) from its sup-

port on the wheel arch.
BODYW - 395
Bodywork V100 E5
• Remove the fixing nut and remove the

SAS valve (12) from the wheel arch.
• Disconnect the connector (13).
• Remove the rear wheelhouse from the

vehicle.
Front mudguard
REMOVAL
• Remove the hose guide (1) from the

rear side of the mudguard.
BODYW - 396
V100 E5 Bodywork
• Remove the two RH fixing screws.
• Remove the two LH fixing screws.
• Remove the front mudguard (2) from

the vehicle.
Pannier mounting
REMOVAL
• First remove the tail fairing, the storage

compartment, the rear light cluster and
• Remove the two screws (1) fastening
the wheel housing to the side panniers
supports.
BODYW - 397
Bodywork V100 E5
• Remove the two screws (2) that join the

left and right supports.
• Remove the left support (5) from the

vehicle.
BODYW - 398
V100 E5 Bodywork
• Remove the right support (8) from the

vehicle.
Rear grab rail
REMOVAL
• Remove the passenger saddle.

• Remove the four fixing screws (1).
BODYW - 399
Bodywork V100 E5
• Remove the rear handle (2) from the

vehicle.
Instrument cluster support
REMOVAL
• First remove the front light assembly

and the instrument panel.
• Remove the connectors (1) and (2) on
the right side of the instrument panel
mount.
• Remove the connector (3) on the left

side of the instrument panel mount.
• Release the connector (4) from the rel-

ative slide on the instrument panel.
BODYW - 400
V100 E5 Bodywork
• Unscrew the upper fixing screw (5) and

the relative lock nut and retrieve the
two T-bushings.
During refitting, tighten the nut to the prescribed

torque.

Upper fixing screw (5) 10 Nm (7.38 lbf ft)
• Unscrew the upper fixing screw (6) and

the relative lock nut and retrieve the
two T-bushings.
During refitting, tighten the nut to the prescribed

torque.

Lower fixing screw (6) 10 Nm (7.38 lbf ft)
• Remove the instrument panel support

from the vehicle, sliding the wiring har-
nesses inside it.
Battery
• Make sure the ignition switch is set to

"KEY OFF";
• Remove the rider saddle;
• Disconnect the connector (1) of the
OBD2 socket;
• Remove the cable (2) of the GMP pro-
vision, moving it forward to release it
from its support;
BODYW - 401
Bodywork V100 E5
• Remove the two fixing screws (3);
• Release the plastic securing the bat-

tery from its mountings to the tank and
remove it by bringing it toward the rear
of the vehicle.
• Unscrew and remove the screw (4)

from the negative terminal (-).
• Move the negative lead (5) aside.
• Move the protection cap (6), unscrew
and remove the screw (7) from the pos-
itive terminal (+).
• Move the positive lead (8) aside.
• Grip the battery firmly and remove from
its seat.
• Put the battery away on a level surface,
in a cool and dry place.
CHECK THAT THE CABLE TERMINALS AND BATTERY

LEADS ARE:
• IN GOOD CONDITION (NOT CORRODED OR
COVERED BY DEPOSITS);
• COVERED BY NEUTRAL GREASE OR PE-
TROLEUM JELLY.
REMOVING THE BATTERY RESETS THE DIGITAL CLOCK

AND THE TRIP JOURNAL FUNCTIONS.
CAUTION
BODYW - 402
V100 E5 Bodywork
ONCE REMOVED, THE BATTERY MUST BE PUT AWAY IN

A SAFE PLACE OUT OF THE REACH OF CHILDREN.
INSTALLATION
• Follow the removal procedure in reverse order; be careful to FIRST CONNECT THE POS-
ITIVE CABLE (+) and then the negative cable (-).
Tail guard
REAR FAIRINGS REMOVAL
• First remove the passenger saddle, the

rider saddle and the rear handle.
• Remove the two upper fixing screws.
• Remove the lower fastening screw.
• Pull outward the front part of the fairing

and bring it toward the tank to release
it from the support then remove it from
the vehicle.
BODYW - 403
Bodywork V100 E5
• When refitting, first insert the rear tooth

securing the fairing into its housing on
the tail light.
• Repeat the operations for the fairing on
the opposite side.
BODYW - 404
A
ABS: 284
Air filter: 71–73, 387
B
Battery: 110, 133, 401
Brake: 289, 291, 293, 295, 297, 299, 308, 314–316
Brake calliper: 289, 291
Brake disc: 293, 295
Brake fluid: 308
Brake pads: 297, 299
Brake pump: 314, 315
Bulbs:
C
CAN line: 152
Cardan shaft: 250
Clutch: 85, 146, 327, 329
Coil: 141
coolant: 331
Coolant: 331
Cylinder: 327, 329
E
ECU:
Electric fan: 148
Electrical system: 7, 23, 91
Engine oil: 66
Engine temperature sensor: 136
Exhaust: 276, 278
Exhaust manifold: 278
F
Fairings: 373
Fork: 182, 183, 188, 197
Front wheel: 236
Fuel: 140, 165, 388
Fuel pump: 140, 165
Fuses: 115
H
Handlebar: 176
Headlight: 85, 349, 354
Horn: 351
I
Identification: 21
Instrument panel: 347
Intake pressure sensor: 135
K
Keys: 106
L
License plate holder: 385
M
Maintenance: 18, 59, 107, 288
Mirrors:
Mudguard: 396
O
Oil filter: 69
Oil pressure sensor: 144
R
Radiator: 334
Rear wheel: 246
Recommended products: 61
S
SAS valve actuator: 148
Scheduled maintenance: 59
Shock absorber:
Shock absorbers: 221
Side fairings: 373
Side stand: 147, 275
Side stand sensor: 147
Spark plug: 61
Spark plugs:
Stand: 147, 274, 275
Start-up: 113
T
Tank: 338, 388
Throttle body: 142, 167, 171
Top fairing:
Transmission: 22, 63
Turn indicators: 352
Tyres: 24

Moto Guzzi V100 Service

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Moto Guzzi V100 Service

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SERVICE STATION MANUAL

THE VALUE OF SERVICE

SPECIAL TOOLS S-TOOLS

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

POWER SUPPLY P SUPP

BRAKING SYSTEM BRAK SYS

CLUTCH SYSTEM CLU SYS

COOLING SYSTEM COOL SYS

Carry out the listed tests before delivering the vehicle.

PROCEED WITH THE UTMOST CAUTION WHEN HANDLING PETROL.

Tightening torques inspection

- Electric helmet compartment lock release switch (if applicable)

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC

TRADITIONAL BATTERY ACTIVATION PRO-

• Place the battery on a flat surface.

• Check that air bubbles come out of the

After performing the battery activation procedure,

Install the battery cover (2) and tighten the fixing

• Braking system liquid level (front and rear)

Static control after the test drive:

• Restarting when warmed up

• Hydraulic braking system

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

Specific operations for the vehicle

THE UNPACKING OF THE VEHICLE REQUIRES THE INTERVENTION OF 2 OPERATORS AND

• Cut the plastic strapping of the pack-

• Grasp the cardboard cover by the

LIFT THE CARDBOARD COVER VERTICALLY, DO NOT

• Store the cardboard cover away from

• Remove the boxes of the components

• Support the vehicle while the second

• Then remove the front retaining straps.

• Using suitable tools, remove the front

• Making sure that the platform remains

• Place the vehicle on the side stand and

• Remove the protective bags of the two

FITTING THE REAR-VIEW MIRRORS

• Screw the mirror into the clutch master

Locking torques (N*m)

• Position the mirror rod in line with the

Locking torques (N*m)

KEEP OUT OF THE REACH OF CHILDREN.

WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC-

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC

REASSEMBLING THE COMPONENTS

SERIAL NUMBER LOCATION

Dimensions and mass

DIMENSIONS AND MASS

Frame and suspensions

Wheels and tyres

RIMS AND WHEELS

FRONT BRAKE MASTER CYLINDER

FRONT BRAKE CALLIPER

FUEL TANK COVER

REAR BRAKE MASTER CYLINDER

REAR WHEEL TRANSMISSION

REAR WHEEL TRANSMISSION - COMPONENTS

REAR BRAKE CALLIPER