APRILIA DORSODURO 1200 2010 User manual

APRILIA WOULD LIKE TO THANK YOU
for choosing one of its products. We have compiled this booklet to provide a comprehensive overview of your vehicle's quality features. Please read it
carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details
and devices to assure you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle
well and that it will continue to give you satisfactory service for many years to come. This booklet is an integral part of the vehicle and must be handed
over to the new owner in the event of sale.
DORSODURO 1200 - DORSODURO 1200 ABS - ATC
Ed. 10 2010

Theinstructionsgiveninthisbookletareintendedtoprovideaclear,simpleguidetousingyourscooter;italsodescribesroutinemaintenanceprocedures
and regular checks that should be carried out on the vehicle at an authorised aprilia Dealer or Workshop. This booklet also contains instructions for
simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technical knowledge: for these
operations, please take your vehicle to an Aprilia Dealer or Authorised Workshop.
2

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 dam-
aging 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.
The symbols illustrated above are very important. They are used to highlight parts of the
booklet that should be read with particular care. The different symbols are used to make
each topic in the manual simple and quick to locate. Before starting the engine, read this
booklet carefully, particularly the "SAFE RIDING" section. Your safety as well as other's
does not only depend on the quickness of your reflexes and agility, but also on how well
youknow yourvehicle, thestate ofmaintenance ofthe vehicleitself andyour knowledge
of the rules for SAFE RIDING. For your safety, get to know your vehicle well so as to
safely ride and master it given any riding condition. IMPORTANT This booklet is an
integral part of the vehicle, and should the vehicle be sold, it must be transferred to the
new owner.
3

4

INDEX
GENERAL RULES....................................................................... 7
Foreword............................................................................... 8
Carbon monoxide.................................................................. 8
Fuel....................................................................................... 8
Hot components.................................................................... 9
Coolant.................................................................................. 9
Used engine oil and gearbox oil............................................ 10
Brake and clutch fluid............................................................ 10
Battery hydrogen gas and electrolyte.................................... 11
Stand..................................................................................... 12
Reporting of defects that affect safety................................... 12
VEHICLE...................................................................................... 13
Arrangement of the main components...................................... 14
Dashboard................................................................................ 19
Instrument panel....................................................................... 21
Light unit................................................................................... 22
Digital lcd display...................................................................... 23
Alarms................................................................................... 25
Mapping selection................................................................. 27
Control buttons...................................................................... 29
Advanced functions............................................................... 34
Ignition switch........................................................................ 42
Locking the steering wheel.................................................... 42
Horn button............................................................................... 43
Switch direction indicators........................................................ 43
Passing button.......................................................................... 44
Start-up button.......................................................................... 44
Engine stop switch.................................................................... 45
System ABS.............................................................................. 45
System ATC (Aprilia Traction Control)...................................... 48
Immobilizer system operation................................................ 51
Opening the saddle............................................................... 52
Glove/tool kit compartment.................................................... 54
Identification.............................................................................. 54
Luggage anchor point............................................................... 55
USE.............................................................................................. 57
Checks...................................................................................... 58
Refuelling.................................................................................. 61
Rear shock absorbers adjustment............................................ 62
Front fork adjustment................................................................ 65
Justering af greb til forbremse.................................................. 67
Clutch lever adjustment............................................................ 67
Running in................................................................................. 67
Starting up the engine............................................................... 68
Ride by wire.............................................................................. 72
Moving off / riding...................................................................... 73
Stopping the engine.................................................................. 78
Parking...................................................................................... 78
Catalytic silencer....................................................................... 79
Stand......................................................................................... 80
Suggestion to prevent theft....................................................... 81
Basic safety rules...................................................................... 82
MAINTENANCE........................................................................... 87
Engine oil level check............................................................ 88
Engine oil top-up................................................................... 89
Engine oil change.................................................................. 90
Engine oil filter replacement.................................................. 90
Tyres......................................................................................... 91
Spark plug dismantlement........................................................ 92
Removing the air filter............................................................... 93
Cooling fluid level...................................................................... 93
Checking the brake oil level...................................................... 95
Braking system fluid top up................................................... 96
Checking clutch fluid................................................................. 96
Topping up clutch fluid.......................................................... 97
Battery removal..................................................................... 97
5

Checking the electrolyte level................................................ 99
Charging the battery.............................................................. 99
Long periods of inactivity.......................................................... 100
Fuses........................................................................................ 101
Lamps....................................................................................... 103
Headlight adjustment............................................................. 104
Front direction indicators........................................................... 105
Rear optical unit........................................................................ 106
Rear turn indicators................................................................... 106
Number plate light..................................................................... 107
Rear-view mirrors...................................................................... 107
Front and rear disc brake.......................................................... 108
Periods of inactivity................................................................... 110
Cleaning the vehicle.................................................................. 111
Transport................................................................................... 114
Transmission chain................................................................... 114
Chain backlash check........................................................... 115
Chain backlash adjustment................................................... 115
Checking wear of chain, front and rear sprockets................. 116
Chain lubrication and cleaning.............................................. 116
TECHNICAL DATA...................................................................... 119
Kit equipment............................................................................ 128
PROGRAMMED MAINTENANCE............................................... 129
Scheduled maintenance table................................................... 130
6

DORSODURO 1200 - DORSODURO
1200 ABS - ATC
Chap. 01
General rules
7

Foreword
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECI-
FIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDI-
TIONS, OFF ROAD OR FOR TRACK USE.
Carbon monoxide
If you need to keep the engine running in order to perform a procedure, please ensure
that you do so in an open or very well ventilated area. Never let the engine run in an
enclosed area. If you do work in an enclosed area, make sure to use a smoke-ex-
traction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS
WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY
FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS
THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTE-
NANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED
8
1 General rules

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.
KEEP OUT OF THE REACH OF CHILDREN.
IF THE VEHICLE FALLS OR IS ON A STEEP INCLINE FUEL CAN LEAK.
Hot components
The engine and the exhaust system components get very hot and remain in this con-
ditionfora certain timeintervalaftertheengine hasbeenswitchedoff.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 ethylene glycol burns, it produces an invisible flame which can nev-
ertheless cause burns.
CAUTION
TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYS-
TEM COMPONENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE
9
1 General rules

FLAME. WHEN CARRYING OUT MAINTENANCE, IT IS ADVISABLE TO WEAR
LATEX GLOVES. EVEN THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLA-
VOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE
COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS
THEY MAY DRINK IT.
KEEP OUT OF THE REACH OF CHILDREN.
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE
COOLANT IS PRESSURISED AND MAY CAUSE SCALDING.
Used engine oil and gearbox oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN
IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BA-
SIS.
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
KEEP OUT OF THE REACH OF CHILDREN.
Brake and clutch fluid
Brake and clutch fluid
10
1 General rules

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAIN-
TED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM
PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR
PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND
CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT
OFACCIDENTALCONTACTWITHTHEEYES, RINSETHEMIMMEDIATELYWITH
PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN.
Battery hydrogen gas and electrolyte
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
GLOVESANDPROTECTIVEAPPAREL.INTHEEVENTOFSKINCONTACTWITH
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 CONTACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN
MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS
ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR
MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK
MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE
GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTH-
ER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING
OR RECHARGING THE BATTERY.
11
1 General rules

KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICU-
LARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID
IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED.
Stand
BEFORE SETTING OFF, MAKE SURE THE STAND HAS BEEN COMPLETELY
RETRACTED TO ITS POSITION.
DO NOT REST THE RIDER OR PASSENGER WEIGHT ON THE SIDE STAND.
Reporting of defects that affect safety
Unless otherwise specified in this Use and Maintenance Booklet, do not remove any
mechanical or electrical component.
CAUTION
SOME CONNECTORS IN THE VEHICLE MAY BE ACCIDENTALLY SWAPPED
AND MAY COMPROMISE NORMAL VEHICLE OPERATION IF INCORRECTLY IN-
STALLED.
12
1 General rules

DORSODURO 1200 - DORSODURO
1200 ABS - ATC
Chap. 02
Vehicle
13

Arrangement of the main components (02_01, 02_02, 02_03,
02_04)
02_01
14
2 Vehicle

02_02
Key - version without ABS:
1. Left side fairing
2. Front left turn indicator
3. Clutch fluid reservoir
4. Left rear-view mirror
5. Passenger seat strap
6. Battery
7. Glove-box / toolkit
8. Saddle
9. Taillight
10. Rear left turn indicator
11. Oil radiator
12. Swingarm
13. Drive chain
15
2 Vehicle

14. Side stand
15. Left hand passenger footrest
16. Gear lever
17. Control unit
18. Horn
19. Auxiliary fuses
20. Main fuses
21. Fuel tank
22. Fuel tank cap
23. Right rear-view mirror
24. Front brake system fluid reservoir
25. Front right turn indicator
26. Headlamp
27. Expansion tank cap
28. Expansion tank
29. Air filter box / air filter
30. Oil filter
31. Engine oil plug
32. Engine oil level
33. Rear brake lever
34. Right hand rider footrest
35. Rear brake system fluid reservoir
36. Rear shock absorber
37. Right hand passenger footrest
38. License plate light
39. Rear right turn indicator
40. Seat lock
16
2 Vehicle

02_03
17
2 Vehicle

02_04
Key - version with ABS - ATC:
1. Left side fairing
2. Front left turn indicator
3. Clutch fluid reservoir
4. Left rear-view mirror
5. Passenger seat strap
6. Battery
7. Glove-box / toolkit
8. Saddle
9. Taillight
10. Rear left turn indicator
11. Oil radiator
12. Swingarm
13. Drive chain
18
2 Vehicle

14. Side stand
15. Left hand passenger footrest
16. Gear lever
17. Control unit
18. Horn
19. Auxiliary fuses
20. Main fuses
21. Fuel tank
22. Fuel tank cap
23. Right rear-view mirror
24. Front brake system fluid reservoir
25. Front right turn indicator
26. Headlamp
27. Expansion tank cap
28. Expansion tank
29. Air filter box / air filter
30. Oil filter
31. Engine oil plug
32. Engine oil level
33. Rear brake lever
34. Right hand rider footrest
35. Rear brake system fluid reservoir
36. Rear shock absorber
37. Right hand passenger footrest
38. License plate light
39. Rear right turn indicator
40. Seat lock
41. ABS control unit
42. Front ABS sensor
43. Front tone wheel
44. Rear ABS sensor
45. Rear tone wheel
Dashboard (02_05)
19
2 Vehicle

02_05
Instrument panel / controls location key
1. Clutch control lever
2. Ignition switch /steering lock
3. Instrument panel
4. Front brake lever
5. Throttle grip
6. High beam flashing switch
7. MODE Control
8. Turn indicator control
9. Horn button
10. Engine stop button
11. Start-up button/mapping selection
20
2 Vehicle