APRILIA DORSODURO 2007 Guide

SERVICE STATION MANUAL
854202
DORSODURO

SERVICE STATION
MANUAL
DORSODURO
THE VALUE OF SERVICE
Thanks to continuous technical updates and specific training programs on aprilia products, only aprilia
Official Network mechanics know this vehicle fully and have the special 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, its regular maintenance and the use of Original aprilia Spare Parts only are essential factors!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.aprilia.com
Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design
stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and
duration.
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this manual remain unchanged, aprilia 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 shown in this publication are available in all countries. The availability of individual
versions should be confirmed with the official aprilia sales network.
© Copyright 2007- aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After sales service.
aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL
DORSODURO
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 Sectionsmarkedwiththis symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
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
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
Safety rules
Carbon monoxide
If you need to keep the engine running in order to carry out any 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-extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN
BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SHUT OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS,
AVOID ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY
CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
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 shut 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 CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING
OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN
THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC-
TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES-
SIBLE TO ANIMALS AS THEY MAY DRINK IT.
DORSODURO Characteristics
CHAR - 7

KEEP OUT OF THE REACH OF CHILDREN
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
ENGINE OR TRANSMISSION 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 INTO THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS
WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYS-
TEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE
EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUN-
DANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT
CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELEC-
TROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTRO-
LYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES AS EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS INTO CONTACT
WITH YOUR EYES, WASH WITH ABUNDANT 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 VEGETA-
BLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE
GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT
SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BAT-
TERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
Characteristics DORSODURO
CHAR - 8

When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
BEFORE DISASSEMBLING COMPONENTS
•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Do not loosen and/or tighten screws and nuts using pliers or other tools other than the
especially designed wrench.
•Mark positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with distinctive symbols.
•Each component needs to be clearly marked in order to be identified during assembly.
•Clean and wash the removed components carefully using a low-flammability detergent.
•Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
•Some components must be used together or replaced altogether.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-
ERWISE THEY NEED REPLACING.
•Only use ORIGINAL APRILIA SPARE PARTS.
•Comply with lubricant and consumables use guidelines.
•Lubricate parts (whenever possible) before reassembling them.
•When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), split pins
and screws with new ones if their tread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
•Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble oil guards and bearings
with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness:
DORSODURO Characteristics
CHAR - 9

Press the relevant safety hooks, if any.
•Grip the two connectors and disconnect them by pulling them in opposite directions.
•Ifthereare signs of dirt, rust, humidity, etc.,cleantheconnector internal parts carefully using
a pressurised air jet.
•Make sure that the cables are correctly linked to the connector internal terminal ends.
•Then insert the two connectors making sure that they couple correctly (if the relevant hooks
are provided, you will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUE
CAUTION
DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY
ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUE OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-
PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Running the engine in is essential to ensure engine durability and correct operation. Twisty roads and
gradients are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed when
running in. This ensures that components operate under both "loaded" and "unloaded" conditions, al-
lowing the engine components to cool.
CAUTION
ONLY AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD CAN THE BEST PERFORM-
ANCE OF YOUR VEHICLE BE OBTAINED.
Follow the guidelines detailed below:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE
CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE
SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Characteristics DORSODURO
CHAR - 10

Vehicle identification
Write down the chassis and engine number in the specific space of this manual. The chassis number
is handy when purchasing spare parts.
CAUTION
ALTERING IDENTIFICATION NUMBERS IS AN OFFENCE WHICH MAY RESULT IN SEVERE
CRIMINAL CHARGES AND FINES. PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL
IMMEDIATELY INVALIDATE THE WARRANTY
This number consists of numbers and letters, as in the example shown below.
ZD4SM0000YSXXXXXX
KEY:
ZD4: WMI (World manufacturer identifier) code;
SM: model;
000: version variation;
0: digit free
Yyear of manufacture
S: production plant (S= Scorzè);
XXXXXX: progressive number (6 digits);
ENGINE NUMBER
The engine number is printed on the base of the
left side engine crankcase.
Engine No. ....................
CHASSIS NUMBER
The chassis number is stamped on the right side of the headstock.
Chassis No. ....................
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Max. length 2210 mm (87.01 in)
Max. width (at hand guards) 905 mm (35.63 in)
Max. height 1185 mm (46.65 in)
Saddle height 900 mm (35.43 in)
Wheelbase 1505 mm (59.25 in)
Kerb weight 206 kg (454 lb)
DORSODURO Characteristics
CHAR - 11

Specification Desc./Quantity
Dry weight (without fuel) 196 kg (432 lb)
Engine
ENGINE
Specification Desc./Quantity
Model M551M
Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 over-
head camshafts.
Cylinder quantity 2
overall cylinder capacity 749.9 cm³ (45.76 cu.in)
Bore / stroke 92 x 56.4 mm (3.62 x 2.22 cu.in)
Intake valve clearance 0.11 - 0.18 mm (0.0043 - 0.0071 in)
Outlet valve clearance 0.16 - 0.23 mm (0.0063 - 0.0091 in)
Compression ratio 11.0: 1
Start-up electric
Engine speed at idle 1400 ± 100 rpm
Clutch Multiple-disk, oil-bathed clutch with control on the left side of
the handlebar
Lubrication system Wetcrankcase.Pressuresystem regulatedby trochoidalpump
Air filter With dry cartridge filter
Cooling Fluid
GEARBOX
Specification Desc./Quantity
Type Mechanical, 6 speeds with foot lever on the left hand side of
the engine
Transmission
GEAR RATIOS
Specification Desc./Quantity
Gear ratio Gear primary drive 38/71
1st gear ratio 14/36 (secondary)
2nd gear ratio 17/32 (secondary)
3rd gear ratio 20/30 (secondary)
4th gear ratio 22/28 (secondary)
5th gear ratio 23/26 (secondary)
6th gear ratio 24/25 (secondary)
Final drive gear ratio 16/46
Capacities
CAPACITY
Specification Desc./Quantity
Fuel capacity (reserve included) 12 l (2.64 UKgal; 3.17 USgal)
Fuel reserve 2.8 l (0.62 UKgal; 0.74 USgal)
Engine oil 3.0 l (without oil filter change) (0.66 UKgal; 0.79 USgal)
3.2 l (with oil filter change) (0.70 UKgal; 0.85 USgal)
Fork oil (check also the correct air level in the stem) 494 cm³ (RIGHT stem) (30.14 cu.in)
494 cm³ (LEFT stem) (30.38 cu.in)
Coolant 1.8 l (0.40 UKgal; 0.48 USgal)
Seats 2
Maximum weight allowed 400 kg (882 lb)
Characteristics DORSODURO
CHAR - 12

Drive chain
DRIVE CHAIN
Specification Desc./Quantity
Type Endless (without master link) and with sealed links. No. of links
108
Model 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 10 Ah
Main fuses 30A
Auxiliary fuses 3A, 10A, 15A, 20A
(Permanent magnet) Generator 13.5 V - 450 W at 6000 rpm
SPARK PLUGS
Specification Desc./Quantity
Standard spark plugs NGK CR7EKB
Spark plug electrode gap 0.6 ÷ 0.7 mm (0.024 ÷ 0.028 in)
Resistance 5 kOhm
BULBS
Specification Desc./Quantity
High-beam light 12 V - 60 W H4
Low-beam light 12 V - 50 W H4
Front tail light 12V - 6W H6
Turn indicator lights 12V - 10W
Rear tail light / stop light LED
License plate light 12V - 5W
Rpm indicator lighting LED
Multifunction display lighting LED
WARNING LIGHTS
Specification Desc./Quantity
High-beam light LED
Right turn indicator LED
Left turn indicator LED
General warning LED
Gear in neutral LED
Side stand down LED
Fuel reserve LED
ABS LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type Component chassis (bolted). Die-cast aluminium plates and
high-strength steel tubular chassis.
Steering inclination angle 25.8°
Trail 108 mm (4.25 in)
DORSODURO Characteristics
CHAR - 13

SUSPENSIONS
Specification Desc./Quantity
Front Upside-down telescopic hydraulic fork. Stem diam. 43 mm
(1.69 in)
Travel 160 mm (6.3 in)
Rear Oscillating swingarm and single adjustable hydraulic shock ab-
sorber
Wheel travel 155 mm (6.1 in)
SIZES A AND B
Specification Desc./Quantity
Size A 693.1 mm (27.29 in)
Size B 369.8 mm (14.56 in)
Brakes
BRAKES
Specification Desc./Quantity
Front Double floating disc, Ø 320 mm (12.60 in), radially-mounted
callipers with four plungers- two of them Ø 27 mm (1.06 in), the
other two Ø 32.03 (1.26 in) and 4 pads
Rear 240 mm (9.45 in) disc brake with 35 mm (1.38 in) single piston
calliper
Wheels and tyres
WHEEL RIMS
Specification Desc./Quantity
Type Light alloy rims with extractable bolt
Front 3.50 x 17"
Rear 6.00 x 17"
TYRES
Specification Desc./Quantity
Tyre type (standard) DUNLOP SPORTMAX QUALIFIER
Front tyre 120/70 ZR17"
Front tyre pressure rider only: 2.3 bar (230 kPa) (33.36 PSI)
rider + passenger: 2.4 bar (240 kPa) (34.81 PSI)
Rear tyre 180/55 ZR17"
Rear tyre pressure rider only: 2.5 bar (250 kPa) (36.26 PSI)
rider + passenger: 2.7 bar (270 kPa) (39.16 PSI)
Characteristics DORSODURO
CHAR - 14

Supply
FUEL SYSTEM
Specification Desc./Quantity
Type Electronic injection (Multipoint)
Throttle valves diameter Ø 52 mm (2.05 in)
Fuel premium unleaded petrol, minimum octane rating of 95
(NORM) and 85 (NOMM)
Tightening Torques
FRAME ASSEMBLY
Name Torque in Nm
TCEI screw fixing Shock Absorber Counterplate to right chas-
sis bracket - M10x30 (1) 50 Nm (36.88 lbf ft)
TCEI screw fixing Fairings to engine - M12x282 (3) 80 Nm (59 lbf ft)
TC TORX screw fixing Perimeter frame to the chassis fairings
- M12x53 (4) 80 Nm (59 lbf ft)
TCEI upper left screw fixing saddle pillar to chassis - M8x55 (1) 25 Nm (18.44 lbf ft)
TCEI upper right screw fixing saddle pillar to chassis - M8x60
(1) 25 Nm (18.44 lbf ft)
TCEI lower screw fixing Saddle pillar to chassis - M8x40 (2) 25 Nm (18.44 lbf ft)
TCEIscrewfixinglambdaprobeplatetoright-sidechassis(pre-
fitted on right fairing - M4x10 (2) 3 Nm (2.3 lbf ft)
Chain roller bracket-left plate screw - M8x20 (1) 25 Nm (18.44 lbf ft) - Loctite 243
Chain roller bracket-left plate screw - M8x35 (1) 25 Nm (18.44 lbf ft) - Loctite 243
Chain roller to chain roller bracket fixing screw- M8x45 (1) 25 Nm (18.44 lbf ft) - Loctite 243
FOOTREST UNIT
Name Torque in Nm
Upper screw fixing passenger footrest to chassis fairings -
M8x35 (2) 25 Nm (18.44 lbf ft)
TCEI lower screw fixing passenger footrest to rider footrest
support - M8x35 (2) 25 Nm (18.44 lbf ft)
TCEI screw fixing rider footrest to chassis - M8x35 (4) 28 Nm (20.65 lbf ft) - Loctite 243
STAND UNIT
Name Torque in Nm
Screw for Stand - M10x1.25 (1) 10 Nm (10.34 lbf ft)
Lower nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)
Spring linking pin (1) 10 Nm (7.37 lbf ft)
SWINGARM UNIT
Name Torque in Nm
Swingarm Pin adjustment Bushing (1) 12 Nm (8.85 lbf ft)
Swingarm Pin Ring Nut (1) 60 Nm (44.25 lbf ft)
Swingarm pin nut (1) 90 Nm (66.38 lbf ft)
Chain tensioner set screw (2) -
SERPRESS nut (on chain tensioner slider set screw) - M8 (2) -
TPSI screw fixing rear stand bushing - M6x40 (2) 10 Nm (7.37 lbf ft)
TBEI screw fixing chain tensioner slider - M5x12 (3) 3 Nm (2.21 lbf ft)
Self-tapping TBEI screw fixing chain guard, brake pipe protec-
tion and counterslider - M5x9 (5) 4 Nm (2.95 lbf ft)
FRONT SUSPENSION UNIT
Name Torque in Nm
Stainlesssteel TCCscrew fixingfork stemson upperand lower
plates - M8x30 (6) 25 Nm (18.44 lbf ft)
Headstock Ring nut - M25x1 (1) 12 Nm (8.85 lbf ft)
Headstock Cap - M22x1 (1) 100 Nm (73.75 lbf ft)
DORSODURO Characteristics
CHAR - 15

Name Torque in Nm
Screw (fasten on Fork Hub caps) - M8x40 (4) 25 Nm (18.44 lbf ft)
REAR SUSPENSION UNIT
Name Torque in Nm
TCEI screw - M10x50 (1) 50 Nm (36.88 lbf ft)
Lower TCEI fixing screw - M10x80 (1) 50 Nm (36.88 lbf ft)
ENGINE UNIT
Name Torque in Nm
TCEI screw fixing Pin to gearbox lever and Gearbox Lever to
knurled shaft- M6x16 (2) 10 Nm (7.37 lbf ft)
Left lock nut for ball joint - M6 (1) 10 Nm (7.37 lbf ft)
Lock nut for ball joint - M6 (1) 10 Nm (7.37 lbf ft)
Clutch pin clamp M6 10
Filler with bleed (Heng Tong) fixing pipe to pin - M10x1 (1) 25 Nm (18.44 lbf ft)
Self-tapping TE screw fixing Pinion - M10x1.25x55 (1) 50 Nm (36.88 lbf ft) - Loctite 243
TE screw fixing negative on engine - M6x12 (1) 10 Nm (7.37 lbf ft)
FILTER CASING SMALL PARTS UNIT
Name Torque in Nm
SWP Self-tapping Crosshead screw - M5x20 (21) 3 Nm (2.21 lbf ft)
FILTER CASE UNIT
Name Torque in Nm
SWP Self-tapping screw - M2.9x12 TCCR (2) 3 Nm (2.21 lbf ft)
EXHAUST SYSTEM UNIT
Name Torque in Nm
SERPRESS self-locking nut fixing Plate on head - M8 (4) 25 Nm (18.44 lbf ft)
PrimaryClamp(betweenfront/rearmanifoldsandcentralmani-
fold) - M6 (2) 7 Nm (5.16 lbf ft)
Silencer Clamp (between central manifold and silencer) - M6
(1) 7 Nm (5.16 lbf ft)
Self-tapping TE screw fixing Muffler holding Bracket to saddle
pillar - M8x20 (2) 25 Nm (18.44 lbf ft)
Self-tapping TE screw fixing Silencer front attachment to muf-
fler holding bracket - M8x35 (2) 35 Nm (25.81 lbf ft)
COOLING SYSTEM UNIT
Name Torque in Nm
Self-tapping TE screw fixing Radiator, left-side, to frame and
radiator bracket to engine - M6x25 (2) 10 Nm (7.37 lbf ft)
Electric fan fixing screw (3) 3 Nm (2.21 lbf ft)
FRONT WHEEL UNIT
Name Torque in Nm
Wheel Pin Nut (1) 80 Nm (59 lbf ft)
Self-tapping TE screw fixing front Disc - M8x20 =S= (12) 30 Nm (22.13 lbf ft) (Loctite 243)
REAR WHEEL UNIT
Name Torque in Nm
Self-tapping TE screw fixing rear Disc - M8x20 =S= (5) 30 Nm (22.13 lbf ft) (Loctite 243)
TCEI screw fixing Anti-vibration buffer on wheel - M10x30 (5) 50 Nm (36.88 lbf ft) (Loctite 270)
Lower Self-locking nut fixing Crown to sprocket carrier - M10
(5) 50 Nm (36.88 lbf ft)
Wheel Pin Nut - M25x1.5 (1) 120 Nm (88.5 lbf ft)
FRONT BRAKE UNIT
Name Torque in Nm
Brake pipe union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)
Characteristics DORSODURO
CHAR - 16

Name Torque in Nm
Filler with bleed (Heng Tong) - M10x1 (2) 25 Nm (18.44 lbf ft)
Self-tapping TE screw fixing Calliper - M10x1.25x55 (4) 50 Nm (36.88 lbf ft)
Brake pipe to steering base retainer - M6x25 (1) 10 Nm (7.37 lbf ft)
REAR BRAKE UNIT
Name Torque in Nm
Rear brake Lever pin - M6 (1) 25 Nm (18.44 lbf ft)
Brake pipe union - M10x1 (2) 25 Nm (18.44 lbf ft)
Self-tapping TE screw fixing Pump to footrest support - M6x20
(2) 10 Nm (7.37 lbf ft)
TBEI screw fixing oil pipe to swingarm and rubber pipe to foot-
rest support - M5x12 (4) 6 Nm (4.42 lbf ft)
Self-locking nut - M6 (1) 10 Nm (7.37 lbf ft)
Self-tapping TE screw - M6x16 (1) 10 Nm (7.37 lbf ft)
Pedal to brake lever retainer, screw + nut - M6 (1+1) 10 Nm (7.37 lbf ft)
HANDLEBAR / CONTROLS / TRASM. UNIT
Name Torque in Nm
Clutch pump to handlebar retainer (2) 10 Nm (7.37 lbf ft)
Front brake pump to handlebar retainer (2) 10 Nm (7.37 lbf ft)
Light switch locking screws (2) 1.5 Nm (1.11 lbf ft)
TCEI screw fixing lower U-bolt on fork plate - M10x60 (2) 50 Nm (36.88 lbf ft)
Stainless steel TCC screw fixing upper to lower U-bolt - M8x25
(4) 25 Nm (18.44 lbf ft)
TCEI screw fixing anti-vibration weight to end - M6x50 (2) 10 Nm (7.37 lbf ft)
ELECTRICAL COMPONENTS UNIT
Name Torque in Nm
Stand switch TCEI fixing screw - M5x16 (2) 7 Nm (5.16 lbf ft)
TE screw fixing regulator to chassis - M6x30 (2) 10 Nm (7.37 lbf ft)
Screw fixing control unit to filter casing base (4) 2.5 Nm (1.47 lbf ft)
SWP Self-tapping screw fixing Demand Support to Demand -
M5x14 (4) 3 Nm (2.21 lbf ft)
Self-tapping TE screw fixing Demand sensor to chassis -
M6x20 (3) 10 Nm (7.37 lbf ft)
Start-up relay retainer (2) 4 Nm (2.95 lbf ft)
Positive on engine retainer (1) 10 Nm (7.37 lbf ft)
LIGHTS UNIT / INSTRUMENT PANEL
Name Torque in Nm
Nut fixing steering head to instrument panel support - M6 (2) 10 Nm (7.37 lbf ft)
TEscrew fixing light to lightsupport-mudguard tosteering base
- M6x16 (2) 10 Nm (7.37 lbf ft)
TE screw fixing rear light to license plate holder frame - M6x45
(3) 10 Nm (7.37 lbf ft)
Rear arrows retainer - M6 (2) 3 Nm (2.21 lbf ft)
Front arrows retainer - M5 (2) 3 Nm (2.21 lbf ft)
Retroreflector retainer - M5 (2) 2 Nm (1.47 lbf ft)
License plate light fixing nut - M5 (1) 5 Nm (3.69 lbf ft)
TANK UNIT
Name Torque in Nm
TCEI screw fixing cap flange filler - M5x16 (5) 6 Nm (4.42 lbf ft)
Tank front retainer spacer - M6 (2) 10 Nm (7.37 lbf ft)
Rear tank TE fixing screw- M6x90 (1) 10 Nm (7.37 lbf ft)
Fuel pump TEFL fixing screw - M5x16 (6) 6 Nm (4.42 lbf ft)
FRONT BODYWORK UNIT
Name Torque in Nm
TBEI screw fixing the fork end stem protection - M5x9 (6) 6 Nm (4.42 lbf ft) - Loctite 243
TCEI screw fixing light support to fork plate - M6 (3) 10 Nm (7.37 lbf ft)
DORSODURO Characteristics
CHAR - 17

Name Torque in Nm
TCEI screw fixing instrument panel support to fork plate -
M6x20 (2) 10 Nm (7.37 lbf ft)
TBEI screw fixing Mudguard to stems - M5x9 (4) 4 Nm (2.95 lbf ft)
Screw fixing number plate to light (4) 1 Nm (0.74 lbf ft)
TBEI screw fixing ignition lock cover to spacer - M5x9 (3) 4 Nm (2.95 lbf ft)
CENTRAL BODYWORK UNIT
Name Torque in Nm
TBEI screw fixing front fairings to tank - M5x9 (4) 4 Nm (2.95 lbf ft)
TBEIscrewfixingfrontfairings/air deflector to radiator-M6x16
(4) 6 Nm (4.42 lbf ft)
Screw fixing tail section to battery compartment (3) 4 Nm (2.95 lbf ft)
TBEI screw fixing tail section to saddle pillar - M5x9 (2) 6 Nm (4.42 lbf ft)
Screws fixing battery cover to compartment - M5 (2+1) 4 Nm (2.95 lbf ft)
TBEI screw fixing battery compartment to saddle pillar - M5x9
(2) 6 Nm (4.42 lbf ft)
REAR BODYWORK UNIT
Name Torque in Nm
TBEI screw fixing right - left cover to silencer - M6x20 (4) 10 Nm (7.37 lbf ft)
TBEI screw fixing chain slide to swingarm - M5x9 (2) 6 Nm (4.42 lbf ft)
TBEI screw fixing chain guard to rear mudguard - M5x9 (1) 4 Nm (2.95 lbf ft)
TBEI screw fixing chain guard to swingarm - M5x9 (1) 6 Nm (4.42 lbf ft)
TBEI screw fixing rear mudguard to swingarm - M5x9 (2) 6 Nm (4.42 lbf ft)
Screw fixing license plate holder cover to license plate holder
(3) 1 Nm (0.74 lbf ft)
TBEI screw fixing license plate holder to support - M5x9 (3) 6 Nm (4.42 lbf ft)
Nuts fixing license plate holder frame to license plate holder
gusset plate - saddle lock - M6 (4) 10 Nm (7.37 lbf ft)
FINISHING SMALL PARTS UNIT
Name Torque in Nm
TCEI screw fixing passenger grab handles to saddle pillar -
M8x80 (4) 30 Nm (22.13 lbf ft)
TCEI screw - M8x40 (1) 25 Nm (18.44 lbf ft)
Switch - shear head screw retainer (1) Manual
Self-tapping TE screw - M6x25 (2) 10 Nm (7.37 lbf ft)
COMPLETE HEAD
Name Torque in Nm
Cam cap/head fixing screws - M6 (16) Pre-tightening: (4.90 - 6.86) Nm ((3.61 - 5.06) lbf ft) Tightening:
(9.81 - 12.75) Nm ((7.24 - 9.40) lbf ft)
Map sensor fitting (brass) (2) 2 Nm (1.48 lbf ft) (Loctite 243)
Map sensor fitting (steel) (2) 3.50 Nm (2.58 lbf ft) (Loctite 243)
H20 Bleed fitting (brass) (1) 2 Nm (1.48 lbf ft) (Loctite 243)
H20 Bleed fitting (steel) (1) 3.50 Nm (2.58 lbf ft) (Loctite 243)
Cap - M6 (1) To fit flush
Oil cap - M10x1.25 (2) 7 Nm (5.16 lbf ft) (3M SCOTCH GRIP 2353)
Screw fixing fitting to bleed - M5 (4) 5.50 Nm (4.06 lbf ft)
842291 - Special screw fixing Head Cover - M6 (8) * 8 Nm (5.90 lbf ft)
874545 - Special screw fixing Head Cover - M6 (8) ** 8 Nm (5.90 lbf ft)
H20 Temperature sensor - M12x1.5 (1) 23 Nm (16.96 lbf ft)
Water sensor housing threaded cap - M12x1.5 (1) 10 Nm (7.38 lbf ft) (Loctite Dri-Seal 506)
Nut fixing Stud Bolts to Head - M10x1.25 (8) Pre-torque 10 Nm (7.38 lbf ft) - Torque 13 Nm (9.59 lbf ft) + 90°
+ 90° (Lubricate threads before tightening)
Head / Cylinder / Crankcase internal side retainer - M6 (4) 12 Nm (8.85 lbf ft)
872433 - Head / Cylinder / crankcase external side retainer -
M6 (2) * 12 Nm (8.85 lbf ft)
874556 - Head / Cylinder / crankcase external side retainer -
M6 (2) ** 12 Nm (8.85 lbf ft)
288245 - Nut fixing Stud Bolts to Head - M6 (4) * 12 Nm (8.85 lbf ft)
874558 - Nut fixing Stud Bolts to Head - M6 (4) ** 12 Nm (8.85 lbf ft)
872434 - Nut fixing Stud Bolts to Head - M8 (2) * 26 Nm (19.18 lbf ft)
874557 - Nut fixing Stud Bolts to Head - M8 (2) ** 26 Nm (19.18 lbf ft)
Characteristics DORSODURO
CHAR - 18

Name Torque in Nm
Spark plug (2) 13 Nm (9.59 lbf ft)
872425 - Screw fixing Pencil to Eldor coil - M6 (2) * 5.50 Nm (4.06 lbf ft)
874554 - Screw fixing Pencil to Eldor coil - M6 (2) ** 5,50 Nm (4.06 lbf ft)
Screw fixing camshaft retaining plate - torx M3 (8) 3 Nm (2.21 lbf ft) (Loctite 270)
Camshaft locking threaded cap 11 Nm (8.11 lbf ft)
* Up to engine M551M8176
** From engine M551M8177
TIMING SYSTEM
Name Torque in Nm
Nut fixing camshaft gears (pre-tightening) - M15x1 (4) 30 Nm (22.13 lbf ft)
Nut fixing camshaft gears - M15x1 (4) 90 Nm (66.38 lbf ft)
Screw fixing Timing system Gear - M24x1.5 (2) 40 Nm (29.50 lbf ft) (3M SCOTCH GRIP 2353)
Special screw fixing Mobile / Fixed Pads - M8 (4) 19 Nm (14.01 lbf ft) (Loctite 242)
872432 - Chain tensioner fixing screw - M6 (4) * 12 Nm (8.85 lbf ft)
874555 - Chain tensioner fixing screw - M6 (4) ** 12 Nm (8.85 lbf ft)
872425 - Cylinder Plate fixing screw - M6 (4) * 12 Nm (8.85 lbf ft)
874554 - Cylinder Plate fixing screw - M6 (4) ** 12 Nm (8.85 lbf ft)
Screw for Chain tensioner adjustment - M6 (2) 5.50 Nm (4.06 lbf ft)
* Up to engine M551M 8176
** From engine M551M 8177
COMPLETE CRANKCASE AND OTHER ELEMENTS
Name Torque in Nm
Oil drainage plug - M16x1.5 19 Nm (14.01 lbf ft)
Special screw for oil calibration on flywheel side crankcase half
- M10x1 (1) 16 Nm (11.80 lbf ft)
Conical cap for crankshaft support lubrication - M8x1 (4) 15 Nm (11.06 lbf ft)
Brass Calibrated dowel fixed on crankcase unit - M8 (2) 5.50 Nm (4.06 lbf ft)
Screw fixing piston oil Jet - M5 (2) 5.50 Nm (4.06 lbf ft) (Loctite 242)
Screw fixing Gear sensor - M5 (2) 5.50 Nm (4.06 lbf ft) (Loctite 243)
872432 - Screw fixing Revolution sensor - M6 (1) * 5.50 Nm (4.06 lbf ft) (Loctite 243)
874555 - Screw fixing Revolution sensor - M6 (1) ** 5,50 Nm (4.06 lbf ft) (loctite 243)
Tone Wheel tightening on Secondary Transmission Shaft -
M16x1 (1) 43 Nm (31.72 lbf ft) (Loctite 270)
Oil pressure adjustment valve, 3/4" Unf 16 (1) 43 Nm (31.72 lbf ft)
Oil Pump fixing screw - M6 (2) 5.50 Nm (4.06 lbf ft) (Loctite 242)
Screw fixing Oil Pump Cover - M3 (2) 0.80 Nm (0.59 lbf ft)
Screw fixing oil Pump with Gear - M5 (1) 8 Nm (5.90 lbf ft) (Loctite 270)
Screw fixing Gear locking pawl - M6 (1) 12 Nm (8.85 lbf ft)
Screw fixing Desmodromic / Sprocket Selector - M8 (1) 23 Nm (16.96 lbf ft)
Selector Plate fixing screw - M5 (3) 5.50 Nm (4.06 lbf ft)
Selector pin retainer on clutch side crankcase half - M10x1.5
(1) 16 Nm (11.80 lbf ft)
849911- Screwfixing clutch/ flywheel side crankcase half - M6
(8) * 12 Nm (8.85 lbf ft)
874548- Screwfixing clutch/ flywheel side crankcase half - M6
(8) ** 12 Nm (8.85 lbf ft)
848465- Screwfixing clutch/ flywheel side crankcase half - M8
(9) * 26 Nm (19.18 lbf ft)
874546- Screwfixing clutch/ flywheel side crankcase half - M8
(9) ** 26 Nm (19.18 lbf ft)
Oil sensor retainer on clutch side crankcase half (1) 13 Nm (9.59 lbf ft)
872432 - Suction rose fixing screw (2) * 12 Nm (8.85 lbf ft)
874555 - Suction rose fixing screw (2) ** 12 Nm (8.85 lbf ft)
Oil Filter fitting retainer on clutch side crankcase half (1) 20 Nm (14.75 lbf ft)
Oil filter (1) 14 Nm (10.33 lbf ft)
Screw fixing bearing retainer - M6 (3) 10 Nm (7.38 lbf ft) (Loctite 270)
* Up to engine M551M 8176
** From engine M551M 8177
SHAFT / FLYWHEEL / CLUTCH
Name Torque in Nm
Nut fixing Crankshaft primaries - M24x1.5 (1) 270 Nm (199.14 lbf ft)
DORSODURO Characteristics
CHAR - 19

Name Torque in Nm
Freewheel ring fixing screw - M6 (6) 14 Nm (10.33 lbf ft) (Loctite 242)
Screw fixing Rotor - Crankshaft - M12x1.25 (1) 120 Nm (88.51 lbf ft)
Screw fixing Retaining Plate - M5 (1) 8 Nm (5.90 lbf ft)
Clutch fixing nut - M24x1.5 (1) 180 Nm (132.76 lbf ft) (Caulk)
Clutch spring fixing screw - M6 (6) 12 Nm (8.85 lbf ft)
Self-tapping TE screw fixing Pinion - M10x1.25x55 (1) 50 Nm (36.88 lbf ft)
Connecting rod screw - M10 (4) 20 + 50 + 70 Nm (14.75 + 36.89 + 51.63 lbf ft) (Lubricate
threads before tightening)
FLYWHEEL COVERS / CLUTCH
Name Torque in Nm
Screw fixing Stator / Flywheel Cover - M6 (3) 9 Nm (6.64 lbf ft)
Screw fixing Pick-up / Flywheel Cover - M5 (2) 3.50 Nm (2.58 lbf ft)
872421 - Screw fixing Flywheel Cover - M6 (11) * 12 Nm (8.85 lbf ft)
874551 - Screw fixing Flywheel Cover - M6 (11) ** 12 Nm (8.85 lbf ft)
872816 - Nut fixing Shaft pump Control inlet - M6 (1) * 12 Nm (8.85 lbf ft) (Loctite 244)
874558 - Nut fixing Shaft pump Control inlet - M6 (1) ** 12 Nm (8.85 lbf ft) (Loctite 244)
Oil drainage cap retainer on Clutch Cover (1) 2 Nm (1.48 lbf ft)
872117 - Screw fixing Clutch side Cover - M6 (13) * 12 Nm (8.85 lbf ft)
874550 - Screw fixing Clutch side Cover - M6 (13) ** 12 Nm (8.85 lbf ft)
871094 - Screw fixing Pump Cover / Clutch side Cover - M6 (3)
*12 Nm (8.85 lbf ft)
874549 - Screw fixing Pump Cover / Clutch side Cover - M6 (3)
** 12 Nm (8.85 lbf ft)
872422 - Screw fixing Pump Cover / Clutch Cover / clutch side
crankcase half - M6 (2) * 12 Nm (8.85 lbf ft)
874552 - Screw fixing Pump Cover / Clutch Cover / clutch side
crankcase half - M6 (2) ** 12 Nm (8.85 lbf ft)
871094 - Screw fixing Clutch Cover / Clutch side Cover - M6
(6) * 12 Nm (8.85 lbf ft)
874549 - Screw fixing Clutch Cover / Clutch side Cover - M6
(6) ** 12 Nm (8.85 lbf ft)
Screw fixing "split" clutch cover gasket retainer - M4 steel A2
(6) 3 Nm (2.21 lbf ft)
Screw fixing Plate / Clutch Control Support - M5 (3) 5.50 Nm (4.06 lbf ft)
Screw fixing Clutch Control Support / flywheel side crankcase
half - M6 (1) 12 Nm (8.85 lbf ft)
872421 - Screw fixing Clutch Control Support / flywheel side
crankcase half - M6 (2) * 12 Nm (8.85 lbf ft)
874551 - Screw fixing Clutch Control Support / flywheel side
crankcase half - M6 (2) ** 12 Nm (8.85 lbf ft)
872432 - Screw fixing Bracket / Starter motor - M6 (2) * 12 Nm (8.85 lbf ft)
874555 - Screw fixing Bracket / Starter motor - M6 (2) ** 12 Nm (8.85 lbf ft)
872432 - Screw fixing engine Bracket / clutch side crankcase
half - M6 (2) * 12 Nm (8.85 lbf ft)
872432 - Screw fixing engine Bracket / clutch side crankcase
half - M6 (2) ** 12 Nm (8.85 lbf ft)
Crankshaft access cover (1) 4 Nm (2.95 lbf ft)
H20 Pump Rotor (1) 4.50 Nm (3.32 lbf ft)
872425 - Screw fixing Stick-coil / Head cover - M6 (2) * 5.50 Nm (4.06 lbf ft)
874554 - Screw fixing Stick-coil / Head cover - M6 (2) ** 5,50 Nm (4.06 lbf ft)
Screw fixing plate / "split" clutch cover - M4 steel A2 (6) 3 Nm (2.21 lbf ft) (Loctite 243)
* Up to engine M551M 8176
** From engine M551M 8177
THROTTLE BODY / FILTER HOUSING
Name Torque in Nm
Intake Fitting fixing screw - M6 (8) 12 Nm (8.85 lbf ft) (Loctite 242)
Screw fixing Injection Throttle Body - M6 (8) 12 Nm (8.85 lbf ft) (Loctite 242)
rbw control unit fixing screw - M5 (2) 3.50 Nm (2.58 lbf ft) (Loctite 242)
Injectors fixing screw - M6 (2) 12 Nm (8.85 lbf ft) (Loctite 242)
Crossheadself-tappingscrewfixingcover/filtercasing-M5x20
(8) 3 Nm (2.21 lbf ft)
Crosshead self-tapping screw fixing partition / filter casing -
M5x20 (10) 3 Nm (2.21 lbf ft)
Characteristics DORSODURO
CHAR - 20