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MANUALE STAZIONE DI SERVIZIO
2Q000020
CAPONORD 1200
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MANUALE
STAZIONE DI
SERVIZIO
CAPONORD 1200
THE VALUE OF SERVICE
As a result of continuous updates and specific technical training programmes for Aprilia products, only
Aprilia 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 Aprilia spare parts only are essential factors!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting aprilia original spare parts can you be sure of purchasing products that were
developed and tested during the actual vehicle design stage. All aprilia original spare parts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
models should be confirmed with the official aprilia sales network.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2013 - 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
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MANUALE STAZIONE DI
SERVIZIO
CAPONORD 1200
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia 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, aprilia 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 aprilia 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 aprilia 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.
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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
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INDEX OF TOPICS
CHARACTERISTICS
SPECIAL TOOLS
S-TOOLS
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
POWER SUPPLY
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CHAR
ENG
P SUPP
SUSPENSIONS
SUSP
CHASSIS
CHAS
BRAKING SYSTEM
BRAK SYS
CLUTCH SYSTEM
CLU SYS
COOLING SYSTEM
COOL SYS
BODYWORK
BODYW
PRE-DELIVERY
PRE DE
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INDEX OF TOPICS
CHARACTERISTICS
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CHAR
Characteristics
CAPONORD 1200
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
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear 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 COMPONENTS; 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 ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT.
CHAR - 8
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CAPONORD 1200
Characteristics
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 PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VEHICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CHAR - 9
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Characteristics
CAPONORD 1200
BEFORE DISASSEMBLING COMPONENTS
•
Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•
Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
•
Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
•
Each component needs to be clearly marked to enable identification during reassembly.
•
Clean and wash the dismantled components carefully using a low-flammability detergent.
•
Keep mated parts together since they have "adjusted" to each other due to normal wear.
•
Some components must be used together or replaced completely.
•
Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
•
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 either from the components with the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in successive steps before applying the tightening torque.
•
Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread 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, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
•
Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand
or batch number facing outward (visible side).
ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
•
Grip the two connectors and disconnect them by pulling them in opposite directions.
CHAR - 10
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CAPONORD 1200
•
Characteristics
If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•
Ensure that the cables are correctly fastened to the internal connector terminals.
•
Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE
IT WITH A NEW ONE.
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
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.
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.
CHAR - 11
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CAPONORD 1200
Characteristics
Vehicle identification
Write down the chassis and engine number in the specific space in this booklet. The chassis number
is handy when purchasing spare parts.
CAUTION
THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.
HOWEVER, THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE
IDENTIFICATION NUMBER (VIN) HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED.
This number consists of numbers and letters, as in the example shown below.
ZD4VKA000YSXXXXXX
KEY:
ZD4: WMI (World manufacturer identifier) code;
VK: model;
A00: version variation;
0: free digit
Y: year of manufacture
S: production plant (S= Scorzè);
XXXXXX: serial number (6 digits);
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
CHASSIS NUMBER
The chassis number is stamped on the right side of the headstock.
Chassis No. ....................
Dimensions and mass
DIMENSIONS
Specification
Max. length
Max. width (at hand guards)
Max. height (fully extracted windshield)
Saddle height
Wheelbase
Kerb weight (Caponord 1200)
Kerb weight (Caponord 1200 Travel Pack)
CHAR - 12
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Desc./Quantity
2245 mm (88.38 in)
1000 mm (39.37 in)
1440 mm (56.69 in)
870 mm (34.25 in)
1555 mm (61.22 in)
251 kg (553.36 lb)
265 kg (584.22 lb)
CAPONORD 1200
Characteristics
Specification
Dry weight (without fuel) (Caponord 1200)
Dry weight (without fuel) (Caponord 1200 Travel Pack)
Desc./Quantity
233 kg (513.68 lb)
247 kg (544.54 lb)
Engine
ENGINE
Specification
Model
Type
No. of cylinders
Total engine capacity
Bore / stroke
Compression ratio
Electric
Engine idle speed
Clutch
Lubrication
Air filter
Cooling
Desc./Quantity
M558M
90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 overhead camshafts.
2
1197 cm³ (73.05 cu in)
106 x 67.8 mm (4.17 x 2.67 in)
12.0 +/- 0.5: 1
Starter
1450 ± 100 rpm
Multiple-disk, oil-bathed clutch with control on the left side of
the handlebar
Wet crankcase. Pressure system regulated by a trochoidal
pump with oil radiator.
Sponge.
Fluid
GEARBOX
Specification
Type
Desc./Quantity
Mechanical, 6 speeds with foot lever on the left hand side of
the engine
Transmission
GEAR RATIOS
Specification
Gear ratio
1st gear ratio
2nd gear ratio
3rd gear ratio
4th gear ratio
5th gear ratio
6th gear ratio
Final drive gear ratio
Desc./Quantity
Gear primary drive 40/69
14/36 (secondary)
17/32 (secondary)
20/30 (secondary)
22/28 (secondary)
23/26 (secondary)
24/25 (secondary)
17/42
Capacities
CAPACITY
Specification
Fuel tank (reserve included)
Fuel reserve
Engine oil
Coolant
Seats
Maximum weight limit
Desc./Quantity
24 l (5.28 UK gal; 6.34 US gal)
4 l (0.88 UK gal; 1.06 US gal)
3.1 l (without oil filter change) (0.68 UK gal; 0.82 US gal)
3.35 l (with oil filter change) (0.74 UK gal; 0.88 US gal)
2.5 l (0.55 UK gal; 0.66 US gal)
2
460 kg (1014.12 lb)
CHAR - 13
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CAPONORD 1200
Characteristics
Drive chain
DRIVE CHAIN
Specification
Type
Desc./Quantity
Endless (without master link) and with sealed links. No. of links
112
525 ZRPK
Model
Electrical system
ELECTRICAL SYSTEM
Specification
Battery
Main fuses
Secondary fuses
Alternator (permanent magnet type)
Desc./Quantity
VTX14-BS 12 V - 12 Ampere/hour
30A
7.5 A; 10 A; 15 A
13 V - 690 W at 6000 rpm
SPARK PLUGS
Specification
Standard spark plugs
Spark plug electrode gap
Resistance
Desc./Quantity
NGK CR8EKB
0.6 - 0.7 mm (0.024 - 0.028 in)
5 kOhm
WARNING LIGHTS
Specification
Turn indicators
High beam light
Fuel reserve
Cruise control warning light
Gear in neutral
General warning
ABS
ATC
Desc./Quantity
LED
LED
LED
LED
LED
LED
LED
LED
BULBS
Specification
Low-/ high beam light
Front daylight running lights
Turn indicators
Rear daylight running light / stop light
Licence plate light
Multifunction display lighting
Desc./Quantity
12V - 55W H11
12V - 5W
12V - 10W (White light)
LED
12V - 5W
LED
Frame and suspensions
CHASSIS
Specification
Type
Steering inclination angle
Trail with suspension fully extended (without load)
Desc./Quantity
Component chassis (bolted). Die-cast aluminium plates and
high-strength steel tubular chassis.
24°
128 mm (5.04 in)
SUSPENSION
Specification
Front (Caponord 1200)
CHAR - 14
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Desc./Quantity
Sachs telescopic "UPSIDE-DOWN" (upside-down stanchions)
fork with full-adjustable stanchions with 43mm diameter (ad-
CAPONORD 1200
Specification
Front (Caponord 1200 Travel Pack)
Travel
Rear (Caponord 1200)
Rear (Caponord 1200 Travel Pack)
Wheel travel
Characteristics
Desc./Quantity
justment of hydraulic brake extended on left stanchion and
compression on right stanchion and of spring preload on both)
Sachs telescopic "UPSIDE-DOWN" (upside-down stanchions)
fork with stanchions with 43mm diameter, hydraulic braking
dynamic adjustment during extension and compression (semiactive Aprilia Dynamic Damping technology) on left stanchion;
and of spring preload on right stanchion, manually adjustable
170 mm (6.69 in)
Oscillating swingarm connected with cantilever type link to a
Sachs single shock absorber, with adjustment of hydraulic
braking during extension and spring preload with knob.
Oscillating swingarm connected with cantilever type link to a
Sachs single shock absorber, with adjustment of hydraulic
braking during extension and compression (semi-active Aprilia
Dynamic Damping technology) with "piggy-back" tank and automated management (or manually on instrument panel) of
spring preload via electro-hydraulic system.
150 mm (5.90 in)
SIZES A AND B
Specification
Size B
Size A
Desc./Quantity
129.2 mm (5.07 in)
519 ± 2 mm (20.43 ± 0.07 in)
Brakes
BRAKES
Specification
Front
Rear
Desc./Quantity
Double floating disc, Ø 320 mm (12.60 in), radially-mounted
calliper with four Ø 32 mm (1.26 in) pistons and two calliper
pads
240 mm (9.45 in) diam. disc brake with 35 mm (1.38 in) diam.
single piston calliper
Wheels and tyres
WHEEL RIMS
Specification
Type
Front
Rear
Desc./Quantity
Light alloy rims with extractable bolt
3.50 x 17"
6.00 x 17"
TYRES
Specification
Tyre type (standard)
Desc./Quantity
DUNLOP QUALIFIER II
CHAR - 15
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CAPONORD 1200
Characteristics
Specification
Front tyre
Front tyre pressure
Desc./Quantity
120/70 ZR17" (58W)
rider only: 2.4 bar (240 kPa) (34.81 PSI)
rider + passenger: 2.5 bar (250 kPa) (36.26 PSI)
180/55 ZR17" (73W)
rider only: 2.6 bar (260 kPa) (37.71 PSI)
rider + passenger: 2.8 bar (280 kPa) (40.61 PSI)
Rear tyre
Rear tyre pressure
Supply
FUEL SYSTEM
Specification
Type
Throttle valve diameter
Fuel
Desc./Quantity
Electronic injection (Multipoint)
Ø 52 mm (2.05 in)
Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Tightening Torques
Chassis
Front side
FRONT BRAKE CALLIPER
pos.
1
Description
Callipers fastening screws
CHAR - 16
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Type
M10x55
Quantity
Torque
4
50 ± 7.5 Nm (36.88 ± 5.53
lb ft)
Notes
-
CAPONORD 1200
Characteristics
FRONT BRAKE PUMP
pos.
1
Description
Brake pump fixing screws
Type
M6
Quantity
Torque
2
10 ± 1,5 Nm (7.37 ± 1.10 lb
ft)
Notes
-
CHAR - 17
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CAPONORD 1200
Characteristics
CONTROLS HANDLEBAR
pos.
1
2
Description
Upper U-bolt fixing screw
Type
M8x25
Anti-vibration weight fastening screws
-
Quantity
Torque
4
25 ± 3.75 Nm (18.44 ± 2.76
lb ft)
2
20 ± 3 Nm (14.75 ± 2.21 lb
ft)
Notes
-
CLUTCH CONTROL
pos.
1
2
Description
Clutch pump fixing screws
Type
M6
Throttle control fixing screws
M6
CHAR - 18
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Quantity
Torque
2
10 ± 1,5 Nm (7.37 ± 1.10 lb
ft)
3
10 Nm (7.37 lb ft)
Notes
-
CAPONORD 1200
Characteristics
INSTRUMENT SUPPORT
Pos.
1
Description
Instrument panel to trellis fixing screws
Type
M8x25
Quantity
Torque
4
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
Notes
-
COOLING SYSTEM
pos.
1
Description
Electric fan fastener screw
Type
M4x45
Quantity
6
Torque
3 Nm (2.21 lb ft)
Notes
-
CHAR - 19
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CAPONORD 1200
Characteristics
pos.
2
3
Description
Flanged TE screw fastening left Radiator to trellis
Flanged TE screw fastening expansion tank
Type
M6x25
Quantity
1
Torque
10 Nm (7.37 lb ft)
Notes
-
M6x20
3
10 Nm (7.37 lb ft)
-
TOP FAIRING_WINDSHIELD
Pos.
1
2
Description
Windshield on support fastener
screw
Bracket retainer screw
CHAR - 20
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Type
M6x18
Quantity
4
Torque
10 Nm (7.37 lb ft)
Notes
-
M6x25
4
10 Nm (7.37 lb ft)
-
CAPONORD 1200
Characteristics
MUDGUARD_LUG
Pos.
1
2
3
4
5
6
7
8
9
Description
Lug fixing screw
Control unit support fixing screw
Front with rear lug fixing screw
Front mudguard fixing screw
Control unit support fixing screw
Lug on support fastener screw
Control unit support fixing screw
Lug on support fastener screw
Spacer TCEI screw
Type
M6x20
M6x35
3.9x14
M6x20
M6x12
M6x25
M5
M8
Quantity
2
1
2
4
1
2
2
2
1
Torque
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
2 Nm (1.47 lb ft)
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
6 Nm (4,42 lb ft)
Tighten by hand
Notes
Loct. 243
CHAR - 21
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CAPONORD 1200
Characteristics
FRONT FAIRING
Pos.
1
2
Description
Deflector fixing screw
Deflector fixing screw
Central part
CHAR - 22
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Type
M5x12
M5x16
Quantity
2
2
Torque
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
Notes
-
CAPONORD 1200
Characteristics
THROTTLE BODY
pos.
Description
Intake union fastener screw
Map sensor fixing screw
Injector fastener screw
Injection Throttle Body fastener
screw
Type
M6
M6
M6
M6
pos.
Description
Flanged TE screw fastening pinion
TCEI screw fastening Pin to gearbox
lever and Gearbox Lever to knurled
shaft
LH lock nut for ball joint
RH lock nut for ball joint
RH ball joint on gearbox control lever
Pinion protector fixing screw
LH ball joint on gearbox control lever
Fastener for positive cable on engine
TE screw fastening negative cable to
engine
Type
M10x1.25
M6x16
M6
M6
M6
M6x12
M6
M6x12
1
2
3
4
Quantity
8
2
2
8
Torque
12 Nm (8.85 lb ft)
5.5 Nm (4.05 lb ft)
12 Nm (8.85 lb ft)
12 Nm (8.85 lb ft)
Notes
Loctite 242
Loctite 242
Loctite 242
Quantity
1
2
Torque
50 Nm (36.88 lbf ft)
12 Nm (8.85 lbf ft)
Notes
Loctite 270
-
1
1
1
2
1
1
1
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
-
ENGINE
1
2
3
4
5
6
7
-
CHAR - 23
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CAPONORD 1200
Characteristics
AIR FILTER BOX
Pos.
1
2
Description
Cross head self-tapping screw fastening covers / filter box
Cross head self-tapping screw fastening blow-by tank
CHAR - 24
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Type
M5x20
Quantity
10
Torque
3 Nm (2.21 lb ft)
Notes
-
M5x20
2
3 Nm (2.21 lb ft)
-
CAPONORD 1200
Characteristics
CENTRE FRAME
pos.
Description
Flanged nut fastening side panels to
engine
pos.
Description
TCEI screw fastening shock absorber counterplate to RH frame bracket
Flanged nut fastening Trellis to frame
side panels
Flanged TE screw fastening chain
roller bracket to LH plate
Flanged TE screw fastening chain
roller to chain roller bracket
Screw fastening chain roller bracket
to LH plate
1
Type
M12
Quantity
3
Torque
80 Nm (59 lbf ft)
Notes
-
FRONT CHASSIS
1
2
3
4
5
Type
M10x30
Quantity
1
Torque
50 Nm (36.88 lbf ft)
Notes
-
M12
4
80 Nm (59 lbf ft)
-
M8x35
1
25 Nm (18.44 lbf ft)
Loctite 243
M8x45
1
25 Nm (18.44 lbf ft)
Loctite 243
M8x20
1
25 Nm (18.44 lbf ft)
Loctite 243
CHAR - 25
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CAPONORD 1200
Characteristics
FUEL TANK
Pos.
1
Description
Plastic ring nut
Type
-
2
Level indicator fixing screws
M6x16
3
Saddle fixing
M5
CHAR - 26
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Quantity
Torque
1
20 ± 3 Nm (14.75 ± 2.21 lb
ft)
4
3 ± 0.45 Nm (2.21 ± 0.33 lb
ft)
1
3 ± 0.45 Nm (2.21 ± 0.33 lb
ft)
Notes
-
CAPONORD 1200
Characteristics
STAND
pos.
1
2
Description
Fixing screw protection
Plate fastening screws
Type
M6x16
M8x30
3
Stand screw
M10
4
Stand nut
M10x1.25
Quantity
Torque
3
5 ± 1 Nm (3.68 ± 0.74 lb ft)
3
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
1
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
1
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
Notes
Loctite 243
Loctite 243
Loctite 243
EXHAUST
pos.
1
Description
Fixing screw protection
Type
M6x16
Quantity
Torque
3
5 ± 1 Nm (3.68 ± 0.74 lb ft)
Notes
-
CHAR - 27
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CAPONORD 1200
Characteristics
REAR BRAKE PUMP
pos.
1
Description
Rear brake lever pin
Type
-
2
Microswitch fixing nuts
M6
3
Spring linking pin
M5x7
4
Microclip plate fixing screw
M5X15
5
Brake lever push rod fixing screw
-
CHAR - 28
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Quantity
Torque
1
25 ± 3.75 Nm (18.44 ± 2.76
lb ft)
2
0.4 ± 0.08 Nm (0.29 ± 0.05
lb ft)
1
6 ± 1.2 Nm (4.42 ± 0.88 lb
ft)
1
6 ± 1.2 Nm (4.42 ± 0.88 lb
ft)
1
10 ± 1.5 Nm (7.37 ± 1.10 lb
ft)
Notes
Loctite 243
Loctite 243
Loctite 243
-
CAPONORD 1200
Characteristics
FOOTRESTS
pos.
1
Description
Rear brake pump fixing screws
Type
M6x20
2
Footrest support fixing screws
M8x40
Quantity
Torque
2
10 ± 1.5 Nm (7.37 ± 1.11 lb
ft)
4
30 ± 4.5 Nm (22.12 ± 3.31
lb ft)
Notes
Loctite 243
Loctite 243
CHAR - 29
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CAPONORD 1200
Characteristics
TANK COVER
Pos.
1
Description
Covers fastening screws
Type
M5x9
Quantity
Torque
4
3 ± 0.60 Nm (2.21 ± 0.44 lb
ft)
Notes
-
Quantity
1
Notes
-
SADDLE
Pos.
1
Description
Saddle fixing screw
CHAR - 30
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Type
M5x12
Torque
6 Nm (4.42 lb ft)
CAPONORD 1200
Characteristics
HELMET COMPARTMENT
Pos.
1
2
Description
Covers fastener screw
Compartment fixing screw
Type
M5x20
M5x12
Quantity
8
2
Torque
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
Notes
-
Torque
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
Notes
-
SIDE FAIRINGS
Pos.
1
2
Description
Fairing fastener screw
Fairing fastener screw
Type
M5x9
M5x16
Quantity
2
4
CHAR - 31
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CAPONORD 1200
Characteristics
Back side
ABS SYSTEM
pos.
-
Description
ABS ECU fastener screw
ABS ECU fastener nut
CHAR - 32
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Type
M6x25
M6
Quantity
1
2
Torque
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
Notes
Loctite 243
-
CAPONORD 1200
Characteristics
REAR SUSPENSION
Pos.
1
2
Description
Upper TCEI mounting screw
Lower TCEI mounting screw
Type
M10x50
M10x80
Quantity
1
1
Torque
50 Nm (36.88 lb ft)
50 Nm (36.88 lb ft)
Notes
-
Torque
50 Nm (36.88 lb ft)
50 Nm (36.88 lb ft)
Notes
-
ADD Version
REAR SUSPENSION ADD
Pos.
1
2
Description
Upper TCEI mounting screw
Lower TCEI mounting screw
Type
M10x50
M10x80
Quantity
1
1
CHAR - 33
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CAPONORD 1200
Characteristics
REAR WHEEL
pos.
1
2
Description
Fastening screws flexible coupling
Rear wheel axle
Type
M10
-
Quantity
5
1
Torque
●
120 ± 18 Nm (88.50 ±
13.27 lb ft)
Notes
-
Torque
12 Nm (8.85 lb ft)
Notes
-
SWINGARM
pos.
1
Description
Swingarm Pin adjustment bushing
CHAR - 34
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Type
-
Quantity
1
CAPONORD 1200
pos.
2
3
4
5
6
7
8
Characteristics
Description
Swingarm pin ring nut
Swingarm pin nut
TPSI screw fastening rear stand
bushing
TBEI screw fastening chain guard to
swingarm
TBEI Chainguard fixing screw
TBEI screw fastening chain guide to
swingarm
Flanged TBEI screw fastening chain
slider
Type
M6x40
Quantity
1
1
2
Torque
60 Nm (44.25 lb ft)
90 Nm (66.38 lb ft)
10 Nm (7.37 lb ft)
Notes
-
M5x9
1
6 Nm (4.42 lb ft)
Loctite 243
M5x9
M5x9
1
2
4 Nm (2.95 lb ft)
6 Nm (4.42 lb ft)
Loctite 243
M5x9
2
6 Nm (4.42 lb ft)
-
Torque
10 ± 2 Nm (7.37 ± 1.47 lb
ft)
Notes
Loctite 243
REAR MUDGUARD
Pos.
1
Description
Mudguard fixing screws on wheel adjustment
Type
-
Quantity
1
CHAR - 35
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CAPONORD 1200
Characteristics
LUGGAGE RACK
Pos.
1
2
3
4
Description
Luggage rack screw
Luggage rack cover screw
Luggage rack fastener screw
Luggage rack screw
CHAR - 36
Downloaded from www.Manualslib.com manuals search engine
Type
3.9x14
M8x20
M8x25
5x14
Quantity
2
2
3
5
Torque
2 Nm (1.47 lb ft)
25 Nm (18.44 lb ft)
25 Nm (18.44 lb ft)
3 Nm (2.21 lb ft)
Notes
-
CAPONORD 1200
Characteristics
REAR BODYWORK
Pos.
Description
Tail fairing fastener screw
Panniers connection fixing screw
License plate holder fastener screw
Type
M5x12
M6
Pos.
Description
Turn indicator fixing screw
Taillight screw
License plate light nut
Type
M5x16
M5x16
M5
1
2
3
Quantity
6
4
3
Torque
6 Nm (4.42 lb ft)
10 Nm (7.37 lb ft)
Notes
-
Torque
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
Notes
-
REAR LIGHTS
1
2
3
Quantity
2
2
1
CHAR - 37
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CAPONORD 1200
Characteristics
Engine
HEAD COVER
pos.
1
2
3
-
Description
Special screw for fastening head
cover
Special screw for fastening head
cover
Oil breather fastener screw
Spark plugs
CHAR - 38
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Type
M6
Quantity
8
Torque
9 Nm (6.64 lbf ft)
Notes
-
M6
2
9 Nm (6.64 lbf ft)
-
M6
-
2
2
5.50 Nm (4.06 lbf ft)
10-12 Nm (7.38-8.85 lbf
ft)
-
CAPONORD 1200
Characteristics
HEAD
pos.
Description
Water Temperature Sensor
Threaded plug for water sensor seat
Head stud bolt fastener nut - pretightening
Type
M12x1.5
M12x1.5
M10x1.25
Quantity
1
1
8
Torque
22 Nm (16.22 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
3
Head stud bolt fastener nut - tightening
M10x1.25
8
13 Nm (9.59 lbf ft) +
135° + 135°
4
Fastener for Head / Cylinder / Outer
side crankcase
Fastener for Head / Cylinder / Inner
side crankcase
Nut fastening Stud Bolts / Head
Nut fastening Stud Bolts / Head
Bleed union fastener screw
M6
2
12 Nm (8.85 lbf ft)
Notes
Loctite Drise AL 506
Lubricate the
threads before tightening
Lubricate the
threads before tightening
-
M6
4
12 Nm (8.85 lbf ft)
-
M6
M8
M5
4
2
4
12 Nm (8.85 lbf ft)
26 Nm (19.18 lbf ft)
5.50 Nm (4.06 lbf ft)
Loctite dry loc 2040
1
2
3
5
6
7
8
CHAR - 39
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CAPONORD 1200
Characteristics
CYLINDER
pos.
1
2
Description
Chain tensioner fastener screw
Cylinder plate fastener screw
Type
M6
M6
Quantity
4
4
3
Chain tensioner adjustment screw
M6
2
CHAR - 40
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Torque
13 Nm (9.59 lb ft)
7.84-9.81 Nm
(5.78-7.23 lb ft)
5.50 Nm (4.06 lb ft)
Notes
-
CAPONORD 1200
Characteristics
TIMING SYSTEM
pos.
1
2
3
4
5
Description
Camshaft gear fastener nut
Timing drive gear fastener screw
Type
M15x1
M24x1.5
Quantity
4
2
Torque
90 Nm (66.38 lbf ft)
40 Nm (29.50 lbf ft)
Special screw for fastening mobile /
fixed shoes
Cam tower / head fastener screws
Camshaft retainer plate fastener
screw
M8
4
19 Nm (14.01 lbf ft)
M6
torx M5
16
8
12 Nm (8.85 lbf ft)
8.5 Nm (6.26 lbf ft)
Notes
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
CHAR - 41
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CAPONORD 1200
Characteristics
6
pos.
Description
Decompression device fixing screw
Type
torx M8
Quantity
2
Torque
28.5 Nm (21.02 lbf ft)
7
Fastener screw
M5
2
5.50 Nm (4.06 lbf ft)
Description
Crankshaft primary gear fastener nut
Connecting rod screw
Type
M24x1.5
M10
Notes
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
CRANKSHAFT
pos.
1
2
CHAR - 42
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Quantity
1
4
Torque
Notes
300 Nm (221.27 lbf ft)
Anticlockwise nut
15 + 30 Nm (11.06 +
Lubricate the
22.13 lbf ft) + 50° ± 2°, threads before tightfinal control torque 65 ening
78 Nm (47.94 - 57.53 lbf
ft)
CAPONORD 1200
Characteristics
OIL PUMP
pos.
Type
M16x1.5
-
Quantity
1
1
Torque
19 Nm (14.01 lbf ft)
13 Nm (9.59 lbf ft)
Notes
-
-
1
20 Nm (14.75 lbf ft)
-
4
5
6
Description
Oil drainage plug
Fastening oil sensor on clutch side
crankcase half
Fastening oil filter union on clutch
side crankcase half
Oil filter
Oil pressure regulator valve
Oil pump fixing screw
M18x1.5
M6
1
1
2
7
8
9
10
Rose pipe fixing screw
Oil pump driven gear fastener nut
By-Pass plate fastener screw
Oil cooling radiator nipple
M6
M6
M5
M16x1.5
2
1
2
2
1
2
3
14 Nm (10.33 lbf ft)
42 Nm (30.98 lbf ft)
5-6 Nm (3.69-4.42 lbf ft) 3M SCOTCH GRIP
2353
12 Nm (8.85 lbf ft)
11 Nm (8.11 lbf ft)
5.50 Nm (4.06 lbf ft)
Loctite 242
42.5 Nm (31.35 lbf ft)
-
CHAR - 43
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CAPONORD 1200
Characteristics
GEAR SELECTOR
pos.
1
2
3
4
5
6
7
Description
Gear retainer pawl fastener screw
Selector plate fastener screw
Type
M6
M5
Quantity
1
3
Torque
12 Nm (8.85 lb ft)
5.50 Nm (4.06 lb ft)
Screw fastening Desmodromic selector drum / Selector sprocket
Gear sensor fastener screw
Selector pin fastener onto clutch side
crankcase half
Gear retainer pawl fastener pin
M8
1
20 Nm (14.75 lb ft)
M5
M10x1.5
2
1
5.50 Nm (4.06 lb ft)
16 Nm (11.80 lb ft)
-
1
-
1
11-13 Nm (8.11-9.59 lb
ft)
10-12 Nm (7.38-8.85 lb
ft)
Gear retainer pawl fastener flanged
nut
CHAR - 44
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Notes
Loctite dry loc 2040
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
Loctite 270
Loctite 242
-
CAPONORD 1200
Characteristics
CLUTCH COVER
pos.
1
2
3
4
5
Description
Screw fastening Clutch Cover / intermediate Clutch side cover
Clutch fastener nut
Fastening oil filler plug on Clutch cover
Screw fastening fixing Plate / Clutch
control Mounting
Screw fastening clutch control
mounting on flywheel side crankcase
half
Type
M6
Quantity
6
Torque
13 Nm (9.59 lbf ft)
Notes
-
M24x1
-
1
1
170 Nm (125.38 lbf ft)
2 Nm (1.48 lbf ft)
Chamfer
-
M5
3
5.50 Nm (4.06 lbf ft)
Loctite 242
M6
2
8 Nm (5.90 lbf ft)
-
CHAR - 45
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CAPONORD 1200
Characteristics
CLUTCH
pos.
Description
Clutch spring fastener screw
Type
M6
pos.
Description
Clutch side cover fastener screw
Type
M6
1
Quantity
6
Torque
11 Nm (8.11 lbf ft)
Notes
-
Torque
13 Nm (9.59 lbf ft)
Notes
-
WATER PUMP
1
CHAR - 46
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Quantity
11
CAPONORD 1200
pos.
2
3
4
5
6
7
8
Description
Fastener screw for Pump Cover /
Clutch side cover
Screw fastening Pump Cover /
Clutch Cover / clutch side crankcase
half
Nut fastening water pump drive gear
sprocket
Water pump rotor
Screw fastening chain tensioner slider to water pump
Water pump support fixing screw
Water pump support plug
Description
Spark plug
Freewheel Ring fastener screw
Screw fixing rotor - Crankshaft - (12
mm - 0.47 in)
Screw fixing rotor - Crankshaft - (14
mm - 0.55 in)
Screw fastening Stator / Flywheel
Cover
Screw fastening pick-up / Flywheel
cover
Flywheel cover fastener screw
Screw fastening starter motor bracket to motor and crankcase
Crankshaft access cap
Retainer plate fastener screw
Characteristics
Type
M6
Quantity
3
Torque
13 Nm (9.59 lbf ft)
Notes
-
M6
2
13 Nm (9.59 lbf ft)
-
M6
1
12 Nm (8.85 lbf ft)
-
M6
1
1
-
M6
M6x10
3
1
4.50 Nm (3.32 lbf ft)
8-10 Nm (5.90-7.38 lbf
ft)
12 Nm (8.85 lbf ft)
6.5 Nm (4.79 lbf ft)
Type
M6
Quantity
4
6
Torque
11 Nm (8.11 lb ft)
14 Nm (10.33 lb ft)
M12x1.25
1
130 Nm (95.88 lb ft)
M12x1.25
1
-
M6
3
190-200 Nm
(140.14-147.51 lb ft)
9 Nm (6.64 lb ft)
M5
2
3.50 Nm (2.58 lb ft)
Loctite 270
M6
M6
10
4
Loct. 242
M6
1
1
13 Nm (9.59 lb ft)
6.86-7.84 Nm
(5.06-5.78 lb ft)
4 Nm (2.95 lb ft)
8 Nm (5.90 lb ft)
3M SCOTCH GRIP
2353
IGNITION
pos.
1
2
3
3
4
5
6
7
8
9
Notes
3M SCOTCH GRIP
2353
-
-
3M SCOTCH GRIP
2353
CHAR - 47
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CAPONORD 1200
Characteristics
CRANKCASE 1
pos.
1
2
3
Description
Bearing retainer fastener screw
Piston oil jet fastener screw
Tapered plug for crankshaft main
bearing lubrication
CHAR - 48
Downloaded from www.Manualslib.com manuals search engine
Type
M6
M5
M8x1
Quantity
3
2
4
Torque
10 Nm (7.38 lbf ft)
5.50 Nm (4.06 lbf ft)
15 Nm (11.06 lbf ft)
Notes
Loctite 270
Loctite 270
-
CAPONORD 1200
Characteristics
CRANKCASE 2
pos.
1
2
3
Description
Special calibrated screw for gearbox
lubrication
Screw fastening flywheel side /
clutch side crankcase halves
Screw fastening flywheel side /
clutch side crankcase halves
Type
M9x1
Quantity
1
Torque
18 Nm (13.28 lbf ft)
Notes
-
M6
11
13 Nm (9.59 lbf ft)
-
M8
9
29 Nm (21.39 lbf ft)
-
Overhaul data
Assembly clearances
Cylinder - piston assy.
The pistons are available in four size types (A, B,
C, D) to be coupled to the four cylinder types (A,
B, C, D).
Only one type of piston ring is available.
CYLINDER-PISTON COUPLING
Name
Cylinder-piston clearance A - A
Cylinder-piston clearance B - B
Cylinder-piston clearance C - C
Cylinder-piston clearance D - D
Initials
Type A - A
Type B - B
Type C -C
Type D - D
Cylinder
105.990 - 105.997 mm
(4.1728 - 4.1731 in)
105.997 - 106.004 mm
(4.1731 - 4.1734 in)
106.004 - 106.011 mm
(4.1734 - 4.1736 in)
106.011 - 106.018 mm
(4.1736 - 4.1739 in)
Piston
105.928 - 105.935 mm
(4.1704 - 4.1707 in)
105.935 - 105.942 mm
(4.1707 - 4.1709 in)
105.942 - 105.949 mm
(4.1709 - 4.1712 in)
105.949 - 105.956 mm
(4.1712 - 4.1715 in)
Play on fitting
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
Crankcase - crankshaft - connecting rod
INTERNAL MARKING ON FIRST GENERATION CRANKCASES
CHAR - 49
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CAPONORD 1200
Characteristics
Crankcases are classified in two classes (1 or 2) depending on the diameter of the main bearing seat.
The class is indicated on both crankcase halves, specifically, in the rear cylinder area on flywheel side
crankcase halves and in the front cylinder area on clutch side crankcase halves.
CRANKCASE CLASSES
Specification
Crankcase class 1
Crankcase class 2
Desc./Quantity
Bushing seat diameter: 53.954 - 53.960 mm (2.1241 - 2.1244
in)
Bushing seat diameter: 53.960 - 53.966 mm (2.1244 - 2.1246
in)
INTERNAL MARKING ON SECOND GENERATION CRANKCASES
Crankcases are classified in two classes (1 or 2) depending on the diameter of the main bearing seat.
The class is indicated on both crankcase halves, specifically, in the starter gear area on flywheel side
crankcase halves and in the gearbox control mechanism area on clutch side crankcase halves.
See also
Removing the flywheel cover
CHAR - 50
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CAPONORD 1200
Characteristics
There are three crankshaft classes selectable for
each bearing:
•
4 - 5 - 6 for the flywheel side;
•
7 - 8 - 9 for the clutch side;
The class is stamped on the outer face of the
crankshaft counterweight.
NOTE
TWO DIFFERENT CRANKSHAFT CLASSES MAY BE POSSIBLE ON THE TWO BEARINGS.
CRANKSHAFT CLASSES
Specification
Crankshaft classes 4 - 7
Desc./Quantity
Main journals - diameter: 49.978 - 49.984 mm (1.9676 - 1.9679
in)
Main journals - diameter: 49.972 - 49.978 mm (1.9674 - 1.9676
in)
Main journals - diameter: 49.984 - 49.990 mm (1.9679 - 1.9681
in)
Crankshaft classes 5 - 8
Crankshaft classes 6 - 9
Once the categories below are checked:
•
crankcase
•
flywheel side main journal
•
clutch side main journal
choose the bushings used for assembly from the following table
See also
Removing the flywheel cover
MAIN BUSHINGS
Main journal
Class 4 main journal (l.v.)
Class 5 main journal (l.v.)
Class 6 main journal (l.v.)
Class 7 main journal (l.f.)
Class 8 main journal (l.f.)
Class 9 main journal (l.f.)
Crankcase class 1
Semi-bushing type A (red)
Semi-bushing type B (blue)
Semi-bushing type E (green)
Semi-bushing type A (red)
Semi-bushing type B (blue)
Semi-bushing type E (green)
Crankcase class 2
Semi-bushing type B (blue)
Semi-bushing type C (yellow)
Semi-bushing type A (red)
Semi-bushing type B (blue)
Semi-bushing type C (yellow)
Semi-bushing type A (red)
Crankcase class (internal marking on first generation crankcases)
Two different crankcase classes (A or B) are available, selected in relation to the centre-to-centre
distance between the primary reduction gears.
The class is indicated on the clutch side crankcase
half near the front cylinder area.
NOTE
IN THE EVENT OF CRANKCASE REPLACEMENT, THE PRIMARY REDUCTION GEAR IS SUPPLIED READY MESHED.
CHAR - 51
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CAPONORD 1200
Characteristics
CRANKCASE CLASSES 01
Specification
Crankcase class A
Desc./Quantity
Centre-to-centre distance: 110.50 - 110.54 mm (4.3504 4.3519 in)
Centre-to-centre distance: 110.46 - 110.50 mm (4.3488 4.3504 in)
Crankcase class B
See also
Removing the flywheel cover
Crankcase class (internal marking on second
generation crankcases)
Two different crankcase classes (A or B) are available, selected in relation to the centre-to-centre
distance between the primary reduction gears.
The class is indicated on the clutch side crankcase
half, in the gearbox control mechanism area.
NOTE
IN THE EVENT OF CRANKCASE REPLACEMENT, THE PRIMARY REDUCTION GEAR IS SUPPLIED READY MESHED.
CRANKCASE CLASSES 02
Specification
Crankcase class A
Crankcase class B
Class one
Two different pinion classes (A or B) are available,
selected in relation to the centre-to-centre distance between the primary reduction gears.
On class B pinions only, the class is indicated on
the pinion itself.
See also
Removing the flywheel cover
CHAR - 52
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Desc./Quantity
Centre-to-centre distance: 110.50 - 110.54 mm (4.3504 4.3519 in)
Centre-to-centre distance: 110.46 - 110.50 mm (4.3488 4.3504 in)
CAPONORD 1200
Characteristics
Crankshaft class (crank pin)
There are four different classes of crankshaft available (0, 1, 2, 3), selected in relation to crank pin
diameter.
There are four different classes of crankshaft available (E1, E2, ...) selectable in relation to connecting rod weight.
Key:
* Class according to connecting rod weight.
** Class according to crank pin diameter.
*** Serial number for traceability and indicating date.
SHAFT CATEGORY
Class
Crank pin diameter (mm)
42.000 - 42.006 mm (1.65354 - 1.65377 in)
41.994 - 42.000 mm (1.65330 - 1.65354 in)
41.988 - 41.994 mm (1.65307 - 1.65330 in)
41.982 - 41.988 mm (1.65283 - 1.65307 in)
0
1
2
3
See also
Removing the flywheel cover
Selecting bushings
There is only one dimension class for the connecting rod. As a result, the bushings used must be
selected in accordance with the dimension class of the crank pin.
BUSHINGS
Crank pin diameter
Connecting rod class 1
Semi-bushing type E (green)
Semi-bushing type A (red)
Semi-bushing type B (blue)
Semi-bushing type C (yellow)
Crankshaft class 0
Crankshaft class 1
Crankshaft class 2
Crankshaft class 3
Selecting connecting rods
Not all weight classes are available as spare parts. Only the two most significant weight classes are
available - refer to the following table for selection:
CONNECTING RODS
Class according to
crankshaft weight
Original connecting rod class (colour)
E1
E2
E3
E4
E5
E6
E7
CAUTION
Brown connecting rod
Blue connecting rod
Yellow connecting rod
Green connecting rod
Pink connecting rod
Black connecting rod
White connecting rod
Original connecting
rod class ("E"
marking)
E1
E2
E3
E4
E5
E6
E7
Spare part connecting
rod class
Cat. A
Cat. A
Cat. A
Cat. A
Cat. B
Cat. B
Cat. B
CHAR - 53
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CAPONORD 1200
Characteristics
WHEN ORDERING A NEW CONNECTING ROD OF CATEGORY "A" OR OF CATEGORY "B" (SEE
TABLE), CAN BE RECEIVED:
- IN THE FIRST CASE (CAT. A) ANY CONNECTING ROD "E1 or E2 or E3 or E4" THAT CAN BE
COUPLED TO THE CRANKSHAFT, EVEN IF IT IS DIFFERENT FROM THE ONE INSTALLED
ORIGINALLY.
- IN THE SECOND CASE (CAT. B) ANY CONNECTING ROD "E5 or E6 or E7" THAT CAN BE
COUPLED TO THE CRANKSHAFT, EVEN IF IT IS DIFFERENT FROM THE ONE INSTALLED
ORIGINALLY
CAUTION
THE CONNECTING RODS OF THE SAME CRANKSHAFT MUST BE THE SAME COLOUR OR
MARKING (EX. E1, E2, E3, ETC.) AND MUST HAVE THE SAME TYPE OF COUPLING WITH THE
CRANKSHAFT.
WHEN REFITTING, ALSO ENSURE THAT THE SEMI-BUSHINGS ARE ALL OF THE SAME CLASS.
See also
Removing the flywheel cover
Recommended products chart
RECOMMENDED PRODUCTS TABLE
Product
ENI i-RIDE PG 15W-50
FUCHS TITAN SAF 1091
OJ RACING FORK OIL TYPE 01
FUCHS TITAN SAF 1091
AGIP MP GREASE
AGIP CHAIN LUBE SPRAY
AGIP BRAKE 4
AGIP PERMANENT SPECIAL
CHAR - 54
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Description
Engine oil
Specifications
Use branded oils with performance
equivalent to or exceeding API SJ, JASO
MA - ACEA A3 - JASO MA2 specifications.
Fork oil (Caponord 1200)
Fork oil (Caponord 1200 Travel Pack)
Actuator oil of the active rear single shock
absorber (Caponord 1200 Travel Pack)
Black smooth textured lithium-calcium ISO L-X-BCHB 2 - DIN 51 825 KP2K-20
soap based grease containing EP (extreme pressure) additives with optimal
water-repellent properties
Spray lubricating grease
Brake / Clutch fluid
SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO
4925 - CUNA NC 956 DOT 4 synthetic
fluid
Ethylene glycol-based antifreeze fluid ASTM D 3306 - ASTM D 4656 - ASTM D
with organic inhibition additives. Red,
4985 - CUNA NC 956-16
ready to use.
INDEX OF TOPICS
SPECIAL TOOLS
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S-TOOLS
CAPONORD 1200
Special tools
SPECIAL TOOLS
Stores code
020709Y
Description
Engine support
020710Y
Engine plate
AP8140187
Engine support stand
020850Y
Primary gear lock
020712Y
Handle for Flywheel cover removal
020713Y
Flywheel extractor
S-TOOLS - 56
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CAPONORD 1200
Special tools
Stores code
020714Y
Description
Dial gauge mounting
9100896
Clutch housing locking tool
020716Y
Connecting rod locking
020894Y
Pin snap ring fitting tool
020895Y
Piston installation ring
020719Y
Timing pin
S-TOOLS - 57
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CAPONORD 1200
Special tools
Stores code
020382Y
Description
Valve cotters removal tool
020896Y
Bushing for valve removal
020720Y
Timing tool
020376Y
Adapter handle
020891Y
Adapter 25 mm (0.98 in)
020362Y
12 mm guide
S-TOOLS - 58
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CAPONORD 1200
Special tools
Stores code
020724Y
Description
Gear control rod roller cage punch
020726Y
Extractor for bushings
020727Y
Punch for bushings
020884Y
46 mm wrench for steering ring nut
020193Y
Gauge for oil pressure check
AP8140612
Fuel pressure gauge
S-TOOLS - 59
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CAPONORD 1200
Special tools
Stores code
AP8140199
Description
Tool panel
8140426
Hooks for panel
020888Y
Pliers for pre-fill pipe
020889Y
Pumping member ring nut locking spanner
020890Y
Pumping member stanchion support rod
020922Y
P.A.D.S.
020957Y
Key for upper fork nut
S-TOOLS - 60
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CAPONORD 1200
Special tools
Stores code
020958Y
Description
Fork cartridge protection
AP8140149
Protection for fitting operations
AP8140189
Oil seal fitting tool for Ø 43 mm (1.69 in)
orifices
AP8140146
Weight
S-TOOLS - 61
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INDEX OF TOPICS
MAINTENANCE
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MAIN
CAPONORD 1200
Maintenance
Maintenance chart
Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum
function and performance.
To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are
summarised in the table shown on the following page. Any minor faults must be reported without delay
to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to
solve it.
All scheduled services must be carried out at the specified intervals and mileage, as soon as the predetermined mileage is reached. Carrying out scheduled services on time is essential for the validity of
your warranty. For further information regarding Warranty procedures and ''Scheduled Maintenance'',
please refer to the ''Warranty Booklet''.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Replace at whichever of the following occurs first: 40,000 km (24854 mi) or 48 months
(2) Replace every 2 years or 50,000 Km (31068 mi).
(3) Replace every 4 years
(4) At each engine start
(5) Check every month
(6) Check each time the rear tyre is replaced
(7) Lubricate if you are riding in the rain, on wet roads or after the vehicle has been washed
ROUTINE MAINTENANCE TABLE
km x 1,000
Rear shock absorber
Spark plug
Drive chain (7)
Transmission cables and controls
Steering bearings and steering clearance
Wheel bearings
Control unit diagnosis
Brake discs
Air filter
Engine oil filter
Fork
General vehicle operation
Valve clearance
Cooling system
1
10
I
I
I
I
I
I
I
R
I
20
I
R
I
I
30
I
40
I
R
I
I
I
I
I
I
I
R
R
I
I
A
I
I
I
I
R
R
I
I
A
I
I
MAIN - 63
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CAPONORD 1200
Maintenance
km x 1,000
Braking systems
Light circuit
Safety switches
Clutch control fluid (2)
Brake fluid (2)
Coolant (2)
Fork oil (1)
Engine oil
Light aiming
Fork oil seals
Flexible coupling (6)
Clutch lever pin (7)
Tyres - pressure/wear (5)
Wheels
Bolts and nuts tightening
Stand joint
Suspension and setting
Fault warning light on instrument panel (4)
Fuel lines (3)
Clutch wear
Brake pad wear
Labour time - Caponord 1200
(minutes)
Labour time - Caponord 1200
ADD (minutes)
1
I
I
10
I
I
I
R
I
L
I
I
I
L
I
L
I
L
20
I
I
I
I
I
I
R
I
I
I
L
I
I
I
L
I
I
110
I
130
I
I
I
320
110
130
320
30
I
L
I
L
40
I
I
I
I
I
I
R
R
I
I
I
L
I
I
I
L
I
I
130
I
I
I
410
130
460
Spark plug
At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
CAUTION
ALWAYS REPLACE ALL SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING.
•
Remove the saddle.
•
Remove the side fairings.
In order to reach the spark plugs:
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS,
LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE.
FRONT SPARK PLUGS
MAIN - 64
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CAPONORD 1200
•
Maintenance
Working on the left side of the vehicle,
unscrew and remove the screw.
•
Turn the radiator forwards to act on the
coils.
•
Unscrew and remove the two screws
fixing coils to head cover.
•
Slide out the front coils.
•
Unscrew and remove the front spark
plugs.
REAR SPARK PLUGS
•
Lift the tank.
•
Unscrew and remove the rear coil fixing screws.
•
Slide out the rear coils.
•
Unscrew and remove the rear spark
plugs.
MAIN - 65
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Maintenance
See also
Fuel tank
•
Check the gap between the electrodes with a feeler gauge.
CAUTION
DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP.
The gap between the electrodes should be 0.6 0.7 mm (0.023 - 0.027 in) Wear limit is achieved
when the gap for one of the two electrodes reaches 1.0 mm (0.039 in)
•
Make sure the washer is in good conditions.
Installation:
•
Once the washer is fitted, screw the
spark plug carefully to avoid damaging
the thread.
•
Screw the spark plug to the prescribed
torque.
CAUTION
TIGHTEN THE SPARK PLUG CORRECTLY, OTHERWISE
THE ENGINE MAY OVERHEAT AND GET IRRETRIEVABLE
DAMAGED. USE ONLY THE RECOMMENDED TYPE OF
SPARK PLUG, OTHERWISE, THE ENGINE DURATION AND
PERFORMANCE COULD BE COMPROMISED.
See also
Engine
MAIN - 66
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CAPONORD 1200
CAPONORD 1200
Maintenance
Engine oil
Check
Check the engine oil level frequently.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.
IF YOU CHECK LEVEL WHEN THE ENGINE IS COLD, OIL LEVEL COULD TEMPORARILY DROP
BELOW THE "MIN" MARK.
THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDED THAT THE ALARM WARNING
LIGHT AND THE ENGINE OIL PRESSURE ICON DO NOT TURN ON SIMULTANEOUSLY ON THE
DISPLAY.
CAUTION
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY
15 Km (10 miles) IN EXTRAURBAN CONDITIONS (ENOUGH TO WARM UP THE ENGINE OIL TO
OPERATING TEMPERATURE).
•
Switch off the engine and wait at least
five minutes to allow the lubricant to
drain back into the sump.
•
Keep the vehicle upright on a level surface and with both wheels on the
ground.
•
Check the oil level from the sight glass
on the clutch case.
MAX = maximum level.
MIN = minimum level
The difference between the "MAX" and "MIN"
marks is approx. 460 cm³ (28.07 cu.in).
CAUTION
DO NOT EXCEED THE MAXIMUM LEVEL
CAUTION
THE VEHICLE MUST BE UNLOADED.
Replacement
Check the engine oil level frequently.
To change the oil:
CAUTION
MAIN - 67
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Maintenance
CAPONORD 1200
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY; IDEAL
TEMPERATURE IS REACHED AFTER THE ENGINE HAS RUN FOR ABOUT TWENTY MINUTES.
OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT; BE CAREFUL NOT TO GET BURNED
WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW.
•
Use a cloth to wipe off any mud deposit
on the area next to the filler plug (1).
•
Place a container with + 4000 cm³ (244
cu.in) capacity under the drainage plug
(2).
•
Unscrew and remove the drainage
plug (2).
•
Unscrew and remove the filler plug (1).
•
Drain the oil into the container; allow
several minutes for oil to drain out completely.
•
Replace the sealing washer of the
drainage plug (2).
•
Remove any metal scrap attached to
the drainage plug (2) magnet.
•
Screw and tighten the drainage plug
(2).
•
Replace the oil filter.
•
Fill up to the right engine oil level by adding recommended engine oil.
See also
Engine
oil filter
Check
Engine oil filter
•
To access the oil filter (1), remove the
ABS control unit first (2).
MAIN - 68
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CAPONORD 1200
•
Maintenance
Unscrew and remove the cap to drain
out the engine oil.
•
Unscrew and remove the engine oil filter.
•
Fit a new engine oil filter.
•
Add engine oil up to the correct level.
•
Start the engine, wait some seconds,
then stop the engine and check the oil
level again. Top up and set the level if
necessary.
Air filter
•
Remove the fuel tank.
•
Unscrew and remove the ten screws.
•
Remove the filter box cover.
COVER THE INTAKE DUCTS WITH A CLEAN CLOTH SO
THAT FOREIGN BODIES DO NOT GET INTO THE INLET
DUCTS. UPON REFITTING AND BEFORE PLACING THE
FILTER BOX COVER, MAKE SURE NEITHER THE CLOTH
NOR ANY OTHER OBJECT HAS BEEN LEFT INSIDE THE
FILTER BOX. MAKE SURE THE FILTERING ELEMENT IS
CORRECTLY PLACED SO THAT UNFILTERED AIR DOES
NOT FLOW IN. DO NOT FORGET THAT EARLY WEAR OF
THE PISTON RINGS AND THE CYLINDER CAN BE
CAUSED BY A MALFUNCTIONING OR MISPLACED FILTERING ELEMENT.
MAIN - 69
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Maintenance
•
Unscrew and remove the four screws.
•
Remove the air-box cover.
•
Remove the filtering element.
CAPONORD 1200
Checking the valve clearance
The following operation can be carried out also with the engine fitted on the vehicle.
•
Remove both head covers.
CAUTION
WHENEVER THE HEAD COVER IS REMOVED, ALL FOUR RUBBER RINGS AND THE GASKET
SHOULD BE REPLACED.
•
Using the pins, synchronise the cylinder being checked.
•
Using a feeler gauge, measure the distance between the cam of the camshaft
and the valve bucket tappet
•
Take note of the measurement.
If valve clearance is not within the tolerance range,
adjust as follows:
•
Take the engine to the TDC.
•
Lock the camshafts by using the corresponding timing pins.
Specific tooling
020719Y Timing pin
Characteristic
Valve clearance at intake
0.15 - 0.20 mm (0.0059 - 0.0079 in)
Outlet valve clearance
0.20 - 0.25 mm (0.0079 - 0.0098 in)
•
Remove one camshaft at a time
•
Leave the other camshaft assembled and blocked by means of the timing pin.
CAUTION
IF BOTH CAMSHAFTS ARE REMOVED, THE ENGINE SPINS MAKING TIMING NECESSARY.
See also
MAIN - 70
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CAPONORD 1200
Maintenance
Removing the
head cover
•
Remove the bowl tappets and the adjustment shims using a magnet.
NOTE
GREASE THE BOWL TAPPETS AND THE ADJUSTMENT
SHIMS PROPERLY EACH TIME THEY ARE REMOVED.
•
Replace calibrated pads with a pad
thick enough to correct the valve clearance previously detected.
•
List of calibrated break pads:
1. Calibrated pad 2.60
2. Calibrated pad 2.65
3. Calibrated pad 2.70
4. Calibrated pad 2.75
5. Calibrated pad 2.80
6. Calibrated pad 2.85
7. Calibrated pad 2.90
8. Calibrated pad 2.95
9. Calibrated pad 3.00
10.Calibrated pad 3.05
11.Calibrated pad 3.10
12.Calibrated pad 3.15
13.Calibrated pad 3.20
14.Calibrated pad 3.25
15.Calibrated pad 3.30
16.Calibrated pad 3.35
17.Calibrated pad 3.40
18.Calibrated pad 2.55
19.Calibrated pad 2.50
20.Calibrated pad 2.45
21.Calibrated pad 2.40
CAUTION
BEFORE REFITTING HEAD COVERS, CLEAN HEAD AND COVER SURFACES CAREFULLY.
MAIN - 71
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Maintenance
CAPONORD 1200
•
Apply THREEBOND on the head cover perimeter along the gasket housing.
•
Apply THREEBOND on the head in the
areas indicated in the figure.
MAIN - 72
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INDEX OF TOPICS
TROUBLESHOOTING
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TROUBL
Troubleshooting
Engine
TROUBL - 74
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CAPONORD 1200
INDEX OF TOPICS
ELECTRICAL SYSTEM
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ELE SYS
CAPONORD 1200
Electrical system
ELECTRICAL SYSTEM
pos.
1
2
3
4
5
6
7
8
-
Description
Coil fixing screw
TE screw fastening regulator to
frame
Screw fastening ECU to filter box
base
Speed sensor TBEI fixing screw
Self-tapping screw fastening demand sensor mounting to demand
sensor
TBEI screw fastening relay support
to demand sensor mounting
TEFL screw fastening cableway to
demand sensor mounting
TEFL horn fixing screw
TBEI starter relay fixing screw
Type
M6
M6x30
Quantity
2
2
Torque
5.50 Nm (4.06 lbf ft)
10 Nm (7.37 lbf ft)
Notes
-
-
4
3 Nm (2.21 lbf ft)
-
M5x16
5x14
1
3
6 Nm (4.42 lbf ft)
4 Nm (2.35 lbf ft)
-
M6x16
4
10 Nm (7.37 lbf ft)
-
M6x12
1
10 Nm (7.37 lbf ft)
-
M6x12
M6x10
1
2
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
-
Electrical system installation
INTRODUCTION
Scope and applicability
The scope of this document is to define exclusively the passages of the electrical cabling of the vehicle,
its positioning, and fastening on the frame, instruments holding support and saddle mounting; the possible critical issues and the particular checks on connections and passages, in order to reach the
reliability objectives of the vehicle. Other particulars that are not necessary to such purpose, could
appear to be little detailed or even not correct.
Materials used and corresponding quantities
The electrical system consists of the following cable harnesses and parts:
ELE SYS - 76
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CAPONORD 1200
•
No.1 Main Cable Harness.
•
No.1 License Plate Cable Harness.
•
No. 25 Large plastic clamp (4.5x280).
•
No. 9 Small plastic clamp (2.5x160).
•
No. 4 Rubber clamp (long).
•
No. 5 Rubber clamp (short).
•
No. 5 Tyco connector support.
•
No. 8 Cable grommets.
•
No. 3 Cable guide.
•
No. 2 Cable guide for ABS sensors.
•
No. 1 Cable grommets.
•
No. 1 Headlamp water seal rubber.
•
No. 2 Headlamp water seal rubber.
Electrical system
Motorcycle division
The wiring timing is subdivided in three essential sections, as indicated in the figure.
1. Front section
2. Central section
3. Rear section
SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES (ALL VERSIONS).
It is extremely important that any security-locks for the following connectors are properly connected and
correctly tightened to ensure proper engine, and therefore, proper vehicle operation.
1. Dashboard connector and cap.
2. Demand Master and Slave connectors, check the closing of the security lock (grey)
3. Adjustable connector, Pick Up and alternator.
4. Gear sensor connector.
5. Side Stand Switch Connector.
6. Coils 1 and 2 connectors on front and rear cylinders.
7. Control unit connectors (7SM).
ELE SYS - 77
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Electrical system
CAPONORD 1200
8. Fuel Pump Connector.
9. Key and aerial key connector (check correct passage).
10.RH and LH light switch connectors, front stop switch, clutch switch, MAP sensor front fork (with
rubber plug well inserted), CDCi front fork.
11.ABS Control Unit Connector, correct positioning of the cap, and correct cabling passage.
12.Front and rear ABS sensor connector (speed).
13.Auxiliary fuses and VCU fuse (rubber housing correct positioning and closing).
14.Throttle motors connectors, check the Security Lock closing (yellow).
15.Map Sensor connectors (front and rear cylinder).
16.Intake air temperature (filter box).
17.Fuel injectors connectors (all 4).
18.Check the ground fastening on motor's rear cylinder head.
19.Check the correct fastening (to torque) of the screws on the positive cables of the starter relay
and the correct passage of the cable Battery-Starter relay.
20.Check the fastening of the positive cable on the starter motor. Check if the cap has a hole and if
it is well inserted.
21.Check the correct passage and fastening of the primary fuses and ABS under the saddle.
22.Check the correct connection VCU control unit and correct cabling passage.
23.Check if the gap of the corrugated under the saddle is hidden (downwards).
24.Check the connection of the rear CDCi shock absorber and if the cap is well inserted.
25.Check the passage of the rear CDCi cable and the correct cabling passage.
26.Check the connection of the rear shock absorber preload.
27.Check the connection of the USB port.
28.Check the connection of the starter relay (under the saddle) and if the fuses are 30A (green).
29.Check the connection of the relays: fans, safety, auxiliary and primary injection.
30.Check the connection on the (front) headlamp relay and the correct insertion of the lamps connectors.
31.Check the fans connections (left and right).
32.Check the connection and the correct positioning of the front and rear Lambda probes.
33.Check the connection and the correct routing of the rotary sensor on saddle mounting (LH side).
34.Check the T.Map on the fork (LH stanchion) and correct cables fastening and routing.
35.Make sure that the cables on the handlebar area are all soft, by turning the handlebar they should
not be in traction.
36.Check correct insertion of the cap on the oil sensor and the presence of the clamp.
37.Check the connection of the motor's exhaust valve.
38.Check the connection of the auxiliary fuel level sensor.
39.Check that the RH light switch has the key "heated handgrips" and "cruise".
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40.Check the positioning of the horn and make sure that the mufflers are not stuck on the flap, check
the presence of the clamp retaining the horn's cables.
41.Check the GAP between the tone wheel and the ABS sensors (it must be between 0.5 and 2mm).
42.Check the correct tightening of the front and rear ABS sensors screws.
General wiring diagram
CAPONORD 1200
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key:
1. MULTIPLE CONNECTORS
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Electrical system
2. FRONT LEFT TURN INDICATOR
3. FRONT HEADLAMP
4. FRONT RIGHT TURN INDICATOR
5. HIGH BEAM LIGHTS RELAY
6. LIGHT RELAY
7. LEFT LIGHT SWITCH
8. HORN
9. BLUEDASH PRE-INSTALLATION
10. INSTRUMENT PANEL
11. HEATED HANDGRIPS (WHERE PROVIDED)
12. POWER SUPPLY FOR GPS
13. RIGHT LIGHT SWITCH
14. QUICK SHIFT
15. FRONT STOP SWITCH
16. REAR STOP SWITCH
17. CLUTCH SWITCH
18. IGNITION SWITCH
19. IMMOBILIZER AERIAL
20. SAFETY RELAY
21. TAIL LIGHT
22. LICENSE PLATE LIGHT
23. REAR RIGHT TURN INDICATOR
24. REAR LEFT TURN INDICATOR
25. EVC CONTROL UNIT
31. EXHAUST VALVE MOTOR
32. ALTERNATOR
33. VOLTAGE REGULATOR
34. REAR ABS SENSOR
35. FRONT ABS SENSOR
36. ABS CONTROL UNIT
37. MAIN FUSES 2
38. STARTER MOTOR
39. START-UP RELAY
40. MAIN FUSE 1
41. BATTERY
42. ELECTRIC FANS
43. ELECTRIC FANS RELAY
44. USB PORT
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45. ECU DIAGNOSIS
46. AUXILIARY INJECTION RELAY
47. PRIMARY INJECTION RELAY
48. FUEL RESERVE SENSOR 1 (NTC)
49. FUEL RESERVE SENSOR 2 (LEVEL)
50. FUEL PUMP
51. OIL PRESSURE SENSOR
52. INTAKE AIR TEMPERATURE SENSOR
53. FALL SENSOR (IF FITTED)
54. STAND SWITCH
55. GEAR SENSOR
56. REAR CYLINDER LAMBDA PROBE
57. FRONT CYLINDER LAMBDA PROBE
58. REAR CYLINDER INJECTOR (MARELLI/INTERNAL)
59. FRONT CYLINDER INJECTOR (MARELLI/INTERNAL)
60. REAR SIDE COIL
61. FRONT SIDE COIL
62. REAR CENTRAL COIL
63. FRONT CENTRAL COIL
64. SPARK PLUG
65. REAR MOTORISED THROTTLE
66. FRONT MOTORISED THROTTLE
67. DEMAND SENSOR
68. ENGINE SPEED SENSOR
69. 7SM MOTOR CONTROL UNIT
70. ANTI-THEFT LED (IF FITTED)
71. ANTI THEFT (IF FITTED)
72. FRONT MAP SENSOR
73. REAR MAP SENSOR
74. WATER TEMPERATURE SENSOR
75. SECONDARY FUSES
77. FRONT INJECTOR 2 (SYNERJET/EXTERNAL)
78. REAR INJECTOR 2 (SYNERJET/EXTERNAL)
80. BLUEDASH (IF FITTED)
81. FOG LIGHT LED (IF FITTED)
CAPONORD 1200 TRAVEL PACK
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CAPONORD 1200
CAPONORD 1200
Electrical system
key:
1. MULTIPLE CONNECTORS
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2. FRONT LEFT TURN INDICATOR
3. FRONT HEADLAMP
4. FRONT RIGHT TURN INDICATOR
5. HIGH BEAM LIGHTS RELAY
6. LIGHT RELAY
7. LEFT LIGHT SWITCH
8. HORN
9. BLUEDASH PRE-INSTALLATION
10. INSTRUMENT PANEL
11. HEATED HANDGRIPS (WHERE PROVIDED)
12. POWER SUPPLY FOR GPS
13. RIGHT LIGHT SWITCH
14. QUICK SHIFT
15. FRONT STOP SWITCH
16. REAR STOP SWITCH
17. CLUTCH SWITCH
18. IGNITION SWITCH
19. IMMOBILIZER AERIAL
20. SAFETY RELAY
21. TAIL LIGHT
22. LICENSE PLATE LIGHT
23. REAR RIGHT TURN INDICATOR
24. REAR LEFT TURN INDICATOR
25. VCU CONTROL UNIT
26. PUMP MOTOR
27. REAR SOLENOID VALVE
28. FRONT SOLENOID VALVE
29. REAR ROTARY SENSOR
30. FRONT TEMPERATURE AND PRESSURE SENSOR
31. EXHAUST VALVE MOTOR
32. ALTERNATOR
33. VOLTAGE REGULATOR
34. REAR ABS SENSOR
35. FRONT ABS SENSOR
36. ABS CONTROL UNIT
37. MAIN FUSES 2
38. STARTER MOTOR
39. START-UP RELAY
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40. MAIN FUSE 1
41. BATTERY
42. ELECTRIC FANS
43. ELECTRIC FANS RELAY
44. USB PORT
45. ECU DIAGNOSIS
46. AUXILIARY INJECTION RELAY
47. PRIMARY INJECTION RELAY
48. FUEL RESERVE SENSOR 1 (NTC)
49. FUEL RESERVE SENSOR 2 (LEVEL)
50. FUEL PUMP
51. OIL PRESSURE SENSOR
52. INTAKE AIR TEMPERATURE SENSOR
53. FALL SENSOR (IF FITTED)
54. STAND SWITCH
55. GEAR SENSOR
56. REAR CYLINDER LAMBDA PROBE
57. FRONT CYLINDER LAMBDA PROBE
58. REAR CYLINDER INJECTOR (MARELLI/INTERNAL)
59. FRONT CYLINDER INJECTOR (MARELLI/INTERNAL)
60. REAR SIDE COIL
61. FRONT SIDE COIL
62. REAR CENTRAL COIL
63. FRONT CENTRAL COIL
64. SPARK PLUG
65. REAR MOTORISED THROTTLE
66. FRONT MOTORISED THROTTLE
67. DEMAND SENSOR
68. ENGINE SPEED SENSOR
69. 7SM MOTOR CONTROL UNIT
70. ANTI-THEFT LED (IF FITTED)
71. ANTI THEFT (IF FITTED)
72. FRONT MAP SENSOR
73. REAR MAP SENSOR
74. WATER TEMPERATURE SENSOR
75. AUXILIARY FUSES 1
76. AUXILIARY FUSE 2
77. FRONT INJECTOR 2 (SYNERJET/EXTERNAL)
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78. REAR INJECTOR 2 (SYNERJET/EXTERNAL)
80. BLUEDASH (IF FITTED)
81. FOG LIGHT LED (IF FITTED)
Colour key:
Ar Orange
Az Sky blue
B Blue
Bi White
G Yellow
Gr Grey
M Brown
N Black
R Red
Ro Pink
V Green
Vi Purple
Conceptual diagrams
Checks and inspections
GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE 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 connector, making sure that the locking catch is released.
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
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Electrical system
the connector (i.e., all terminals aligned at the
same depth) and terminal integrity (i.e., that terminals are not loose, open/bent, etc.). For connectors 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 CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT
ALL DUE CHECKS LOOKING FOR FAULT BY MOVING
SLIGHTLY THE CABLE HARNESS BEING INSPECTED.
3. Pulling the cables slightly from the back of the connector in order to check the correct position of
terminals on the connector and of the cable on the terminal.
CONTINUITY check
Check goal: this control is to check that there are not any circuit interruptions nor excessive resistance,
for instance caused by rust, on the two terminals being inspected.
Tester: set the tester on the "continuity" symbol and place the tester probes on the two circuit ends:
the tester emits a sound signal only if there is continuity; the tester can also be set to the Ohm symbol
to check that the circuit resistance is null or a few tenths of an Ohm.
CAUTION: THE CIRCUIT SHOULD NOT BE ENERGISED, OTHERWISE THE TEST IS IRRELEVANT.
GROUND CONNECTION check
Check goal: this control is to check if a cable or a circuit is in contact with the vehicle ground (-)
connection.
Tester: set the tester on the "continuity" symbol and place one tester probe on the vehicle ground
connection (or on the battery - terminal) and the other probe on the cable being inspected: the tester
sends out a sound signal only if there is continuity. The tester can also be set to the Ohm symbol to
check that the circuit resistance is null or a few tenths of an Ohm.
CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE
SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIRCUIT.
VOLTAGE check
Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the
battery or the control unit.
Tester: set the tester on the direct current symbol and place the tester red probe on the cable being
inspected and the black probe on the vehicle ground connection (or on the battery - terminal).
CAUTION
IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR
FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED.
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CAPONORD 1200
Immobiliser
System components
Function
detects the transponder code in the key and sends
it to the instrument panel
Level in electrical circuit diagram:
Immobilizer
Location:
•
on the vehicle: in the ignition switch assembly
•
connector: two-way, black, behind the
instrument panel
Electrical specifications
•
~ 10 - 20 Ohm
Pin out
not significant
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
IMMOBILIZER ERRORS
Error code B0003 (KEY CODE READ BUT NOT RECOGNISED)
The key has the working transponder, but it is not within the recognised ones.
Troubleshooting
Store the new key.
Error code B0004 (ERROR READING KEY CODE)
The key has no transponder or the transponder is damaged.
Troubleshooting
Replace the key and store it.
Error code B0005 (AERIAL ELECTRICAL FAILURE (A.C. O S.C.))
An electric interruption or a ground short circuit or voltage to the circuit have been detected.
Troubleshooting
Check the sensor connector on the cable harness and the instrument panel connector. If not OK, restore; if OK, check electrical characteristics and aerial circuit continuity from the instrument panel
connector on PIN 24 and 25: if not OK, restore cable harness; if OK, check circuit ground insulation: if
not ground insulated, restore cable harness; if insulated, with key ON and instrument panel connector
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Electrical system
disconnected, check that there is not voltage at the circuit ends: if there is voltage, restore the cable
harness.
Error code B0006 (INSIDE ERROR)
There is a fault in the instrument panel.
Troubleshooting
Replace the instrument panel.
Error code B0007 (INSUFFICIENT NUMBER OF MEMORISED KEYS)
The number of stored keys is less than two.
Dashboard
In case of doubts in operation of the engine revs indication, it is possible to connect the vehicle to the
diagnostics instrument and activate the engine revs indication choosing the function "Rpm indicator"
from the "Devices Activation" screen page (injector icon)
SELECTING kph - mph UNIT OF MEASUREMENT
•
Connect the diagnostics instrument to the Marelli (7SM) engine control unit and start a diagnostics session.
•
Go to the "adjustments" page and configure the vehicle.
•
Close the current diagnosis session.
•
Enter the instrument panel diagnosis and do a KEY OFF / KEY ON
•
Enter the instrument panel diagnosis and make sure the error is present.
•
To solve the error, go to the "adjustments" page and carry out a "Vehicle configuration reset".
•
Follow the instructions on the screen.
•
Delete the errors stored by the instrument panel.
Diagnosis
The instrument errors are detected by means of the diagnosis instrument. It is therefore necessary to
connect it to the vehicle.
Following are listed the errors generated by the instrument panel.
CONFIGURATION
Error code B0000 (CONFIGURATION ERROR)
Error cause
The configuration memorised in the instrument panel does not correspond to the one detected in the
vehicle where it is installed (e.g. configuration unit of measurement miles/kilometres).
Identification
Warning light on.
Troubleshooting
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CAPONORD 1200
Check the mapping of the control unit and reset the vehicle configuration.
OIL SENSOR
Error code B0001 (OIL SENSOR FAILURE)
Oil motor low pressure alarm:
This alarm occurs when the engine is off and the pressure of the engine oil is low. If during the following
OFF-ON key switching, the fault is not immediately detected, the error is no longer displayed. Only in
case the fault occurs again after performing two TRIPs (minimum TRIP: 10 km) and following the third
OFF-ON key switching, the error is displayed again.
Identification
Oil warning light fixed.
Troubleshooting
Check the connector on the component and the instrument panel connector. Disconnect the two connectors and check the continuity of the cable between the sensor and the PIN 17 of the instrument panel
(grey connector) and restore the cable harness. If the cable harness is not damaged, replace the sensor.
Error code B0002 (OIL PRESSURE FAILURE)
Oil sensor disconnected alarm:
This alarm occurs when the sensor is disconnected, rpm higher than 900.
Identification
Oil warning light flashing.
Troubleshooting
Disconnect the connector of the component and check the insulation from ground: if the insulation is
not present, restore the cabling, otherwise replace the sensor. It this error persists, use a pressure
gauge to check the pressure of the oil in the engine circuit.
CAN LINE
Error code B0008 (CAN LINE RECEPTION ERROR)
Error cause
The instrument panel is coded at the first key insertion, if the CAN line is missing, the error is activated.
Identification
Warning light on.
Troubleshooting
Check the cable harness of the CAN line.
Error code B0009 (CAN LINE TRANSMISSION ERROR)
Error cause
The instrument panel is coded at the first insertion of the key, if the received data do not coincide with
the memorised ones, the error is activated.
Identification
Warning light on.
Troubleshooting
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Check the cable harness of the CAN line.
ENGINE TEMPERATURE
Error code B0010 (ENGINE OVERTEMPERATURE)
Error cause
Engine temperature > 115 °C.
Troubleshooting
The error is no longer displayed when the temperature falls below 113 °C. If the error continues to be
displayed also with low engine temperature, the failure is probably in the sensor that is shortcircuited
or in the cable harness: perform the diagnosis by connecting to the engine control unit.
HEATED HANDGRIPS
Error code B0011 (HANDGRIPS HEATING BUTTON LOCKED)
Error cause
Alarm handgrips button locked:
This alarm occurs when, for various reasons, the activation button is locked.
Identification
Fixed warning light.
Troubleshooting
Check the correct operation of the contact of the button and the insulation from ground and from supply
of PIN 15 of the instrument panel (grey connector).
Battery recharge circuit
RECHARGING SYSTEM
•
Remove the tank and the filter casing;
•
Disconnect the three-way connector
(1) (white).
NOTE
THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A"
Measurement of resistance (with engine off)
•
For a correct detection of the alternator
resistance, an ambient temperature
measurement must be carried out and
afterwards a heat stabilisation (after
turning fan on) by using a tester, using
alternatively the 3 connector pins:
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CAPONORD 1200
stage "1" (pin 1-2), stage "2" (pin 1-3),
stage "3" (pin 2-3).
•
Take the measurement; The correct value is determined by the value measured for each
stage in which from time to time the resistance of the tester wires is subtracted, obtained by
touching the two lugs.
Example:
•
Resistance of stage 1 read on the display = 0.65 Ohm
•
Resistance of the wires read on the display = 0.47 Ohm
•
Effective resistance stage 1 = 0.65-0.47 = 0.18 Ohm
•
If there is a significant difference between one stage and another (other than 0.15 Ohm),
this means that the alternator is defective and must be replaced.
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RESISTANCE MEASUREMENT
Winding stage
Stage 1
Stage 2
Stage 3
Ambient temperature (ohm)
0.15 - 0.20
0.15 - 0.20
0.15 - 0.20
Afterwards heat stabilisation (ohm)
0.18 - 0.23
0.18 - 0.23
0.18 - 0.23
Empty voltage
•
Disconnect the three-way connector (1);
•
For a correct detection of the alternator voltage, a measurement must be carried out using
alternatively the 3 engine side connector pins: stage "1" (pin 1-2), stage "2" (pin 1-3), stage
"3" (pin 2-3).
•
Take the measurements;
•
If there is a significant difference between one stage and another (other than 15 V), this
means that the alternator is defective and must be replaced.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE
DETECTED WITH THE ENGINE COLD.
EMPTY VOLTAGE
rpm
Vm linked voltage Reference values (V rms)
2000
20 - 30
6000
75 - 85
8000
95 - 105
Short circuit current
•
For a correct detection of the short circuit current, a connector must be prepared that generates a downstream
short circuit between the three alternator cables;
•
Start the engine and with an ammeter
clamp measure each single cable.
•
If there is a significant difference between the measure of the single cables
(other than 10 A), this means that the
alternator is defective and must be replaced.
CAUTION
WITH THE ENGINE HOT THE VALUES RECORDED ARE
ON AVERAGE 2-3 A LESS THAN THOSE DETECTED WITH
THE ENGINE COLD.
WARNING
NEVER KEEP THE ENGINE RUNNING FOR MORE THAN
ONE MINUTE; FAILURE TO DO SO COULD CAUSE SERIOUS OVERHEATING DAMAGES TO THE MOTORCYCLE
CIRCUITS.
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COLD SHORT CIRCUIT CURRENT
RPM
RMS DC current (Arms) (average of the 3 stage
currents)
2000
26 - 31
4000
26 - 31
6000
26 - 31
8000
26 - 31
Voltage on battery poles with engine speed always between 3000 - 5000 RPM
•
Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM,
then measure with a tester the voltage at the battery poles that must always be between
13V and 15V. Otherwise, if the correct operation of the alternator has already been checked,
replace the regulator.
CAUTION
PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION (START
VOLTAGE ABOUT 13V) MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIRCUIT.
Start-up system check
Function
Communicates to the control unit the will to startup the engine.
Operation / Operating principle
Press the start-up button to close the specific circuit taking the PIN 58 of the control unit to a voltage
equal to zero (ground closing).
Level in electrical circuit diagram:
Start-up signal
Location:
•
on the vehicle: right light switch.
•
connector: between filter box and water radiator, at the centre.
Electrical characteristics:
•
key released: the circuit is open
•
key pressed: the circuit is closed
Pin out:
4: voltage + 5V
5: ground connection
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
Starter switch P0170
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•
Electrical system
shorted to positive / open circuit, shorted to negative.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 58; if the circuit is open,
shorted to negative: voltage equal to zero has been detected.
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
Starter switch P0169
•
signal not valid.
Error cause
•
Fault in the switch (lock) of the engine start-up. The instrument panel does not indicate the
presence of this error even in the ATT status.
Troubleshooting
•
Check the locking cause and restore.
Lights list
Headlamp
Characteristic
Front daylight running lights
2V - 5W W5WB x 2
Low beam light
12V - 55W H11 x 2
High beam light
12V - 55W H11
Taillight
Characteristic
Rear daylight running light / stop light
LED
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Fuses
AUXILIARY FUSES (front left, above the water
radiator)
1 - Safety relay, stop lights, horn, daylight running
light, license plate light (10 A)
2 - Instrument panel, anti-theft, VCU, BlueDash
positive live (7.5 A)
3 - Engine control unit positive live (15 A).
4 - Permanent engine control unit positive (7.5 A).
5 - Coils, petrol pump, injectors (15 A)
6 - Low beam/high beam light logic (15 A)
7 - Fans (15 A).
8 - VCU positive live (15 A) (only Caponord 1200
Travel Pack)
Spare fuses (7.5 - 10 - 15 A)
MAIN FUSES - (under the saddle, remove the
battery protection)
A - Battery recharge, primary injection relay, live
positive, permanent BlueDash positive (30 A)
B - Permanent ABS control unit positive (20 A)
C - USB jack, heated handgrips, anti-theft, GPS,
BlueDash (7.5 A)
D - Spare fuses (30 - 20 - 7.5 A)
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CAPONORD 1200
Electrical system
Control unit
•
Unscrew and remove the control unit
cover screws.
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•
CAPONORD 1200
Unscrew and remove the control unit
fixing screw.
•
Slide off the control unit from the
mountings and remove it from the vehicle.
NOTE
DURING THE REFITTING, PAY PARTICULAR ATTENTION TO FIX THE CONTROL UNIT IN THE
MOUNTINGS.
CONTROL UNIT - Diagnosis
Function
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it controls the Ride by wire system, the injection/ignition, the system safety checks and the self-diagnosis
function
Level in electrical circuit diagram:
Each level in which the main component involves the control unit
Location:
•
on the vehicle: above the filter box
•
connector: on the 52 PIN connector ENGINE control unit, 28 PIN connector VEHICLE
Pin out:See the CONNECTORS section
DIAGNOSTICS INSTRUMENT: PARAMETERS ISO Screen page
(screen/example value with key set to ON)
•
ISO Code / -
•
Type-approval Code / -
•
Mapping / -
•
Marelli spare part code / IAW7SMHW430
•
Frame number (VIN) or diagnostics instrument serial number / -
•
Drawing number / -
•
Person in charge for last programming / - Indicates the series number of the DIAGNOSTICS
INSTRUMENT that has carried out the last control unit remapping
•
BOOT version / -
•
Control unit serial number (NIP) / -
•
Vehicle model / -
•
Internal code (IDVAG1) / -
•
Internal code (IDEEKE) / -
•
HW code / -
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DIAGNOSTICS INSTRUMENT: PARAMETERS
•
Engine revs (rpm)
•
Front throttle position (pot. 1) (°)
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CAPONORD 1200
•
Rear throttle position (pot. 1) (°)
•
Front throttle position correction (°)
•
Rear throttle position correction (°)
•
Front lambda probe tension (mV)
•
Rear lambda probe tension (mV)
•
Correction front cylinder value (%)
•
Correction rear cylinder value (%)
•
Front cylinder fuel adaptive correction (%)
•
Rear cylinder fuel adaptive correction (%)
•
Grip opening percentage (%)
•
Advance front cylinder ignition (central spark plug) (°)
•
Advance front cylinder ignition (side spark plug) (°)
•
Advance rear cylinder ignition (central spark plug) (°)
•
Advance rear cylinder ignition (side spark plug) (°)
•
Motor temperature (°C)
•
Intake air temperature (°C)
•
Front Cylinder Intake Pressure (mbar)
•
Reference Front Cylinder Intake Pressure (mbar)
•
Rear Cylinder Intake Pressure (mbar)
•
Reference Rear Cylinder Intake Pressure (mbar)
•
Battery voltage (V)
•
Exhaust butterfly valve target position (%)
•
Blue connector throttle grip position sensor - track A (mV)
•
Blue connector throttle grip position sensor - track B (mV)
•
White connector throttle grip position sensor - track C (mV)
•
White connector throttle grip position sensor - track D (mV)
•
Tension Front throttle Potentiometer 1 (mV)
•
Tension Front throttle Potentiometer 2 (mV)
•
Tension Rear throttle Potentiometer 1 (mV)
•
Tension Rear throttle Potentiometer 2 (mV)
•
Front throttle Limp Home position (mV)
•
Front throttle lower position (mV)
•
Rear throttle Limp Home position (mV)
•
Rear throttle lower position (mV)
•
Front throttle position (potentiometer 2) (°)
•
Rear throttle position (potentiometer 2) (°)
•
Motor temperature at start (°C)
•
Front cylinder injection time (ms)
Electrical system
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Electrical system
•
Rear cylinder injection time (ms)
•
Nominal idle speed (rpm)
•
Vehicle speed (km/h)
•
Front wheel speed (km/h)
•
Rear wheel circumference (mm)
•
Final drive gear ratio
CAPONORD 1200
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
Front cylinder title control
•
Open loop/Closed loop/Rich in half closed loop/Lean in half closed loop
Rear cylinder title control
•
Open loop/Closed loop/Rich in half closed loop/Lean in half closed loop
Front lambda probe
•
Operative/Inoperative (Rich)/Inoperative (Lean)/Inoperative (Start-up)
Rear lambda probe
•
Operative/Inoperative (Rich)/Inoperative (Lean)/Inoperative (Start-up)
Front cylinder value
•
Rich/Lean/Not detected
Rear cylinder value
•
Rich/Lean/Not detected
Engine status
•
Indefinite / Key ON / Running engine / Stopped / Power latch / Power latch 2 / Power latch
finished
Engine mode
•
Indefinite / Start-up / Stable / Idle / Acceleration /Deceleration / Cut Off Input / Cut Off / Cut
Off Output
Handle self-learning
•
Carried out/Not carried out
Front throttle self-acquisition
•
Ice/Interrupted/Carried out/Limp home/Closed throttle stop/Springs check/Limp home selfacquisition/Initialise
Rear throttle self-acquisition
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CAPONORD 1200
•
Electrical system
Ice/Interrupted/Carried out/Limp home/Closed throttle stop/Springs check/Limp home selfacquisition/Initialise
Throttle self-learning with diagnostics instrument
•
Carried out/Not carried out
Start up enabling
•
Yes/No
Immobilizer signal
•
Yes/No
Gearbox in neutral
•
Yes/No
Side stand
•
Down/Up
fall sensor
•
Normal / Tip over
Fan relay
•
On / Off
RUN / STOP switch
•
Run/Stop
Clutch lever
•
Pulled/Released
Gear engaged
•
0 / 1 / 2 / 3 / 4 / 5 / 6 / Indeterminate
Throttle grip
•
Slightly twisted/Choked/Fully twisted
Rpm sensor signals panel
•
Synchronized/Partially synchronized/Not synchronized
Button + (during ATC setting)
•
Pressed/Released
Button - (during ATC setting)
•
Pressed/Released
ATC (Aprilia Traction Control)
•
Present/Not present
Exhaust butterfly valve
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Electrical system
•
Indeterminate / Search / Self-cleaning / Operation / Failure / Home position search
Performing ATC (on bend)
•
Present/Not present
AQS (Aprilia Quick Shift)
•
Present/Not present
•
Present/Not present
ABS
Front brake lever
•
Pulled/Released
rear brake pedal
•
Pressed/Released
ADD (Aprilia Dynamic Damping)
•
Present/Not present
Cruise control button
•
Pressed/Released
Cruise control
•
Enabled/Disabled/Set
Cruise control + button
•
Pressed/Released
Button - cruise control
•
Pressed/Released
ACC (Aprilia Cruise Control)
•
Present/Not present
Speedometer unit of measurement
•
kph / mph
Vehicle configuration
•
Valid/Not valid
EVC (Exhaust Valve Control)
•
CAPONORD 1200
Present/Not present
DIAGNOSTICS INSTRUMENT: ACTIVATION
•
Rear cylinder central coil
•
Front cylinder central coil
•
Rear cylinder side coil
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CAPONORD 1200
•
Front cylinder side coil
•
Internal rear cylinder injector
•
Internal front cylinder injector
•
External front cylinder injector
•
External rear cylinder injector
•
Deleting stored errors
•
Freezes and saves the parameter and states values
•
Rpm indicator
•
Errors ambient parameters reading
•
STOP light
•
Fuel pump
•
Heater rear lambda probe
•
Heater front lambda probe
•
Fan
Electrical system
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
Error EEPROM P0601
•
circuit not operational
Error cause
•
Replace injection ECU. The instrument panel does not indicate the presence of this error
even in the ATT status
Error RAM P0604
•
circuit not operational
Error cause
•
Replace injection ECU. The instrument panel does not indicate the presence of this error
even in the ATT status
Error ROM P0605
•
circuit not operational
Error cause
•
Replace injection ECU. The instrument panel does not indicate the presence of this error
even in the ATT status
A/D converter P0607
•
circuit not operational
Error cause
•
Replace injection ECU
Error stop lights relay P0610
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Electrical system
•
CAPONORD 1200
short circuit to positive/ short circuit to negative / open circuit
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 31. If shorted to negative:
no voltage has been detected. If the circuit is open: an interruption has been detected
Troubleshooting
•
If shorted to positive: check the relay electrical specifications are correct by disconnecting
it from the cable harness. If they are not correct, replace the relay; if OK, restore the cable
harness (Blue/Pink cable)
•
If shorted to negative: check the relay electrical specifications are correct by disconnecting
it from the cable harness. If they are not correct, replace the relay; if OK, restore the cable
harness (Blue/Pink cable)
•
If the circuit is open: check the relay electrical characteristics are correct by disconnecting
it from the cable harness; if not OK, replace the relay, if OK, check relay connector, enginevehicle cable harness connector and ENGINE connector of the Marelli control unit: if not
OK, restore; if OK, check continuity of cable harness (Blue/Pink cable)
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
Level 2 safety reset P0608
Error cause
•
As the level 2 safety system (comparison between requested torque and calculated torque)
has detected a fault, the control unit has reset engine (C gravity). The instrument panel does
not indicate the presence of this error even in the ATT status.
Troubleshooting
•
Continue fault search for the other errors detected.
Safety Engine Stop P0609
Error cause
•
Since the safety system has detected a serious fault, the control unit has shut off the engine.
Troubleshooting
•
Continue fault search for the other errors detected.
Saved data file (for safety) P0611
•
Filled
Error cause
•
This indication appears only if the Level 2 safety has reset the engine (C gravity). The instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting
•
Continue fault search for the other errors detected.
DIAGNOSTICS INSTRUMENT: ADJUSTMENTS
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CAPONORD 1200
•
Handle self-learning
•
Throttle self-learning with diagnostics instrument
•
EEPROM reset
•
Saved data file download
•
Saved data file deletion
•
Vehicle configuration
•
Exhaust valve (step 1) - Acquire home position
•
Exhaust valve (step 2) - Self-learning
Electrical system
CAUTION
DELETING ALL THE SAVED DATA WHEN THE VEHICLE IS BEING MANUFACTURED (INCLUDING THE SELF-ADJUSTABLE PARAMETERS), THEN YOU MUST SELECT: HANDLE SELFLEARNING AND CHECK THE TWO "AUTOMATIC FRONT THROTTLE SELF-LEARNING" AND
"AUTOMATIC REAR THROTTLE SELF-LEARNING" STATUSES ARE "PERFORMED".
See also
Cylinders synchronisation
CONTROL UNIT - Diagnosis
(IF APPLICABLE)
Function
it manages the suspensions system, the exhaust butterfly valve, and the self-diagnosis function
Level in electrical circuit diagram:
Each level in which the main component involves the control unit
Location:
•
on the vehicle: in the front part, on the right side
•
connector: on the control unit
Pin out:See the CONNECTORS section
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Electrical system
DIAGNOSTICS INSTRUMENT:PARAMETERS
•
Battery voltage (V)
•
Tension potentiometer at the exhaust butterfly valve (mV)
•
Rotary sensor trace 1 (mV)
•
Rotary sensor trace 2 (mV)
•
Pressure sensor (mBar)
•
Temperature sensor (°C)
•
Current front valve (mA)
•
Current rear valve (mA)
•
Number operations preload motor
•
Exhaust butterfly valve target position (%)
•
Exhaust butterfly valve upper travel limit
•
Exhaust butterfly valve lower travel limit
•
Maximum travel preload in impulses
DIAGNOSTICS INSTRUMENT:STATUSES
Suspensions map
•
Indeterminate / 1 / ... / 8
Preload level
•
Indeterminate / 1 / ... / 5
Preload motor
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CAPONORD 1200
CAPONORD 1200
•
Electrical system
Travel limits not acquired / Manual / Automatic / Fault
Exhaust butterfly valve automatic
•
Indeterminate / Seek / Verify / Adjustment / Fault / Zero
Front Suspension Valve
•
Operation / Constant Current Fault / Zero Current Fault
Rear suspension valve
•
Operation / Constant Current Fault / Zero Current Fault
Cruise Control button
•
Released / Pressed / Short-circuit Fault / Open Circuit Fault / Indeterminate Fault
Switch front brake
•
Released / Pressed / Short-circuit Fault / Open Circuit Fault
Switch rear brake
•
Released / Pressed / Short-circuit Fault / Open Circuit Fault
Exhaust butterfly valve output
•
Not active / Active / Short-circuit Fault / Open Circuit Fault
Preload motor control output
•
Not active / Active / Short-circuit Fault / Open Circuit Fault
Rotary sensor reset
•
Not Carried out / Carried out
DIAGNOSTICS INSTRUMENT: ACTIVATION
•
Reset control unit
•
Front Suspension Valve
•
Rear suspension valve
•
Exhaust butterfly valve
•
Preload motor
DIAGNOSTICS INSTRUMENT: ERRORS
Error VCU code C1000
Error cause
•
The stored IDMODELV and the current one do not coincide: the VCU is programmed for a
vehicle different from the one on which it is fitted.
Troubleshooting
•
Replace the motor control unit or perform the reset of the VCU using a diagnosis instrument.
Control unit internal error C1200
Error cause
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Electrical system
•
CAPONORD 1200
The VCU memory was deleted following an unforeseen lack of supply; all stored data have
been lost, such as the travel limits of the exhaust valve, of the shock absorber preload, or
the idle position of the rotary potentiometer.
Troubleshooting
•
Rest the VCU using the diagnosis instrument.
Battery
Function
Battery YTX 14-BS, which must be activated and
loaded.
Level in electrical circuit diagram:
Battery recharge
Location:
•
on the vehicle: under the saddle
•
connector: on the battery
Electrical specifications: 12 Ah
Pin out:
1. Positive pole (red): approx. 12.6 V
2. negative pole (black): ground connection
DIAGNOSTICS INSTRUMENT:PARAMETERS
Battery voltage
•
Example value with key ON: 12.0 V
•
Example value with engine on: 14.2 V
In case of recovery, this value is set by the control
unit
Battery voltage pre Recovery
•
Example value with key ON: 12.0 V
•
Example value with engine on: 14.2 V
Value drawn from the signal read without taking
into account any recovery
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
Battery voltage P0560
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CAPONORD 1200
•
Electrical system
too high/too low
Error cause
•
If too high: too high a voltage has been detected at PIN 42. If too low: too low a voltage has
been detected at PIN 42. The instrument panel does not indicate the presence of this error
even in the ATT status.
Troubleshooting
•
If too high: check correct operation of the voltage regulator.
•
If too low: check voltage regulator connectors, engine - vehicle cable harness connector and
the control unit connector (paying special attention to possible oxidation): if not OK, restore;
if OK, check that Red/White cable resistance from the voltage regulator connector to the
control unit connector is a few tenths of Ohm: if not OK, restore cable harness; if OK, check
correct operation of the electrical alternator: if not OK, restore; if OK, check operation of the
voltage regulator
VCU ERRORS
Battery tension too low or too high C1001
Error cause
•
The battery tension is below the minimum threshold (6 V with engine on, 10 V with engine
off) or above the maximum threshold (16 V).
Troubleshooting
•
Check the battery.
Speed sensor
VEHICLE FRONT SPEED SENSOR
FUNCTION:To indicate the vehicle speed by reading the front wheel turning speed.
OPERATION / OPERATING PRINCIPLE:Magnetoresistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and
11.25 V
WIRING DIAGRAM Level in wiring diagram: ABS.
REMOVAL
LOCATION ON THE VEHICLE:on the fork, right
stem, next to the brake calliper support.
CONNECTOR LOCATION (if available): under
the helmet compartment.
PINS
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Electrical system
•
PIN 1- Ground connection (white)
•
PIN 2 - Power supply voltage/Output
CAPONORD 1200
signal (white/brown)
DIAGNOSIS INSTRUMENT
Parameters: Speed (km/h) - Vehicle speed.
ELECTRICAL ERRORS
Speed sensor
5D90 electric malfunction: Electrical fault in sensor or cable harness.
Troubleshooting: Check the sensor connector and the ABS control unit connector. If they are not OK,
restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the
sensor on the cable harness side and PIN 14 of the ABS control unit connector. If there is no continuity,
restore them. If there is, PIN 2 of the sensor on the cable harness side, with the sensor disconnected
and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity
with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control
unit. If PIN 2 has approx. 12 V, check the continuity of the white cable between PIN 1 of the sensor on
the cable harness side and PIN 13 of the ABS control unit connector. If there is no continuity, restore
the cable harness. If there is, replace the logic errors sensor.
LOGIC ERRORS
Speed sensor
5D91 the signal works irregularly: faulty sensor or signal interference.
Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone
wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise,
replace the speed sensor.
5D92 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations.
Troubleshooting: Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not
OK, replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace the
bearings.
5D93 missing signal or speed measured too low in relation to the rear wheel: faulty sensor or
missing sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel
with wrong number of teeth.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, replace the speed sensor.
5D94 no acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel.
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CAPONORD 1200
Electrical system
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, replace the speed sensor.
5D95 excessive speed measured: Faulty sensor or tone wheel, or tone wheel with wrong number of
teeth or wrong tyre size.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, check that the tyre size is the correct one. If it is not OK, replace it. If it is
OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed
sensor.
VEHICLE REAR SPEED SENSOR
FUNCTION:To indicate the vehicle speed by reading the rear wheel turning speed.
OPERATION / OPERATING PRINCIPLE:Magnetoresistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and
11.25 V
WIRING DIAGRAM Level in wiring diagram: ABS.
REMOVAL
LOCATION ON THE VEHICLE:on the swingarm,
right side, under the chain tension screw.
CONNECTOR LOCATION (if available): under
the saddle, right side.
PINS
•
PIN 1- Ground connection (yellow)
•
PIN 2 - Power supply voltage/Output
signal (yellow/brown)
DIAGNOSIS INSTRUMENT
Parameters: Speed (km/h) - Vehicle speed.
ELECTRICAL ERRORS
Speed sensor
5DA0 electric malfunction:Electrical fault in sensor or cable harness.
Troubleshooting:Check the sensor connector and the ABS control unit connector. If they are not OK,
restore the connectors. If they are OK, check continuity of the yellow/brown cable between PIN 2 of the
sensor on the cable harness side and PIN 11 of the ABS control unit connector. If there is no continuity,
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Electrical system
CAPONORD 1200
restore them. If there is, PIN 2 of the sensor on the cable harness side, with the sensor disconnected
and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity
with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control
unit. If PIN 2 has approx. 12 V, check continuity of the yellow cable between PIN 1 of the sensor on the
cable harness side and PIN 12 of the ABS control unit connector. If this is not OK, restore the cable
harness. If it is OK, replace the sensor.
LOGIC ERRORS
Speed sensor
5DA1 the signal works irregularly:faulty sensor or signal interference.
Troubleshooting:Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone
wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise,
replace the speed sensor.
5DA2 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations.
Troubleshooting: Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not
OK, replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace the
bearings.
5DA3 no signal or speed measured too low in relation to the front wheel: Faulty sensor or missing
sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel with
wrong number of teeth.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, replace the speed sensor.
5DA4 missing acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel
or excessive distance between the sensor and the tone wheel.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, replace the speed sensor.
5DA5 excessive measured speed: Faulty sensor or tone wheel, or tone wheel with wrong number of
teeth or wrong tyre size.
Troubleshooting:Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, check that the tyre size is the correct one. If it is not OK, replace it. If it is
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CAPONORD 1200
Electrical system
OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed
sensor.
Engine rpm sensor
ENGINE SPEED SENSOR
Function
It informs crankshaft position and speed to the
Marelli control unit.
Operation / Operating principle
Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the
reference position.
Level in electrical circuit diagram: engine speed sensor
Location:
•
on the vehicle: inside the flywheel cover
•
connector (if available): near the Marelli control unit
Electrical specifications:
•
Resistance at ambient temperature:
130 +/- 20 Ohm
Pin-out:
1. Negative signal
2. Positive signal
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
Synchronised panel
•
No_under analysis_standby_Yes
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
CAUTION
IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT-CIRCUITED, NO ERROR IS DISPLAYED. CHECK THE ENGINE SPEED SENSOR CONNECTOR AND THE MARELLI CONTROL
UNIT CONNECTOR: IF NOT OK, RESTORE; IF OK, CHECK THE CORRECT ELECTRIC CHARACTERISTICS OF THE SENSOR: IF NOT OK, REPLACE THE SENSOR. IF OK, CHECK THAT
THERE IS CONTINUITY ON BOTH CABLES, SUPPLY INSULATION AND GROUND INSULATION.
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CAPONORD 1200
CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR. IF NOT OK, RESTORE THE CABLE HARNESS/REPLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PIN
20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR.
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
Engine speed sensor P0336
•
signal not valid
Error cause
•
Probable bad contact in the electric circuit detected at PIN 20 - 35 of the ENGINE connector
Troubleshooting
•
Check the electric circuit is in good conditions and the flywheel teeth cleaning and correct
positioning of the sensor in its own housing: if it is not, replace it. If it is OK, replace the
sensor
Twistgrip position sensor
Removal
•
Remove the filter box.
•
Loosen the throttle cable nuts.
•
Unscrew and remove the two fixing
screws.
•
Disconnect the two connections and
remove the throttle grip position sensor.
•
Remove the throttle cables.
See also
Air box
THROTTLE GRIP POSITION SENSOR
Function
The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rider's
power request (Demand) into an electrical signal to be sent to the electronic control unit.
Operation / Operating principle
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CAPONORD 1200
Electrical system
The two throttle cables (opening and closing) actuate on a scroll mounted on a shaft which is sent back
to its home position by a return spring. On the shaft covers there are 2 double track potentiometers (4
control tracks) by means of which the torque demand is read (and checked). The 4 potentiometers are
tinned and magnetically controlled (contactless); they cannot be overhauled nor replaced
Level in electrical circuit diagram:Throttle grip position sensor.
Location:
•
on the vehicle: left side, under the filter box
•
connector: on the sensor
Electrical characteristics:
•
Not detected by a multimeter as they are contactless: read the voltage of the 4 tracks by the
diagnosis instrument.
MASTER connector (blue)
•
A: Track A supply
•
B: Track A ground
•
C: Track A signal
•
D: Track B supply
•
E: Track B ground
•
F: Track B signal
SLAVE connector (white)
•
A: Track C supply
•
B: Track C ground
•
C: Track C signal
•
D: Track D supply
•
E: Track D ground
•
F: Track D signal
DIAGNOSIS INSTRUMENT: PARAMETERS
Blue front connector throttle grip position sensor - track A
•
Example value with key ON: 1107 mV
•
Example value with engine on: -
Voltage value of the front potentiometer - track A
Blue front connector throttle grip position sensor - track B
•
Example value with key ON: 1070 mV
•
Example value with engine on: -
Voltage value times 2 of the front potentiometer track B
White rear connector throttle grip position sensor - track C
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Electrical system
•
Example value with key ON: 3560 mV
•
Example value with engine on: -
CAPONORD 1200
Voltage value of the rear potentiometer track C
White rear connector throttle grip position sensor - track D
•
Example value with key ON: 3555 mV
•
Example value with engine on: -
Voltage value times 2 of the rear potentiometer track D
Throttle grip position sensor
•
Example value with key ON: 1107 mV
•
Example value with engine on: -
Voltage corresponding to the potentiometer track A
Throttle grip opening percentage
•
Example value with key ON: 0 mV
•
Example value with engine on: -
With a released throttle grip, the value read should be 0%, whereas 100 % should be read with throttle
grip fully twisted.
DIAGNOSIS INSTRUMENT: STATUSES
Throttle grip
•
Slightly twisted_choked_fully twisted
Handle self-learning
•
carried out/not carried out
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
Blue front connector throttle grip position sensor - track A P0150
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 39 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 39 of the ENGINE connector.
Troubleshooting
•
shorted to positive: check the value shown by the parameter of the BLUE front connector
Throttle Grip Position Sensor - track A: disconnect the connector and read the value indi-
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Electrical system
cated by the diagnostics instrument: if the voltage does not vary, there is a short circuit in
the cable wiring; replace the throttle grip sensor if the voltage drops to zero.
•
if the circuit is open, shorted to negative: check the throttle grip sensor connector and the
Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the
two cable terminals. If not OK, restore; if OK, check the cable ground insulation (from the
throttle grip sensor connector or the control unit connector): if the cable is not ground insulated, restore the wiring. If it is ground insulated, and with the key set to ON, check that there
is power supply for the potentiometer PIN A and that PIN C is connected to ground. If both
are correct, replace the throttle grip sensor; if not, check the continuity of the cable that is
not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring
Blue front connector throttle grip position sensor - track B P0151
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 13 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 13 of the ENGINE connector
Troubleshooting
•
short circuit to positive: check the value shown by the parameter of the BLUE front connector
Throttle Grip position Sensor track B: disconnect the connector and read the value indicated
by the diagnostics instrument: if the voltage does not vary, there is a short circuit in the cable
wiring; replace the throttle grip sensor if the voltage drops to zero.
•
if the circuit is open, shorted to negative: check the throttle grip sensor connector and the
Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the
two cable terminals. If not OK, restore; if OK, check the cable ground insulation (from the
throttle grip sensor connector or the control unit connector): if the cable is not ground insulated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check
that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
If both are correct, replace the throttle grip sensor; if not, check the continuity of the cable
that is not functioning properly: if there is continuity, replace the control unit; if not, restore
the wiring
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
White rear connector throttle grip position sensor - track C P0152
•
short circuit to positive / open circuit, short circuit to negative
Error cause
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CAPONORD 1200
If shorted to positive: excessive voltage has been detected at PIN 23 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 23 of the ENGINE connector
Troubleshooting
•
shorted to positive: check the value shown by the parameter of the white rear connector
Throttle Grip Position Sensor - track C: disconnect the connector and read the value indicated by the diagnostics instrument: if the voltage does not vary, there is a short circuit in
the cable wiring; replace the throttle grip sensor if the voltage drops to zero.
•
if the circuit is open, shorted to negative: with open circuit, short it to negative: check the
throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If
OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check
the cable ground insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not ground insulated, restore the wiring. If it is ground insulated, and
with the key set to ON, check that there is power supply for the potentiometer PIN A and
that PIN C is connected to ground. If both are correct, replace the throttle grip sensor; if not,
check the continuity of the cable that is not functioning properly: if there is continuity, replace
the control unit; if not, restore the wiring
White rear connector throttle grip position sensor - track D P0153
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 11 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 11 of the ENGINE connector
Troubleshooting
•
shorted to positive: check the value shown by the parameter of the white rear connector
Throttle Grip Position Sensor - track D: disconnect the connector and read the value indicated by the diagnostics instrument: if the voltage does not vary, there is a short circuit in
the cable wiring; replace the throttle grip sensor if the voltage drops to zero.
•
if the circuit is open, shorted to negative: check the throttle grip sensor connector and the
Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the
two cable terminals. If not OK, restore; if OK, check the cable ground insulation (from the
throttle grip sensor connector or the control unit connector): if the cable is not ground insulated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check
that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
If both are correct, replace the throttle grip sensor; if not, check the continuity of the cable
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that is not functioning properly: if there is continuity, replace the control unit; if not, restore
the wiring
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
Blue front connector throttle grip position (tracks A-B) P0154
•
inconsistent signal
Error cause
•
Two illogical voltage signals have been detected at PIN 13 and 39 of the ENGINE connector
(tracks A-B)
Troubleshooting
•
Check the parameters of the blue front connector Throttle Grip Position Sensor - tracks A
and B: if one of the two values clearly deviates from 600-1400 mV, it means that this potentiometer is defective. Check the throttle grip sensor connector and the control unit
connector: if not OK, restore. If OK, check that cable resistance between the throttle grip
sensor connector and the control unit is a few tenths of Ohm: if this is not the case, restore
wiring. If the value is correct, replace the complete throttle grip sensor
White rear connector throttle grip position (tracks C-D) P0155
•
inconsistent signal
Error cause
•
Two illogical voltage signals have been detected at PIN 23 and 11 of the ENGINE connector
(tracks A-B)
Troubleshooting
•
Check the parameters of the white rear connector Throttle Grip Position Sensor - tracks C
and D: if one of the two values clearly deviates from 600-1400 mV, it means that this potentiometer is defective. Check the throttle grip sensor connector and the control unit
connector: if not OK, restore. If OK, check that cable resistance between the throttle grip
sensor connector and the control unit is a few tenths of Ohm: if this is not the case, restore
wiring. If the value is correct, replace the complete throttle grip sensor
Throttle grip position P0156
•
inconsistent signal
Error cause
•
The value of the front side sensor (tracks A-B) does not coincide with the value of the rear
sensor (tracks C-D)
Troubleshooting
•
Replace the throttle grip sensor
DIAGNOSTICS INSTRUMENT: ADJUSTABLE PARAMETERS
Handle self-learning: ELE SYS - 121
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RESET PROCEDURE
•
If Marelli control unit or its mapping are replaced or if you carry out control unit EEPROM
zero setting or if you replace the throttle grip sensor, it is necessary to carry out the Handle
self-learning procedure with the diagnostics instrument: once the check is completed, make
sure that the Handle self-learning status indicates: carried out
CAUTION
THE TWO CONNECTORS WHICH GET TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY
SHOULD NEVER BE INVERTED. MARK OR CHECK THE CONNECTOR MARKING BEFORE REMOVING THEM (BLUE STAMP + BLUE BAND). THE CONNECTOR AND THE BLUE BAND
SHOULD BE PLACED AT THE FRONT. THE CONNECTOR AND THE WHITE BAND SHOULD BE
PLACED AT THE BACK.
Intake pressure sensor
Figure key
•
A - Rear
•
B - Front
Function
The pressure sensors (one at the front, one at the
rear) are fundamental for calculation of generated
torque, for calculation of ambient pressure and for
correct ignition timing during start-up.
Operation / Operating principle
Diaphragm sensor which translates the diaphragm
position into electrical voltage when in contact with
the intake air.
Level in electrical circuit diagram:
Intake air pressure sensor
Location:
•
on the vehicle: rear cylinder sensor on
rear throttle body right side, front cylinder sensor on front throttle body left
side.
•
connector: on the sensor.
Electrical specifications: Pin out:
1. Power supply 5V
2. Ground connection
3. Output signal
DIAGNOSIS INSTRUMENT: PARAMETERS
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Front Cylinder Intake Pressure
•
Example value with key ON: 1004 mbar
•
Example value with engine on: 715 mbar
•
NOTE: pressure read by the front sensor
Rear Cylinder Intake Pressure
•
Example value with key ON: 1003 mbar
•
Example value with engine on: 720 mbar
•
NOTE: pressure read by the rear sensor
Front Cylinder estimated Intake Pressure
•
Example value with key ON: 1004 mbar
•
Example value with engine on: 735 mbar
•
NOTE: pressure estimated by the control unit according to the throttle position
Rear Cylinder estimated Intake Pressure
•
Example value with key ON: 1003 mbar
•
Example value with engine on: 721 mbar
•
NOTE: pressure estimated by the control unit according to the throttle position
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS
front cylinder air pressure sensor P0105
•
shorted to positive / open circuit, shorted to negative.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 24. If the circuit is open,
shorted to negative: voltage equal to zero has been detected at PIN 24.
Troubleshooting
•
If shorted to positive: verify that the parameter of the front cylinder air Pressure Sensor on
the diagnosis instrument is approx. 1200 mbar; disconnect the sensor connector: if the value
does not vary, it means that the cable is shorted between the control unit connector and the
sensor connector: restore the cable harness; Replace the sensor if the value varies.
•
If the circuit is open, shorted to negative: check the Marelli control unit connector and the
sensor connector; if not OK, restore. If everything is OK, with key set to OFF, check if there
is continuity between the PIN 24 of the Marelli control unit and the sensor connector PIN 3:
if there is no continuity, restore the cable harness. If there is continuity, check the cable
ground insulation: if there is continuity to ground, restore the cable harness; if not, with key
set to ON check that the voltage on sensor connector PIN 1 is approx. 5 V: if not OK, set
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the key to OFF and check continuity between the ENGINE connector PIN 25 and the sensor
connector PIN 1: if not OK, restore the cable harness; if OK, replace the control unit; if there
is 5V voltage at PIN 1, and with key set to ON, check the continuity to ground of the sensor
connector PIN 3: if not OK, restore the cable harness; if OK, replace the sensor.
rear cylinder air pressure sensor P0106
•
shorted to positive / open circuit, shorted to negative.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 49. If the circuit is open,
shorted to negative: voltage equal to zero has been detected at PIN 49.
Troubleshooting
•
If shorted to positive: verify that the parameter of the rear cylinder air Pressure Sensor on
the diagnosis instrument is approx. 1200 mbar; disconnect the sensor connector: if the value
does not vary, it means that the cable is shorted between the control unit connector and the
sensor connector: restore the cable harness; Replace the sensor if the value varies.
•
If the circuit is open, shorted to negative: check the Marelli control unit connector and the
sensor connector; if not OK, restore. If everything is OK, with key set to OFF, check if there
is continuity between the PIN 49 of the Marelli control unit and the sensor connector PIN 3:
if there is no continuity, restore the cable harness. If there is continuity, check the cable
ground insulation: if there is continuity to ground, restore the cable harness; if not, with key
set to ON check that the voltage on sensor connector PIN 1 is approx. 5 V: if not OK, set
the key to OFF and check continuity between the ENGINE connector PIN 25 and the sensor
connector PIN 1: if not OK, restore the cable harness; if OK, replace the control unit; if there
is 5V voltage at PIN 1, and with key set to ON, check the continuity to ground of the sensor
connector PIN 3: if not OK, restore the cable harness; if OK, replace the sensor.
DIAGNOSIS INSTRUMENT: LOGIC ERRORS
front cylinder air pressure sensor P0107
•
signal not valid.
Error cause
•
According to the engine operation data (rpm, throttle, etc.) an average value for the intake
pressure is estimated: if the value read deviates by a given percentage, this error is activated. The most frequent causes can be: abnormal resistance in the sensor circuit (for
example, rusted terminals) or sensor with poor performance.
Troubleshooting
•
Check the Marelli control unit connector and the sensor connector; if not OK, restore. If
everything is OK, check that resistance between ENGINE connector PIN 24 and sensor
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connector PIN 3 is a few tenths of an Ohm; If it is above that value, restore cable harness.
Replace the sensor if it is correct.
rear cylinder air pressure sensor P0108
•
signal not valid.
Error cause
•
According to the engine operation data (rpm, throttle, etc.) an average value for the intake
pressure is estimated: if the value read deviates by a given percentage, this error is activated. The most frequent causes can be: abnormal resistance in the sensor circuit (for
example, rusted terminals) or sensor with poor performance.
Troubleshooting
•
Check the Marelli control unit connector and the sensor connector; if not OK, restore. If
everything is OK, check that resistance between ENGINE connector PIN 49 and sensor
connector PIN 3 is a few tenths of an Ohm; If it is above that value, restore cable harness.
Replace the sensor if it is correct.
Error for unexpected air intake in the front cylinder manifold P0210
•
signal not valid.
Error cause
•
A small difference between the estimated pressure and the measured pressure has been
detected: the measured pressure is higher than the estimated one (intake manifold conditions).
Troubleshooting
•
Check the conditions of the intake manifold and cleanliness of the hole for pressure reading.
Error for unexpected air intake in the rear cylinder manifold P0211
•
signal not valid.
Error cause
•
A small difference between the estimated pressure and the measured pressure has been
detected: the measured pressure is higher than the estimated one (intake manifold conditions).
Troubleshooting
•
Check the conditions of the intake manifold and cleanliness of the hole for pressure reading.
Estimation error for front cylinder intake manifold pressure P0215
•
too high pressure/too low pressure.
Error cause
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CAPONORD 1200
A substantial difference between the estimated pressure and the measured pressure has
been detected (for example, the hole for pressure reading is clogged or sensor screw is
loose).
Troubleshooting
•
Check the conditions of the intake manifold and cleanliness of the hole for reading the pressure: there is an evident defect in the intake and pressure reading systems.
Estimation error for rear cylinder intake manifold pressure P0216
•
too high pressure/too low pressure.
Error cause
•
A substantial difference between the estimated pressure and the measured pressure has
been detected (for example, the hole for pressure reading is clogged or sensor screw is
loose).
Troubleshooting
•
Check the conditions of the intake manifold and cleanliness of the hole for reading the pressure: there is an evident defect in the intake and pressure reading systems.
Pressure too low at front cylinder manifold error P0217
•
signal not valid.
Error cause
•
A small difference between the estimated pressure and the measured pressure has been
detected: the measured pressure is below the estimated one (for example, smeared throttle
body).
Troubleshooting
•
Check the conditions of the intake manifold and cleanliness of the hole for pressure reading.
Pressure too low at rear cylinder manifold error P0218
•
signal not valid.
Error cause
•
A small difference between the estimated pressure and the measured pressure has been
detected: the measured pressure is below the estimated one (for example, smeared throttle
body).
Troubleshooting
•
Check the conditions of the intake manifold and cleanliness of the hole for pressure reading.
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Engine temperature sensor
Function
It tells the engine temperature to the control unit to
improve its performance and to calculate the engine friction for a better estimation of the generated
torque.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:
Temperature sensors
Location:
•
on the vehicle: on the front cylinder, inside the "V"
•
connector: on the sensor.
Electrical characteristics:
•
Resistance at 25°: 2.05 kΩ ± 100 Ω
•
Resistance at 60°: 575 kΩ ± 15 Ω
•
Resistance at 90°: 230 kΩ ± 5 Ω
Pin out:
1. Yellow/Brown: 0-5 V signal
2. Green/Pink: Ground connection
DIAGNOSIS INSTRUMENT: PARAMETERS
Engine temperature:
•
Example value with key ON: 25° C
•
Example value with engine on: 75° C
•
In case of recovery, this value is set by the control unit: if there is a malfunction after engine
start-up, temperature decreases up to approximately 90°.
Engine temperature pre Recovery:
•
Example value with key ON: -40° C
•
Example value with engine on: -40° C
•
Value drawn from the signal read without taking into account any recovery: the value in the
example refers to an open circuit.
Engine temperature at start-up:
•
Example value with key ON: -40° C
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CAPONORD 1200
•
Example value with engine on: 25° C
•
The temperature value is stored during engine start-up. With key ON, value -40°C is read.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
engine temperature sensor P0115
•
open circuit, shorted to positive / shorted to negative.
Error cause
•
If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 12 of
the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The
instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting
•
If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if OK,
check continuity between the ENGINE connector PIN 12 and the sensor PIN 1: restore cable
harness if there is not continuity; if it is OK, reconnect the control unit connector and, with
key set to key ON, check the continuity between the sensor connector PIN 2 and the vehicle
ground connection: if OK, it means that the error cause is that the cable is shorted to positive
and it is necessary to restore the cable harness between ENGINE PIN 12 and sensor PIN
1; if there is no continuity with the ground connection, check the sensor connector and the
Marelli control unit connector. If not OK, restore the cable harness. If OK, check continuity
between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2: restore the
cable harness if there is not continuity. If there is, it means that the control unit does not
supply the ground connection and therefore should be replaced.
•
If shorted to negative, check sensor correct resistance: if resistance is null, replace the sensor; if resistance is correct, it means that the Yellow/Brown cable has ground connection:
restore the cable harness
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
engine temperature sensor P0116
•
signal not valid.
Error cause
•
An excessive temperature variation has been detected: for example, the cause may be a
contact resistance between the terminals. The instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting
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•
Electrical system
Check the sensor connector and the ENGINE connector of the Marelli control unit.
NOTES
No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals
are rusty: then use the diagnostics instrument to check if the temperature indicated is the same as the
engine temperature. Check also that the sensor electrical characteristics are observed: replace the
sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector.
Air temperature sensor
Function
it tells the control unit the intake air temperature in
order to calculate oxygen presence so as to optimise the petrol quantity necessary for correct combustion
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature)
Level in wiring diagram:
Temperature sensors
Location:
•
sensor: on filter box left side, next to
rear throttle body
•
connector: on the sensor
Electrical characteristics:Resistance
•
at 0 °C (32 °F): 32.5 kΩ ± 5%
•
at 25 °C (77 °F): 10.0 kΩ ± 5%
Pin out:
1. 0-5 V signal
2. Ground connection
DIAGNOSIS INSTRUMENT: PARAMETERS
Air temperature
Example value with key ON: 45 °C (113 °F)
In case of recovery, this value is set by the control
unit
Air temperature pre Recovery
Example value with key ON: -40 °C (-40.0 °F)
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Value drawn from the signal read without taking
into account any recovery: the value in the example refers to an open circuit
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS
air temperature sensor P0110
•
open circuit, shorted to positive / shorted to negative
Error cause
•
If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of
the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The
instrument panel does not indicate the presence of this error even in the ATT status.
Troubleshooting
•
If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if OK,
check continuity between the ENGINE connector PIN 37 and the sensor PIN 1: restore cable
harness if there is not continuity; if it is OK, reconnect the control unit connector and, with
key set to key ON, check the continuity between the sensor connector PIN 2 and the vehicle
ground connection: if OK, it means that the error cause is that the cable is shorted to positive
and it is necessary to restore the cable harness between ENGINE PIN 37 and sensor PIN
1; check the sensor connector and the Marelli control unit connector. If not OK, restore the
cable harness. If OK, check continuity between the ENGINE connector PIN 6 or 17 and the
sensor connector PIN 2: restore the cable harness if there is not continuity. If there is, it
means that the control unit does not supply the ground connection and therefore should be
replaced
•
If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;
if resistance is correct, it means that the Purple/Black cable has ground connection: restore
the cable harness
Lambda sensor
Function
In charge of telling the control unit whether the mixture is lean or rich.
Operation / Operating principle
The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen
content between the exhaust fumes and the ambient. It does not require an external supply source but,
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in order to work properly, it should reach a high operating temperature: that is why there is a heating
circuit inside.
Level in electrical circuit diagram:
Lambda probe
FRONT CYLINDER LAMBDA PROBE
Location:
•
on the vehicle: exhaust end behind the
rear head
•
connector: on the right side, at the back
of the filter box
Electrical specifications
•
Heater circuit: 7-9Ω at Ambient temp.
Pin out:
1. Sensor signal + (black wire)
2. Sensor signal - (grey wire)
3. Heater ground connection (white cable)
4. Heater power supply (white cable)
REAR CYLINDER LAMBDA PROBE
Location:
•
on the vehicle: exhaust end behind the
rear head
•
connector: on the right side, at the back
of the filter box
Electrical specifications
•
Heater circuit: 7-9Ω at Ambient temp.
Pin out:
1. Sensor signal + (black wire)
2. Sensor signal - (grey wire)
3. Heater ground connection (white cable)
4. Heater power supply (white cable)
DIAGNOSTICS INSTRUMENT:PARAMETERS
Lambda probe
•
Example value with key ON: 0 mV
•
Example value with engine on: 100--900 mV
If there is a short circuit at + 5 V or above, the lambda probe parameter is not equal to the value read
by the control unit; a recovery value is displayed instead.
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Lambda sensor correction
•
Example value with key ON: 1.00 mV
•
Example value with engine on: 0.90 - 1.10mV
In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault):
for example, value 0.75 corresponds to +25% with respect to the reference injection time; 1.25 corresponds to -25%. In an open circuit, the oxygen sensor signal is too low. Therefore, the control unit takes
it as a lean combustion condition and will try to enrich it. The value read will be 0.75: once this correction
has been tried, the value shifts to 1.00 fixed and the Lambda probe error is signalled.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
Lambda probe: Start-up_Lean_Rich_Fault due to rich value_Fault due to lean value
•
If the probe connector is removed (voltage almost equal to zero), the status is Fault due to
lean value.
Lambda check: Open loop/Closed loop/Rich in closed loop/Lean in closed loop/enriched
•
Closed loop indicates that the control unit is using the oxygen sensor signal to keep the
combustion as close as possible to the stoichiometric value.
DIAGNOSTICS INSTRUMENT: ACTIVATION
Lambda probe heating
•
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left
side; CHECK, however, the identification of the relay with the colour of the cables) is energised and the heating circuit is closed to ground 5 times (pin 3 of the lambda probe
connector). The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
Front lambda probe P0130
•
shorted to positive
Error cause
•
Excessive voltage (battery voltage) has been detected at PIN 10 and 22 of the ENGINE
connector. Caution: the 'Oxygen sensor' parameter is not the real value that is read; a recovery value is displayed instead. The instrument panel does not indicate the presence of
this error even in the ATT status.
Troubleshooting
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Electrical system
shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN
1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the
cable harness; if there is not, replace the lambda probe.
Rear lambda probe P0136
•
shorted to positive
Error cause
•
Excessive voltage (battery voltage) has been detected at PIN 9 and 38 of the ENGINE
connector. Caution: the 'Oxygen sensor' parameter is not the real value that is read; a recovery value is displayed instead. The instrument panel does not indicate the presence of
this error even in the ATT status.
Troubleshooting
•
shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN
1 voltage on the cable harness side (orange cable): if there is voltage (5 or 12 V), restore
the cable harness; if there is not, replace the lambda probe.
Front lambda probe heating P0135
•
short circuit to positive/ open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 32 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 32 of the ENGINE connector. The instrument panel does not indicate the presence
of this error even in the ATT status.
Troubleshooting
•
If shorted to positive: disconnect the probe connector and check the correct resistance of
the sensor: if not OK, replace the sensor; if OK restore the cable harness (green/red cable).
•
If circuit is open, shorted to negative: check circuit continuity from probe connector (PIN 3
and 4) toward the probe: if it is not OK, replace the probe; if it is OK, check the sensor
connector and the Marelli control unit connector: if it is not OK, restore; if it is OK, with key
set to ON and sensor connector disconnected, check if there is battery voltage at PIN 4: if
it is not OK, check the Red/Brown cable continuity between the probe connector and the
auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left side;
CHECK, however, the identification of the relay with the colour of the cables). If there are
also coil, lower and upper injector and secondary air errors, check the relay and its excitation
and power line; if there is voltage at PIN 4, check the Green/Red cable ground insulation
(PIN 3): if not OK, restore the cable harness. If it is OK, check the continuity of the Green/
Red cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the
cable harness.
Rear lambda probe heating P0141
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•
CAPONORD 1200
short circuit to positive/ open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 44 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 44 of the ENGINE connector. The instrument panel does not indicate the presence
of this error even in the ATT status.
Troubleshooting
•
If shorted to positive: disconnect the probe connector and check the correct resistance of
the sensor: if not OK replace the sensor; if OK restore the cable harness (black cable).
•
If circuit is open, shorted to negative: check circuit continuity from probe connector (PIN 3
and 4) toward the probe: if it is not OK, replace the probe; if it is OK, check the sensor
connector and the Marelli control unit connector: if it is not OK, restore; if it is OK, with key
set to ON and sensor connector disconnected, check if there is battery voltage at PIN 4: if
it is not OK, check the Red/Brown cable continuity between the probe connector and the
auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left side;
CHECK, however, the identification of the relay with the colour of the cables). If there are
also coil, lower and upper injector and secondary air errors, check the relay and its excitation
and power line; if there is voltage at PIN 4, check the Black cable ground insulation (PIN 3):
if not OK, restore the cable harness. If it is OK, check the continuity of the Black cable
(between the sensor connector PIN 3 and the ENGINE PIN 44) and restore the cable harness.
WARNING
The control unit does not detects the following malfunctions of the oxygen sensor circuit according to
the signal: interrupted circuit, shorted to ground or sensor malfunction (for example non variable voltage). In case of fault indication, carry out the following troubleshooting.
Injector
Injectors key:
1. Front cylinder internal injector (Marelli)
2. Rear cylinder internal injector (Marelli)
3. Front cylinder external injector (Synerject)
4. Rear cylinder external injector (Synerject)
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CAPONORD 1200
Electrical system
Function
To supply the correct amount of petrol at the right timing.
Operation / Operating principle
Injector coil is excited for the petrol passage to open.
The external injectors (Synerject) are always working, whereas the internal ones (Marelli, aka "highpressure" injectors) are opened only when high power is required.
Level in electrical circuit diagram:
Coils and injectors
Location:
A. External injectors (Synerject)
B. Internal injectors (Marelli)
•
on the vehicle: intake manifold
•
connector: on injectors
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Electrical system
CAPONORD 1200
Electrical specifications:
•
internal injectors (Marelli): 14.8 Ω ± 5% (at ambient temp.)
•
external injectors (Synerject): 12.0 Ω ± 5% (at ambient temp.)
Pin out:
1. Fuel system
2. Negative from control unit
DIAGNOSTICS INSTRUMENT:PARAMETERS
Front cylinder injection time
•
Example value with engine on: 1.9 ms
Rear cylinder injection time
•
Example value with engine on: 1.9 ms
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ACTIVATION
Internal front cylinder injector
•
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left
side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit is closed to ground for
4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the
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CAPONORD 1200
Electrical system
relay and injector activation. The continuity of the wiring is necessary for correct activation:
no error indications are displayed in case of lack of activation.
Internal rear cylinder injector
•
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left
side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit is closed to ground for
4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the
relay and injector activation. The continuity of the wiring is necessary for correct activation:
no error indications are displayed in case of lack of activation.
External front cylinder injector
•
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left
side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit is closed to ground for
4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the
relay and injector activation. The continuity of the wiring is necessary for correct activation:
no error indications are displayed in case of lack of activation.
External rear cylinder injector
•
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left
side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit is closed to ground for
4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the
relay and injector activation. The continuity of the wiring is necessary for correct activation:
no error indications are displayed in case of lack of activation.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
External front cylinder injector P0201
•
short circuit to positive/ short circuit to negative / open circuit
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 8. If shorted to negative:
no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting
•
If shorted to positive: disconnect the injector connector, set key to ON, activate the component with the diagnosis instrument and check the voltage on the white/green cable on the
injector connector. If following the activation the voltage does not drop, restore the cabling,
otherwise replace the injector.
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•
CAPONORD 1200
If shorted to negative: disconnect the injector connector, set the key to ON and check if there
is a ground connection on the white/green cable: if there is connection, restore the cable
harness. If there is no connection, replace the injector.
•
If the circuit is open: check the connector on the component and the Marelli control unit
connector: if not OK, restore. If OK, check cable continuity between the ENGINE PIN 8 and
component PIN 2 and restore the cable harness.
External rear cylinder injector P0202
•
short circuit to positive/ short circuit to negative / open circuit
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 46. If shorted to negative:
no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting
•
If shorted to positive: disconnect the injector connector, set key to ON, activate the component with the diagnosis instrument and check the voltage on the orange/white cable on the
injector connector. If following the activation the voltage does not drop, restore the cabling,
otherwise replace the injector.
•
If shorted to negative: disconnect the injector connector, set the key to ON and check if there
is a ground connection on the orange/white cable: if there is connection, restore the cable
harness. If there is no connection, replace the injector.
•
If the circuit is open: check the connector on the component and the Marelli control unit
connector: if not OK, restore. If OK, check cable continuity between the ENGINE PIN 46 and
component PIN 2 and restore the cable harness.
Internal front cylinder injector P0205
•
short circuit to positive/ short circuit to negative / open circuit
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 53. If shorted to negative:
no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting
•
If shorted to positive: disconnect the injector connector, set key to ON, activate the component with the diagnosis instrument and check the voltage on the grey/red cable on the
injector connector. If following the activation the voltage does not drop, restore the cabling,
otherwise replace the injector.
•
If shorted to negative: disconnect the injector connector, set the key to ON and check if there
is a ground connection on the Grey/Red cable: if there is connection, restore the cable harness. If there is no connection, replace the injector.
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CAPONORD 1200
•
Electrical system
If the circuit is open: check the connector on the component and the Marelli control unit
connector: if not OK, restore. If OK, check cable continuity between the ENGINE PIN 53 and
component PIN 2 and restore the cable harness.
Internal rear cylinder injector P0206
•
short circuit to positive/ short circuit to negative / open circuit
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 67. If shorted to negative:
no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting
•
If shorted to positive: disconnect the injector connector, set key to ON, activate the component with the diagnosis instrument and check the voltage on the white/black cable on the
injector connector. If following the activation the voltage does not drop, restore the cabling,
otherwise replace the injector.
•
If shorted to negative: disconnect the injector connector, set the key to ON and check if there
is a ground connection on the White/Black cable: if there is connection, restore the cable
harness. If there is no connection, replace the injector.
•
If the circuit is open: check the connector on the component and the Marelli control unit
connector: if not OK, restore. If OK, check cable continuity between the ENGINE PIN 67 and
component PIN 2 and restore the cable harness.
Fuel pump
Function
Fuel pump: keeps pressure of the injectors supply
duct.
Low fuel: tells to the instrument panel about low
fuel
Operation / Operating principle
Low fuel: it is a resistance that if correctly supplied
varies its electrical resistance if it is damped or not
by petrol.
Level in electrical circuit diagram:
Injection load relay
Location:
•
on the vehicle: on the tank.
•
connector: near the fuel pump (4 ways,
black).
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Electrical system
CAPONORD 1200
Electrical characteristics:
PIN 1-2: 0.5 - 1 ohm; PIN 3-4: you do not need to
measure the component electrical resistance
since it works correctly with suitable supply from
the instrument panel only. Check correct operation
as follows: connect in series a bulb of approximately 2 W: it should turn on if the tank is in
reserve, otherwise, it remains off.
Pin out:
1. + 12 V
2. ground connection
3. ground connection
4. + 12 V (signal)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ACTIVATION
Fuel pump
NOTE: The auxiliary injection relay (No. 35 on the electrical circuit diagram, in the two relay box, however VERIFY the identification of the relay with the colour of the cables) is energised for 30 seconds.
The continuity of the wiring is necessary for correct activation: no error indications are displayed in case
of lack of activation
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
fuel pump relay control P0230
•
shorted to positive / open circuit, shorted to negative.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 73 of the VEHICLE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 73 of the VEHICLE connector.
Troubleshooting
•
If shorted to positive: check whether the relay electrical specifications are correct by disconnecting it from the cable harness. If are not OK, replace the relay; if OK, restore the cable
harness (Brown/Black cable).
•
If the circuit is open, shorted to negative: check the relay electrical characteristics are correct
by disconnecting it from the cable harness; if it is not OK, replace the relay, if it is OK, check
relay connector, engine-vehicle cable harness connector and VEHICLE connector of the
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CAPONORD 1200
Electrical system
Marelli control unit: if not OK, restore; if OK, check continuity of cable harness (Brown/Black
cable)
Coil
Coils key:
1. Front cylinder central coil
2. Front cylinder side coil
3. Rear cylinder central coil
4. Rear cylinder side coil
Function
Spark generation
Operation / Operating principle
Inductive discharge system
Level in electrical circuit diagram:
Coils and injectors
Location:
•
on the vehicle: on the head covers.
•
connector:
- FRONT CENTRAL COIL with long cable, left side, on the frame near filter box cover, above the front
side coil connector.
- FRONT SIDE COIL with short cable and retaining tongue, left side, on the frame near filter box cover,
below the front central coil connector.
- REAR CENTRAL COIL with long cable, at the centre, under the filter box, at the back compared to
connector.
- REAR SIDE COIL with short cable and retaining tongue, at the centre, under the filter box, at the front
compared to the rear central coil connector.
Electrical specifications:
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CAPONORD 1200
0.7 - 0.9 Ω at ambient temperature
Pin out:
1. Power supply + Vbatt
2. Secondary circuit to ground
3. Activation from control unit
DIAGNOSTICS INSTRUMENT:PARAMETERS
Example value with key ON: Current ignition advance.
Example value with engine on: Indicates the cylinder advance where combustion will take place.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ACTIVATION
Front Central Coil:
The auxiliary relay (No. 46 in the wiring diagram, placed in the front relay box, left side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the coil
Pink cable is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump
to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct
activation: no error indications are displayed in case of lack of activation.
Rear Central Coil:
The auxiliary relay (No. 46 in the wiring diagram, placed in the front relay box, left side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the coil
Purple/Grey cable is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel
pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for
correct activation: no error indications are displayed in case of lack of activation.
Front Side Coil:
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left side; CHECK,
however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the
coil Brown/Green cable is closed to ground for 2 ms per second. Disconnect the 4-way connector of
the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary
for correct activation: no error indications are displayed in case of lack of activation.
Rear Side Coil:
The auxiliary injection relay (No. 46 in the wiring diagram, placed in the front relay box, left side; CHECK,
however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the
coil Brown/White cable is closed to ground for 2 ms per second. Disconnect the 4-way connector of the
fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary
for correct activation: no error indications are displayed in case of lack of activation.
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
Front cylinder central coil P0351
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CAPONORD 1200
•
Electrical system
shorted to positive / shorted to negative, open circuit.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 28 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 28 of the ENGINE connector.
Troubleshooting
•
If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
the diagnostics instrument and check voltage at connector PIN 28: if there is voltage, restore
the cable harness; if voltage = 0, replace the coil.
•
If the circuit is open, shorted to negative: check electric characteristics of the coil: if not OK,
replace the coil, if OK check the coil connector and the Marelli control unit connector; if not
OK, restore, if OK, check cable continuity between the two cable terminals: if there is not
continuity, restore the cable harness; if there is cable continuity, with key set to ON, check
the ground insulation of the cable (from coil connector or control unit connector), if not OK,
restore cable harness.
Rear cylinder central coil P0352
•
shorted to positive / shorted to negative, open circuit.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 27 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 27 of the ENGINE connector
Troubleshooting
•
If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
the diagnostics instrument and check voltage at connector PIN 27: if there is voltage, restore
the cable harness; if voltage = 0, replace the coil.
•
If the circuit is open, shorted to negative: check electric characteristics of the coil: if not OK,
replace the coil, if OK check the coil connector and the Marelli control unit connector; if not
OK, restore, if OK, check cable continuity between the two cable terminals: if there is not
continuity, restore the cable harness; if there is cable continuity, with key set to ON, check
the ground insulation of the cable (from coil connector or control unit connector), if not OK,
restore cable harness.
Front cylinder side coil P0353
•
shorted to positive / shorted to negative, open circuit.
Error cause
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•
CAPONORD 1200
If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 2 of the ENGINE connector.
Troubleshooting
•
If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
the diagnostics instrument and check voltage at connector PIN 2: if there is voltage, restore
the cable harness; if voltage = 0, replace the coil.
•
If the circuit is open, shorted to negative: check electric characteristics of the coil: if not OK,
replace the coil, if OK check the coil connector and the Marelli control unit connector; if not
OK, restore, if OK, check cable continuity between the two cable terminals: if there is not
continuity, restore the cable harness; if there is cable continuity, with key set to ON, check
the ground insulation of the cable (from coil connector or control unit connector), if not OK,
restore cable harness.
Rear cylinder side coil P0354
•
shorted to positive / shorted to negative, open circuit.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 1 of the ENGINE connector. If the circuit is open, shorted to negative: voltage equal to zero has been detected
at PIN 1 of the ENGINE connector.
Troubleshooting
•
If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
the diagnostics instrument and check voltage at connector PIN 1: if there is voltage, restore
the cable harness; if voltage = 0, replace the coil.
•
If the circuit is open, shorted to negative: check electric characteristics of the coil: if not OK,
replace the coil, if OK check the coil connector and the Marelli control unit connector; if not
OK, restore, if OK, check cable continuity between the two cable terminals: if there is not
continuity, restore the cable harness; if there is cable continuity, with key set to ON, check
the cable ground insulation (from coil connector or control unit connector), if not OK, restore
cable harness
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CAPONORD 1200
Electrical system
Throttle body
Function
Sends to the injection control unit the throttle position and activates the throttle according to the
control unit
Operation / Operating principle
All the unit internal components (potentiometer
and electric motor) are contactless; therefore, no
electrical diagnosis is possible for the throttle
body, but for the circuits connected to it only.
Level in electrical circuit diagram:
Throttle check and throttle grip sensor (Demand)
Location:
•
on the vehicle: inside the filter box
•
connector: near the throttle motors
Pin out:
1. potentiometer signal 1
2. supply voltage + 5V
3. throttle valve control (+)
4. potentiometer signal 2
5. throttle valve control (+)
6. ground connection
DIAGNOSIS INSTRUMENT: PARAMETERS
Front cylinder throttle correction
•
Example value with key ON: 0.0°
•
Example value with engine at idle: -0.5°
The system, reading the intake pressure, tries to balance the intake pressures between the front cylinder
and the rear one working on the throttle position: an acceptable value should be between -0.8º and
+0.8º.
Rear cylinder throttle correction
•
Example value with key ON: 0.0°
•
Example value with engine on: -0.3°
The system, reading the intake pressure, tries to balance the intake pressures between the front cylinder
and the rear one working on the throttle position: an acceptable value should be between -0.8º and
+0.8º.
Front throttle Potentiometer 1 (degrees)
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Electrical system
•
Example value with key ON: 5.5°
•
Example value with engine at idle: 2.1°
CAPONORD 1200
With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts
up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°). When the gear
is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low
(around 5-7°)
Rear throttle Potentiometer 1 (degrees)
•
Example value with key ON: 5.2°
•
Example value with engine on: 2.2°
With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts
up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°). When the gear
is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low
(around 5-7°)
Front throttle Potentiometer 1 (voltage)
•
Example value with key ON: 761 mV
•
Example value with engine on: 610 mV
Rear throttle Potentiometer 1 (voltage)
•
Example value with key ON: 746 mV
•
Example value with engine on: 605 mV
Front throttle Potentiometer 2 (degrees)
•
Example value with key ON: 5.5°
•
Example value with engine on: 2.5°
With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts
up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°). When the gear
is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low
(around 5-7°)
Rear throttle Potentiometer 2 (degrees)
•
Example value with key ON: 5.2°
•
Example value with engine on: 2.5°
With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts
up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°). When the gear
is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low
(around 5-7°)
Front throttle Potentiometer 2 (voltage)
•
Example value with key ON: 4245 mV
•
Example value with engine on: 4377 mV
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CAPONORD 1200
Electrical system
Rear throttle Potentiometer 2 (voltage)
•
Example value with key ON: 4226 mV
•
Example value with engine on: 4372 mV
Key to throttle connectors figure:
•
A - Front cylinder throttle connector
•
B - Rear cylinder throttle connector
Front cylinder throttle Limp Home position
•
Example value with key ON: 878 mV
Voltage stored in the control unit corresponding to the Limp home position
Rear cylinder throttle Limp Home position
•
Example value with key ON: 888 mV
Voltage stored in the control unit corresponding to the Limp home position
Front throttle lower position
•
Example value with key ON: 502 mV
Voltage stored in the control unit corresponding to the throttle mechanical minimum position
Rear throttle lower position
•
Example value with key ON: 492 mV
Voltage stored in the control unit corresponding to the throttle mechanical minimum position
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSIS INSTRUMENT: STATUSES
Front throttle automatic self-acquisition
•
ice/ interrupted/carried out/limp home/closed throttle stop/springs check/limp home self-acquisition/initialise
Indicates if self-acquisition carried out by control unit has/has not been carried out: it is essential to
know if the last self-acquisition with key ON has been successful
Rear throttle automatic self-acquisition
•
ice/ interrupted/carried out/limp home/closed throttle stop/springs check/limp home self-acquisition/initialise
Indicates if self-acquisition carried out by control unit has/has not been carried out: it is essential to
know if the last self-acquisition with key ON has been successful
Throttle self-learning with diagnostics instrument
•
carried out/not carried out
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CAPONORD 1200
Indicates whether the self-acquisition process through the diagnosis instrument has/has not been carried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero
setting is carried out
DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS
CAUTION
IF ERRORS ARE DETECTED ON BOTH THROTTLE BODIES, CHECK ALSO THE CORRECT SUPPLY OF THE CONTROL UNIT TO PIN 42.
potentiometer 1 sensor, front throttle position P0120
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 48. If the circuit is open,
shorted to negative: voltage equal to zero has been detected at PIN 48.
Troubleshooting
•
If shorted to positive: check the value shown by the parameter of the front throttle Potentiometer 1 (voltage): disconnect the connector and read the value indicated by the diagnosis
instrument: if the voltage does not vary, there is a short circuit in the cable; replace the throttle
body if the voltage drops to zero
•
If the circuit is open, shorted to negative: check the throttle body connector and the control
unit connector. If not OK, restore; if everything is OK, check circuit continuity between the
two terminals. If not OK, restore the cable harness; if OK, check the circuit ground insulation
(from throttle sensor connector or control unit connector). If it is ground insulated, check that
there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to
ground. If both are correct, replace the throttle body
potentiometer 2 sensor, front throttle position P0122
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 50. If the circuit is open,
shorted to negative: voltage equal to zero has been detected at PIN 50.
Troubleshooting
•
If shorted to positive: check the value shown by the parameter of the front throttle Potentiometer 2 (voltage): disconnect the connector and read the value indicated by the diagnosis
instrument: if the voltage does not vary, there is a short circuit in the cable; replace the throttle
body if the voltage drops to zero
•
If the circuit is open, shorted to negative: check the throttle body connector and the control
unit connector. If not OK, restore; if everything is OK, check circuit continuity between the
two terminals. If not OK, restore the cable harness; if OK, check the circuit ground insulation
(from throttle sensor connector or control unit connector). If it is ground insulated, check that
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Electrical system
there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to
ground. If both are correct, replace the throttle body
potentiometer 1 sensor, rear throttle position P0125
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 36. If the circuit is open,
shorted to negative: voltage equal to zero has been detected at PIN 36
Troubleshooting
•
If shorted to positive: check the value shown by the parameter of the Rear throttle Potentiometer 1 (voltage): disconnect the connector and read the value indicated by the diagnosis
instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace
the throttle body if the voltage drops to zero.
•
If the circuit is open, shorted to negative: check the throttle body connector and the control
unit connector. If not OK, restore; if everything is OK, check circuit continuity between the
two terminals. If not OK, restore the cable harness; if OK, check the circuit ground insulation
(from throttle sensor connector or control unit connector). If it is ground insulated, check that
there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to
ground. If both are correct, replace the throttle body
potentiometer 2 sensor, rear throttle position P0127
•
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 21. If the circuit is open,
shorted to negative: voltage equal to zero has been detected at PIN 21.
Troubleshooting
•
If shorted to positive: check the value shown by the parameter of the Rear throttle Potentiometer 2 (voltage): disconnect the connector and read the value indicated by the diagnosis
instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace
the throttle body if the voltage drops to zero.
•
If the circuit is open, shorted to negative: check the throttle body connector and the control
unit connector. If not OK, restore; if everything is OK, check circuit continuity between the
two terminals. If not OK, restore the cable harness; if OK, check the circuit ground insulation
(from throttle sensor connector or control unit connector). If it is ground insulated, check that
there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to
ground. If both are correct, replace the throttle body
Front throttle control circuit P0166
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CAPONORD 1200
short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal
temperature.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to
negative: no voltage has been detected. If the circuit is open: an interruption or excessive
ampere input or control unit overheating has been detected
Troubleshooting
•
If shorted to positive: disconnect the throttle body connector, set key to ON and check voltage at PIN 3: if the voltage read is higher or equal to 5V, there is a short circuit on the cable
harness; replace the throttle body if the voltage is null
•
If shorted to negative: disconnect the throttle body connector, set the key to ON and check
if PIN 3 is in continuity with the vehicle ground connection: if there is continuity, restore the
cable harness; if there is not continuity, replace the throttle body
•
If the circuit is open, there is overvoltage or excessive internal temperature: check the throttle
body connector and the control unit connector: if not OK, restore; if OK, disconnect the
throttle body connector and control unit connector and check if there is cables continuity; if
there is no continuity, restore the cable harness. If there is continuity, with the throttle body
connector connected, check that the resistance, from the throttle control unit connector,
between PIN 29 and 41 is within 1 and 2.5 Ohm; if it is not, replace the throttle body; if it is,
check that the throttle body is not mechanically blocked: if blocked, solve the problem and
replace the body; if it is not, replace the control unit
Rear throttle control circuit P0186
•
short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal
temperature circuit open
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 3 - 15. If shorted to negative: no voltage has been detected. If the circuit is open: an interruption or excessive
ampere input or control unit overheating has been detected
Troubleshooting
•
If shorted to positive: disconnect the throttle body connector, set key to ON and check voltage at PIN 3: if the voltage read is higher or equal to 5V, there is a short circuit on the cable
harness; replace the throttle body if the voltage is null
•
If shorted to negative: disconnect the throttle body connector, set the key to ON and check
if PIN 3 is in continuity with the vehicle ground connection: if there is continuity, restore the
cable harness; if there is not continuity, replace the throttle body
•
If the circuit is open, there is overvoltage or excessive internal temperature: check the throttle
body connector and the control unit connector: if not OK, restore; if OK, disconnect the
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Electrical system
throttle body connector and control unit connector and check if there is cables continuity; if
there is no continuity, restore the cable harness. If there is continuity, with the throttle body
connector connected, check that the resistance, from the throttle control unit connector,
between PIN 3 and 15 is within 1 and 2.5 Ohm; if it is not, replace the throttle body; if it is,
check that the throttle body is not mechanically blocked: if blocked, solve the problem and
replace the body; if it is not, replace the control unit
DIAGNOSIS INSTRUMENT: LOGIC ERRORS
potentiometer 1 sensor, front throttle position P0121
•
signal not valid
Error cause
•
Signal not within the expected value drawn according to the values of the intake pressure
Troubleshooting
•
Check the parameter of the Potentiometer 1 Front throttle (voltage) to get which signal the
control unit receives and to compare it to the Potentiometer 1 Rear throttle (voltage). Check
the throttle body connector as well as the control unit connector. Check that cable resistance
between the throttle body connector (PIN 1) and the control unit (PIN48) is a few tenths of
an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the
complete throttle body
potentiometer 2 sensor, front throttle position P0123
•
signal not valid
Error cause
•
Signal not within the expected value drawn according to the values of the intake pressure
Troubleshooting
•
Check the parameter of the Potentiometer 2 Front throttle (voltage) to get which signal the
control unit receives and to compare it to the Potentiometer 2 Rear throttle (voltage). Check
the throttle body connector as well as the control unit connector. Check that cable resistance
between the throttle body connector (PIN 4) and the control unit (PIN 50) is a few tenths of
an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the
complete throttle body
front throttle position potentiometer P0124
•
incongruent signal
Error cause
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CAPONORD 1200
Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages
should be constant. The cause may be a malfunction in one of the two sensors or an abnormal resistance in one of the two circuits
Troubleshooting
•
Check the throttle body connector as well as the control unit connector. Check that cable
resistance between the throttle body connector (PIN 1) and the control unit (PIN 48) is a few
tenths of an Ohm. Check that cable resistance between the throttle body connector (PIN 4)
and the control unit (PIN 50) is a few tenths of an Ohm. If one of the two is different, restore
the cable harness. If correct, replace the complete throttle body.
potentiometer 1 sensor, rear throttle position P0126
•
signal not valid
Error cause
•
Signal not within the expected value drawn according to the values of the intake pressure
Troubleshooting
•
Check the parameter of the Potentiometer 1 Rear throttle (voltage) to get which signal the
control unit receives and to compare it to the Potentiometer 1 Front throttle (voltage). Check
the throttle body connector as well as the control unit connector. Check that cable resistance
between the throttle body connector (PIN 1) and the control unit (PIN 36) is a few tenths of
an Ohm. If this is not the case, restore the cable harness. If the value is correct, replace the
complete throttle body
potentiometer 2 sensor, rear throttle position P0128
•
signal not valid
Error cause
•
Signal not within the expected value drawn according to the values of the intake pressure
Troubleshooting
•
Check the parameter of the Potentiometer 2 Rear throttle (voltage) to get which signal the
control unit receives and to compare it to the Potentiometer 2 Front throttle (voltage). Check
the throttle body connector as well as the control unit connector. Check that cable resistance
between the throttle body connector (PIN 4) and the throttle control unit (PIN 21) is a few
tenths of an Ohm. If this is not the case, restore the cable harness. If the value is correct,
replace the complete throttle body
rear throttle position potentiometer P0129
•
incongruent signal
Error cause
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•
Electrical system
Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages
should be constant. The cause may be a malfunction in one of the two sensors or an abnormal resistance in one of the two circuits
Troubleshooting
•
Check the throttle body connector as well as the control unit connector. Check that cable
resistance between the throttle body connector (PIN 1) and the control unit (PIN 36) is a few
tenths of an Ohm. Check that cable resistance between the throttle body connector (PIN 4)
and the throttle control unit (PIN 21) is a few tenths of an Ohm. If one of the two is different,
restore the cable harness. If correct, replace the complete throttle body.
Front throttle Limp Home self-acquisition P0160
•
failed test
Error cause
•
Throttle position, kept by the springs, not within the expected range (at each key ON). The
instrument panel does not indicate the presence of this error even in the ATT status
Troubleshooting
•
Check if the throttle body and the intake duct are clean. If OK, replace the throttle body
Front throttle mechanical springs self-acquisition P0161
•
failed test
Error cause
•
Return time of the throttle, kept in position by the springs, not within the expected limits: the
causes can be a deterioration of the performance of the springs or excessive throttle friction
(at each key ON)
Troubleshooting
•
Check if the throttle body and the intake duct are clean. If OK, replace the throttle body
Front throttle minimum mechanical position self-acquisition P0162
•
failed test
Error cause
•
Position of the throttle stop not within the expected field (at each key ON)
Troubleshooting
•
Check if the throttle body and the intake duct are clean. If OK, replace the throttle body
Detection of the front throttle Recovery conditions (air temp., water temp.) P0163
•
possible presence of ice
Error cause
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CAPONORD 1200
A correct throttle rotation cannot be detected given low ambient and engine temperatures:
some ice may have formed in the duct (at each key ON). The instrument panel does not
indicate the presence of this error even in the ATT status
Troubleshooting
•
Check that the throttle body is clean and that there is no ice or condensation in the intake
duct. If OK, replace the throttle body
Front throttle power supply voltage during self-acquisition P0164
•
low power supply voltage
Error cause
•
The throttle power supply voltage is too low to carry out the self-acquisition test correctly (at
each key ON). The instrument panel does not indicate the presence of this error even in the
ATT status
Troubleshooting
•
Delete errors hindering throttle self-learning.
Front throttle position error P0167
•
misalignment between control and activation
Error cause
•
The throttle mechanical control may be damaged
Troubleshooting
•
Replace the throttle body
Rear throttle Limp Home self-acquisition P0180
•
failed test
Error cause
•
Throttle position, kept by the springs, not within the expected range (at each key ON). The
instrument panel does not indicate the presence of this error even in the ATT status
Troubleshooting
•
Check if the throttle body and the intake duct are clean. If OK, replace the throttle body
Rear throttle mechanical springs self-acquisition P0181
•
failed test
Error cause
•
Return time of the throttle, kept in position by the springs, not within the expected limits: the
causes can be a deterioration of the performance of the springs or excessive throttle friction
(at each key ON)
Troubleshooting
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•
Electrical system
Check if the throttle body and the intake duct are clean. If OK, replace the throttle body
Rear throttle minimum mechanical position self-acquisition P0182
•
failed test
Error cause
•
Position of the throttle stop not within the expected field (at each key ON)
Troubleshooting
•
Check if the throttle body and the intake duct are clean. If OK, replace the throttle body
Detection of the rear throttle Recovery conditions (air temp., water temp.) P0183
•
possible presence of ice
Error cause
•
A correct throttle rotation cannot be detected given low ambient and engine temperatures:
some ice may have formed in the duct (at each key ON). The instrument panel does not
indicate the presence of this error even in the ATT status
Troubleshooting
•
Check that the throttle body is clean and that there is no ice or condensation in the intake
duct. If OK, replace the throttle body
Rear throttle supply voltage during self-acquisition P0184
•
low power supply voltage
Error cause
•
The throttle power supply voltage is too low to carry out the self-acquisition test correctly (at
each key ON). The instrument panel does not indicate the presence of this error even in the
ATT status
Troubleshooting
•
Delete errors hindering throttle self-learning.
Rear throttle position error P0187
•
misalignment between control and activation
Error cause
•
The throttle mechanical control may be damaged
Troubleshooting
•
Replace the throttle body
DIAGNOSIS INSTRUMENT: ADJUSTABLE PARAMETERS
Throttle Self-learning
NOTE
THROTTLE BODY ACTIVATION TAKES PLACE EVERY TIME THE KEY IS SET TO ON: CORRECT
ACTIVATION IS INDICATED WHEN THE STOP LIGHTS TURN ON: IF DURING ACTIVATION, THE
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ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT
TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTIVATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SECONDS), THE ENGINE WILL NOT START.
FITTING: MECHANICAL/ELECTRICAL REFIT
RESET PROCEDURE
If a throttle body is replaced, after key is set to ON, do not start the engine within the 3 seconds; during
this time the control unit carries out the throttle self-learning process: according to the throttle body
replaced check that the status "Front throttle automatic self-acquisition" or "Rear throttle automatic selfacquisition" indicates: "carried out". If indication is not "Carried out", delete possible errors on the vehicle
and then, with key set to ON, check that the statuses are "Carried out". If necessary, carry out "Throttle
self-learning" process on the adjustable parameters screen page (screwdriver and hammer), and check
again that the "Throttle self-learning with diagnostics instrument" status indicates: "Carried out" and that
the "Front throttle automatic self-acquisition" or "Rear throttle automatic self-acquisition" indicate: "carried out"
Engine oil pressure sensor
ENGINE OIL PRESSURE SENSOR
Function: it indicates to the instrument panel if
there is enough oil pressure (0.5 + / - 0.2 bar (7.25
+ / - 2.9 PSI)) in the engine.
Operation / Operating principle: normally closed
switch. With oil pressure above 0.5 + / -0.2 bar
(7.25 + / - 2.9 PSI), open circuit.
Location on the vehicle: right side of the vehicle,
under the oil sump
Pin-out: Voltage 5V
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Electrical system
Neutral sensor
Function
It tells the gear position to the control unit, from the
1st gear to the 6th gear, and if the gear is neutral
or riding.
Operation / Operating principle
The sensor has 2 circuits: one to indicate the engaged gear, whose resistance varies according to
the gear engaged: in this way, the injection ECU,
according to detected electric voltage, identifies
the engaged gear and sends the information via
CAN to the instrument panel; the other indicates
neutral gear, whose voltage is taken to zero if in
neutral position.
Level in electrical circuit diagram:
Start-up enabling switches
Location:
•
on the vehicle: under chain pinion, behind the pinion cover.
•
connector: left side, on flywheel cover
Electrical characteristics:
PIN 64: gear indication: closed circuit (continuity);
gear engaged: open circuit (infinite resistance).
Gear engaged circuit resistance: 1st gear: 0.8
kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th
gear 6.9 kohm, 5th gear 2.8 kohm, 6th gear 1.5
kohm.
Pin out:
White/Black: ground from ECU, Light Blue: + 12V
from ECU (gear), Pink: + 5V from ECU (gears).
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
Gearbox in neutral
•
Yes/No
Gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6
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DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
Gear sensor P0461
•
shorted to positive or open circuit / shorted to negative.
Error cause
•
If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 72. If
shorted to negative: voltage equal to zero has been detected at PIN 72.
Troubleshooting
•
If the circuit is open, shorted to positive: the error is detected with gear engaged only. Check
the sensor connector and the VEHICLE connector of the control unit: if not OK, restore; if
they are OK, check the continuity of the Grey/Black cable between the two connectors: if
not OK, restore; if they are OK, with key set to ON and control unit connector disconnected,
check from the control unit side if the cable is in voltage: if it is in voltage, disconnect the
sensor connector and check if the cable is in voltage: if it is in voltage, restore the cable
harness; if it is not in voltage, replace the sensor (there is an interruption or shorted to positive
of the Pink/Black cable in the section from the sensor connector to the sensor or inside the
sensor).
•
If shorted to negative: disconnect the sensor connector and with key set to ON, check Grey/
Black cable voltage: if equal to zero, restore the cable harness; if equal to approx. 5 V,
replace the sensor (there is short circuit to ground of the Pink/Black cable in the section from
the sensor connector to the sensor or inside the sensor).
Side stand sensor
Function
It tells the side stand position to the control unit.
Operation / Operating principle
If the gear is engaged and the side stand is unfolded, and therefore the circuit is open, the control
unit does not enable vehicle start-up or shuts off
the engine if it is rotating.
Level in electrical circuit diagram:
Start-up enabling switches
Location:
•
on the vehicle: on the stand
•
connector: on the alternator cover (2way connector)
Pin out:
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Electrical system
1. Ground connection
2. Voltage 12V
Electrical specifications:
•
Side Stand Up: closed circuit (continuity)
•
Side Stand Down: open circuit (infinite
resistance)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
Side stand sensor: up/down
•
indication on the diagnostics instrument always down: check the connector: if not OK, restore; if it is OK, disconnect the two terminals from the sensor and check continuity to ground
of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor.
•
Indication on the diagnostics instrument always up: disconnect the terminals from the sensor
and check if there is continuity between the two PINS, with stand down: if there is continuity,
replace the sensor; if the circuit is open, it means that the brown/green cable from sensor
PIN 2 to VEHICLE connector PIN 70 is short circuit to ground: restore the cable harness.
Bank angle sensor
(IF APPLICABLE)
Function
It tells the vehicle position to the control unit.
Operation / Operating principle
When the sensor is inverted, the circuit is closed
to ground: When the Marelli control unit detects
this ground connection, it does not enable start-up
or shuts off the engine.
Level in electrical circuit diagram:
Start-up enabling switches
Location:
•
on the vehicle: under the saddle, behind the battery.
•
connector: next to the sensor (4-ways
connector).
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Electrical specifications:
•
Sensor in vertical position: open circuit
(resistance: 62 kOhm)
•
Sensor inverted: closed circuit (continuity)
Pin out:
1. Voltage 5V
2. Ground connection
3. Signal
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
Fall sensor: Normal / Tip over
•
Indication on diagnostics instrument always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the
PINS 2 and 3 of the sensor: If there is not continuity, replace the sensor; if there is continuity,
check the connector: if not OK, restore the cable harness. If OK, check continuity to ground
of PIN 2 (pink/black cable): if there is no continuity, restore the cable harness; otherwise,
with key set to ON, check if there is 5V voltage at PIN 1 (orange/black cable). If there is not,
check the Marelli control unit connector (PIN 65).
•
Indication on the diagnostics instrument always Tip over: disconnect the connector and, with
sensor upright, check if there is continuity between the PINS 2 and 3 of the sensor: if there
is continuity, replace the sensor; if there is not, it means that, with key set to ON, there is no
5V voltage at PIN 1: restore the cable harness whose orange/black cable will be shorted to
ground.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
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Electrical system
Electric fan circuit
Function
Radiator fan and coolant - Operation
Operation / Operating principle
When the control unit detects a temperature of approx. 102 °C, it closes the fan control relay pickup
circuit to ground
Level in electrical circuit diagram:
electric fan
Location:
•
sensor: relay located inside the rear relay box, the one toward motorcycle
rear end (also CHECK relay identification with the colour of the cables)
•
connector: on the relay
Electrical specifications:
•
relay normally open;
•
drive coil resistance 110 Ohm (+/- 10
%)
DIAGNOSTICS INSTRUMENT:STATUSES
Fan relay
•
on/off
DIAGNOSTICS INSTRUMENT:ACTIVATION
Fan
•
The fan relay (No. 43 in the wiring diagram) is energised for 10 seconds. The
continuity of the wiring is necessary for
correct activation: no error indications
are displayed in case of lack of activation
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
Cooling fan relay P0480
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short circuit to positive/ short circuit to negative / open circuit
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 61 of the VEHICLE connector. If shorted to negative: no voltage has been detected. If the circuit is open: 5V voltage
has been detected. Error recognition carries out only when the fan relay is activated.
Troubleshooting
•
If shorted to positive: check the relay electrical specifications are correct by disconnecting
it from the cable harness. If not OK, replace the relay; if OK, restore the cable harness (Brown
cable)
•
If shorted to negative: check the relay electrical specifications are correct by disconnecting
it from the cable harness. If not OK, replace the relay; if OK, restore the cable harness (Brown
cable)
•
If the circuit is open: check the relay electrical characteristics are correct by disconnecting
it from the cable harness; if not OK, replace the relay, if OK, check relay connector and
VEHICLE connector of the Marelli control unit: if not OK, restore; if OK, check continuity of
cable harness (Brown cable)
RUN/STOP switch
Function
It tells the control unit if the rider wishes to enable
engine start-up or to keep the engine running.
Operation / Operating principle
If the rider wants to shut off the engine or to disable
engine start-up, the switch should be open, i.e.
VEHICLE connector PIN 78 of the Marelli control
unit must not be connected to ground.
Level in electrical circuit diagram:
Start-up enabling switches
Location:
•
on the vehicle: right light switch.
•
connector: at the centre between air filter box and water radiator.
Electrical specifications:
•
STOP position: the circuit is open
•
RUN position: closed circuit (continuity)
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Electrical system
Pin out:
1 blue/green cable: ground connection
2 yellow/red cable: 5 V
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING,
CAREFULLY READ THE GENERAL TROUBLESHOOTING
CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: STATUSES
RUN / STOP switch
•
Run/Stop
NOTES
•
Indication on the diagnostics instrument always on STOP: disconnect the connector and,
with the switch set to RUN, check if there is continuity towards the two cables switch - Blue/
Green and Yellow/Red: If there is not continuity, replace the sensor; if there is continuity,
check the connector: if not OK, restore the cable harness; if OK, check, with key set to ON,
if there is voltage on Yellow/Red cable: if there is no voltage, restore the cable harness; if
there is, check the Yellow/Red cable ground insulation: If there is continuity with ground
connection, restore the cable harness; if OK, set the key to OFF and check the VEHICLE
connector and the engine-vehicle cable harness connector: if it is not OK, restore; if it is OK,
check the continuity of the Yellow/Red cable between the switch connector and VEHICLE
connector PIN 78: if not OK, restore the cable harness; if OK, replace the Marelli control
unit.
•
Indication on the diagnostics instrument always on RUN: disconnect the connector and, with
the switch set to STOP, check if there is continuity between the two cables of the switch: if
there is continuity, replace the switch; otherwise, it means that, with key set to ON, the
Yellow/Red cable (between switch and the PIN 78 of the control unit connector) is shorted
to positive: restore the cable harness.
Butterfly valve in exhaust
Function
It optimised the operation of the engine at low revolutions without compromising the efficiency of the
exhaust system at high revolutions.
Operation / Operating principle
The system consists of a throttle valve with a return spring placed on the exhaust pipe. Two cables
operated by an electric motor control the closing
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Electrical system
of the valve; the logic and the control of the motor
are provided by the VCU control unit (Caponord
1200 Travel Pack) or by the EVC control unit (Caponord 1200).
The motor is fitted with an integrated potentiometer for controlling the position. The exhaust butterfly valve is managed as follows:
•
With engine off: open by 75%;
•
With engine running: regardless of the
gear, at low revolutions and small throttle opening, it is completely closed; if
the revolutions or the throttle opening
exceed preset thresholds defined during calibration, it is completely open,
otherwise it is in an intermediate position. With bike stopped and in neutral
the valve stays closed, regardless of
rpm.
Level in electrical circuit diagram:
Exhaust valve control unit - Caponord 1200
VCU (Vehicle Control Unit) control unit - Caponord
1200 Travel Pack
Location:
•
On the vehicle: The motor is placed in
the front lower part of the engine.
•
The valve in the exhaust duct.
•
Connector: on the motor.
Connector:
1. Caponord 1200
2. Caponord 1200 Travel Pack
Pin out:
1. Supply from VCU
2. Exhaust valve potentiometer signal
3. Ground from VCU
4. Exhaust valve positive
5. Exhaust valve negative
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CAPONORD 1200
CAPONORD 1200
Electrical system
DIAGNOSTICS INSTRUMENT: ADJUSTMENTS
Exhaust valve - Zero position search
•
After having pressed the enter button for the zero position search, shut off the vehicle and
leave the keys in OFF, even in the event that the instruments indicate the opposite.
•
Slacken the exhaust throttle valve cable tension.
NOTE
IF IT IS NECESSARY TO REPLACE THE MOTOR, FROM POSITION ZERO LOOSEN THE CABLES
COMPLETELY TO REMOVE THEM, THEN, AFTER DISCONNECTING THE CONNECTOR, REMOVE THE MOTOR ITSELF.
•
Using the specific adjuster screw, tension the upper cable and leave around 1.8 mm (0.07
in) between the retainer and opening travel limit of the valve.
•
Using the specific adjuster screw, tension the lower cable until the tensioning is as close as
possible to the one of the upper cable (failing this the subsequent adjustment with the tool
will fail).
•
Tightening the lower cable will probably have caused the travel limit to shift: repeat the
procedure until the correct position is obtained.
•
Turn the key to ON.
CAUTION
THE ZERO SEARCH OF THE DISCHARGE VALVE MOTOR PROCEDURE ENTAILS RESETTING
THE EXISTING MECHANICAL STOPS. AN ERROR FOR STOP SEARCH NOT CARRIED OUT IS
THEN INDICATED, WHICH REMAINS UNTIL THE SELF-LEARNING OF THE DISCHARGE VALVE
PROCEDURE IS PERFORMED. DO NOT CARRY OUT THIS OPERATION WHEN USING A NONORIGINAL EXHAUST SYSTEM WHERE ANY CABLES CONSIDERED NOT NECESSARY HAVE
BEEN DISCONNECTED.
Exhaust valve - Self-acquisition
•
The search for the opening travel limit (open valve) and of the closing travel limit (closed
valve) is performed. During both normal operation and the self-cleaning cycle, the valve will
only move within this range and without reaching the mechanical end stops, to prevent strain
to the electric motor.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
CAPONORD 1200
Exhaust butterfly valve stop research P0191
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Electrical system
•
CAPONORD 1200
excessive time / search not performed, wrong stroke
Error cause
•
If time is excessive: failed memorisation of the travel limit positions of the valve. The EVC
control unit is not able to record the valve's travel limits: possible interruption of the circuit.
If research has not been carried out or wrong stroke: failed memorisation of the travel limit
positions of the valve: this occurs in case of first ignition of the motorbike or following a reset
of the control unit.
Troubleshooting
•
If time is excessive: check the connector on the component and the EVC connector. Disconnect the two connectors and check the continuity of the cable between the PIN 4 engine
- PIN C1 EVC and between PIN 5 engine - PIN A1 EVC. If all the above-mentioned tests
have a positive outcome, replace the motor.
•
If research has not been carried out or wrong stroke: carry out the self-learning procedure
using the diagnosis instrument.
Exhaust valve engine P0192
•
open circuit / shortcircuit to negative / shortcircuit to positive, shortcircuit between the two
cables
Error cause
•
If the circuit is open: an interruption of the circuit has been detected. If shorted to negative:
a null tension has been detected on PIN A1 or on PIN C1 EVC. If shorted to positive or short
circuit between both cables: an excessive tension has been detected on PIN A1 or on PIN
C1 EVC.
Troubleshooting
•
If the circuit is open: check the connector on the component and the EVC connector. Disconnect the two connectors and check the continuity of the cable between the PIN 4 engine
- PIN C1 EVC and between PIN 5 engine - PIN A1 EVC. If the cable harness is not damaged,
replace the component.
•
If shorted to negative: disconnect the connector of the engine and check its insulation from
ground of PIN 4 and 5: if the insulation is not present, restore the cabling, otherwise replace
the component.
•
If shorted to positive or short circuit between both cables: check the connector on the component and the EVC connector. Disconnect the connector of the component and check its
insulation from supply system of PIN 4 and 5; also ensure that the two PINs are insulated
between each other. If all the above-mentioned tests have a positive outcome, replace the
component.
Exhaust valve potentiometer P0193
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CAPONORD 1200
•
Electrical system
short circuit to positive / open circuit, short circuit to negative
Error cause
•
If shorted to positive: an excessive voltage has been detected at PIN A5 EVC. If the circuit
is open, shorted to negative: a null voltage has been detected at PIN A5 EVC.
Troubleshooting
•
If shorted to positive: disconnect the connector of the component and check its insulation
from supply system of PIN 2; if the insulation is not present, restore the cabling, otherwise
replace the component.
•
If the circuit is open, shorted to negative: check the connector on the component and the
EVC connector. Disconnect the two connectors and check the continuity of the cable between PIN 2 potentiometer and PIN A5 EVC and restore the cable harness. If the cable
harness is not damaged check the insulation from ground of PIN 2 of the component: if the
insulation is not present, restore the cabling, otherwise replace the component.
CAPONORD 1200 TRAVEL PACK
VCU ERRORS
Error control output exhaust valve Status Flag active C1613
Error cause
•
Overcurrent on exhaust valve: the VCU goes in the recovery mode.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the connector
of the component and check its insulation from ground and supply system of PIN 4 and 5;
also ensure that the two PINs are insulated between each other. If all the above-mentioned
tests have a positive outcome, replace the component.
Error control output exhaust valve shortcircuit C1614
Error cause
•
A shortcircuit on PIN L1 or on PIN L2 of the VCU connector has been detected.
Troubleshooting
•
Disconnect the connector of the valve and check its insulation from ground and supply system of PIN 4 and 5: if the insulation is not present, restore the cabling, otherwise replace
the component.
Error control output exhaust valve open circuit C1615
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between the PIN 4 valve - PIN L1 VCU and
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Electrical system
CAPONORD 1200
between PIN 5 valve - PIN L2 VCU. If the cable harness is not damaged, replace the component.
Error potentiometer exhaust valve shortcircuit C1707
Error cause
•
An excessive or null tension has been detected on PIN B4 VCU.
Troubleshooting
•
Disconnect the connector of the component and check its insulation from ground and supply
system of PIN 2: if the insulation is not present, restore the cabling, otherwise replace the
component.
Error potentiometer exhaust valve open circuit C1708
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between PIN 2 potentiometer and PIN B4 VCU
and restore the cable harness. If the cable harness is not damaged, replace the component.
Cruise Control Button
(IF APPLICABLE)
Function
Cruise Control is an electronic system that makes
it possible to set the desired speed and keep it
constant also in case of driving uphill or downhill,
without using the gas control.
The system is deactivated automatically when the
rider uses any of the brake/clutch controls or
Cruise Control button. It is very useful during long
motorway journeys, because it helps saving fuel
and makes riding less tiring.
Operation / Operating principle
To activate the function (switching from OFF to
ON), press and hold the Cruise Control button on
the handlebar for approximately 2 seconds: the
warning light on the instrument panel flashes to
indicate the ON status of the Cruise Control. The
set speed must be within the thresholds below:
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CAPONORD 1200
Electrical system
- 3rd gear: 50 - 100 km/h;
- 4th gear: 60 - 120 km/h;
- 5th gear: 65 - 160 km/h;
- 6th gear: 70 - 180 km/h.
Once the desired speed is reached, the system
may be activated (SET state) by pressing the
cruise control button briefly: the instrument panel
indicator lamp lights continuously to indicate that
the system is active. The throttle grip may now be
released, and the cruise control function will autonomously maintain the selected speed.
During the run at cruising speed, it is possible to
use the accelerator to increase the speed up to a
maximum of 30 km/h without causing the system
to deactivate. By using again the accelerator, the
Cruise Control will be deactivated (back to ON status, the warning light starts flashing again). The
speed control is deactivated (warning light starts
flashing) if:
- you accelerate until the cruising speed is exceeded by more than 30 km/h;
- the clutch is activated;
- one of the brake switches is activated;
- the vehicle speed goes out of the speed range
previously shown;
- the button ON/OFF Cruise is pressed briefly.
The system deactivates completely, the cruising
speed is reset, and the warning light goes off, if:
- the ON/OFF Cruise button is pressed for longer;
- the RUN/STOP switch is set to STOP;
- the key is set to OFF.
Level in electrical circuit diagram:
Pre-installations and accessories
Location:
•
On the vehicle: on the handlebar, right
hand side.
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Electrical system
•
CAPONORD 1200
Connector: under the dashboard cover.
Pin out:
M/N - Ground
Gr - Signal
(WHERE DIAGNOSIS IS AVAILABLE)
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
VCU ERRORS
Error Cruise Control ON/OFF button shortcircuit C1401
Error cause
•
A shortcircuit on PIN A4 or on PIN F4 of the VCU connector has been detected.
Troubleshooting
•
Check the insulation from ground and from supply system of the two cables of the Cruise
Control button (PIN A4 and PIN F4 VCU).
Error Cruise Control ON/OFF button open circuit C1402
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the continuity of the two cables between the connector of the Cruise Control button
and the VCU connector (PIN A4 and PIN F4).
Error Cruise Control ON/OFF button indeterminate C1403
Error cause
•
An interruption of the circuit or a shortcircuit on PIN A4 or on PIN F4 of the VCU connector
has been detected.
Troubleshooting
•
Check the correct operation of the contact of the button, the insulation from ground and from
the supply system of the two cables of the button (PIN A4 and PIN F4 VCU) and their continuity.
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CAPONORD 1200
Electrical system
Brake switch
(WHERE DIAGNOSIS IS AVAILABLE)
Function
Communicate the braking phase to the VCU control unit.
Operation / Operating principle
On the basis of the condition of the brake lever
(pulled/released) the switch communicates the
status to the VCU control unit.
Level in electrical circuit diagram:
VCU (Vehicle Control Unit) control unit
Location:
•
On the vehicle: on the brake.
•
Connector: on the component.
Connector:
1. Switch front brake
2. Switch rear brake
Pin out:
Gr/N - ground
M/Bi - Brake released signal
G/Ro - Pulled brake signal
Pin out:
Gr/N - ground
M/V - Brake released signal
G/Vi - Pulled brake signal
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
VCU ERRORS
Error switch front brake shortcircuit C1505
Error cause
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Electrical system
•
CAPONORD 1200
A shortcircuit on PIN C2 or on PIN D2 of the VCU connector has been detected.
Troubleshooting
•
Check the insulation from ground and from supply system of the two cables of the button
(PIN C2 and PIN D2 VCU).
Error switch front brake open circuit C1506
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the correct operation of the contacts of the button on its two positions and the continuity of the cables between the button connector and VCU connector (PIN C2 and PIN D2).
If the above-mentioned tests have a positive outcome, replace the button.
Error switch rear brake shortcircuit C1507
Error cause
•
A shortcircuit on PIN E2 or on PIN F2 of the VCU connector has been detected.
Troubleshooting
•
Check the insulation from ground and from supply system of the two cables of the button
(PIN E2 and PIN F2 VCU).
Error switch rear brake open circuit C1508
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the correct operation of the contacts of the button on its two positions and the continuity of the cables between the button connector and VCU connector (PIN E2 and PIN F2).
If the above-mentioned tests have a positive outcome, replace the button.
Temperature and pressure sensor
(IF APPLICABLE)
Function
Detect the temperature and the diving/extension
speed of the fork.
Operation / Operating principle
The system, by means of the VCU control unit
(Vehicle Control Unit), measures in real time the
energy transmitted to Caponord 1200 (damping of
the shock absorber) from the roughness of the
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CAPONORD 1200
Electrical system
road surface and it adapts the calibration of the
suspension in real time in order to maximise comfort and keep the correct setup of the motorbike.
Level in electrical circuit diagram:
VCU (Vehicle Control Unit) control unit
Location:
•
On the vehicle: in the upper part from
the active fork leg (LH) of the fork.
•
Connector: on the component.
Pin out:
1. Ground from VCU
2. Temperature signal output
3. Supply from VCU
4. Pressure signal output
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
VCU ERRORS
Error pressure sensor shortcircuit C1407
Error cause
•
An excessive tension or a null tension has been detected on PIN A3 VCU.
Troubleshooting
•
Disconnect the connector of the sensor and check its insulation from ground and supply
system of PIN 4: if the insulation is not present, restore the cabling, otherwise replace the
sensor.
Error pressure sensor open circuit C1408
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between PIN 4 sensor and PIN A3 VCU and
restore the cable harness. If the cable harness is not damaged, replace the sensor.
Error temperature sensor shortcircuit C1409
Error cause
•
An excessive or null tension has been detected on PIN D1 VCU.
Troubleshooting
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Electrical system
•
CAPONORD 1200
Disconnect the connector of the sensor and check its insulation from ground and supply
system of PIN 2: if the insulation is not present, restore the cabling, otherwise replace the
sensor.
Error temperature sensor open circuit C1410
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between PIN 2 sensor and PIN D1 VCU and
restore the cable harness. If the cable harness is not damaged, replace the sensor.
Rotary sensor
(IF APPLICABLE)
Function
Detect the position of the fork, that is the angle between the fork and the frame.
Operation / Operating principle
The system, by means of the VCU control unit
(Vehicle Control Unit), measures in real time the
energy transmitted to Caponord 1200 (damping of
the shock absorber) from the roughness of the
road surface and it adapts the calibration of the
suspension in real time in order to maximise comfort and keep the correct setup of the motorbike.
Level in electrical circuit diagram:
VCU (Vehicle Control Unit) control unit
Location:
•
On the vehicle: on the LH of the motorbike, fastened to the frame.
•
Connector: on the component.
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CAPONORD 1200
Electrical system
Pin out:
1. Supply from VCU
2. Output 1
3. 4. Supply from VCU
5. Output 2
6. 7. Ground from VCU
8. Ground from VCU
DIAGNOSTICS INSTRUMENT: ADJUSTMENTS
Rotary sensor reset
•
When the motorbike comes off the assembly line, a setup measurement (in mm) is set
(height from the ground) that the system recognises as reference position.
•
In case of replacement of the rotary potentiometer or of the VCU control unit, it is necessary
to reset the potentiometer by putting the motorbike on the central stand with the rear wheel
raised above the ground.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
VCU ERRORS
Error rotary sensor Output 1 shortcircuit or open circuit C1404
Error cause
•
If shortcircuit: an excessive or a null tension has been detected on PIN B3 VCU. If the circuit
is open: an interruption has been detected.
Troubleshooting
•
If shortcircuit: disconnect the connector of the rotary sensor and check its insulation from
ground and supply system of PIN 2: if the insulation is not present, restore the cabling,
otherwise replace the sensor.
•
If the circuit is open: Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between PIN 2 sensor and
PIN B3 VCU and restore the cable harness. If the cable harness is not damaged, replace
the sensor.
Error rotary sensor Output 2 shortcircuit or open circuit C1405
Error cause
•
If shortcircuit: an excessive or a null tension has been detected on PIN C3 VCU. If the circuit
is open: an interruption has been detected.
Troubleshooting
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•
CAPONORD 1200
If shortcircuit: disconnect the connector of the rotary sensor and check its insulation from
ground and supply system of PIN 5: if the insulation is not present, restore the cabling,
otherwise replace the sensor.
•
If the circuit is open: Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between PIN 5 sensor and
PIN C3 VCU and restore the cable harness. If the cable harness is not damaged, replace
the sensor.
Error rotary sensor failed consistency C1406
Error cause
•
The sum of the tensions detected on the two outputs of the sensor (PIN 2 and PIN 5) is
different from 5 V.
Troubleshooting
•
Replace the sensor.
Preload motor
(IF APPLICABLE)
Function
Check the preload of the rear single shock absorber in order to keep the optimal setup.
Operation / Operating principle
It is possible to adjust the preload of the spring of
the rear shock absorber using an electrical device,
on 5 positions, which are highlighted with specific
icons on the digital instrument panel: only rider,
only rider with luggage, rider with passenger, rider
with passenger and luggage, automatic. During
the automatic operation, the system will adjust automatically the preload level, on the basis of the
motorbike load, in order to maintain the optimal
setup. The system works in two phases:
1. With the vehicle at a standstill, the engine running, gear in idle, crutch closed, the system performs a first overall preload adjustment.
2. With the vehicle moving, the system constantly
monitors (cyclically every minute) various signals
coming from the vehicle and if some conditions are
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CAPONORD 1200
Electrical system
not met (speed and constant setup), it acts on the
preload until it reaches the ideal setup.
If the system has already reached the ideal position, it will make no further adjustments.
Level in electrical circuit diagram:
VCU (Vehicle Control Unit) control unit
Location:
•
On the vehicle: under the saddle.
•
Connector: on the component.
Pin out:
1. Negative preloaded motor
2. Positive preloaded motor
3. Ground from VCU
4. Encoder 2
5. Supply from VCU
6. Encoder 1
DIAGNOSTICS INSTRUMENT: ADJUSTMENTS
Travel limits preloaded motor
•
When you replace the hydraulic press of the rear shock absorber preload, do the self-acquisition of the end-of-travel positions.
•
Otherwise, if you replace the VCU control unit with a new from spare parts, the procedure
is automatically performed the first time the engine is switched ON.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
VCU ERRORS
Error preload motor Status Flag active C1619
Error cause
•
Overcurrent on the preload motor.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the connector
of the component and check its insulation from ground and supply system of PIN 1 and 2;
also ensure that the two PINs are insulated between each other. If all the above-mentioned
tests have a positive outcome, replace the motor.
Error blocked preload motor C1620
Error cause
•
The motor does not run not even with routing of current greater than ~ 4 A.
Troubleshooting
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Electrical system
•
CAPONORD 1200
Check the preload motor because it is likely to be mechanically locked, otherwise replace
the motor.
Error preload motor control open circuit C1621
Error cause
•
An interruption of the circuit has been detected.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between the PIN 1 motor - PIN M2 VCU and
between PIN 2 motor - PIN M1 VCU. If the cable harness is not damaged, replace the motor.
Error acquisition travel limits preload motor C1701
Error cause
•
Failed memorisation of the travel limit positions of the motor: this occurs in case of first
ignition of the motorbike or following a reset of the VCU.
Troubleshooting
•
Carry out the self-learning procedure using the diagnosis instrument.
Error timeout search travel limits preload motor C1702
Error cause
•
Failed memorisation of the travel limit positions of the preload motor. The error occurs if,
after 2 minutes from the start of the acquisition procedure, the VCU cannot record the motor's
travel limits: possible interruption of the circuit.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the two connectors and check the continuity of the cable between the PIN 4 motor - PIN B2 VCU and
between PIN 6 motor - PIN A2 VCU. If all the above-mentioned tests have a positive outcome, replace the motor.
Error connections preload motor C1703
Error cause
•
Inverted connections of the preload motor.
Troubleshooting
•
Check the connector on the component and the VCU connector. Disconnect the connector
of the component and ensure that PIN 1 and 2 are insulated between themselves. Disconnect also the VCU connector and check the continuity of the cable between PIN 1 motor PIN M2 VCU and between PIN 2 motor - PIN M1 VCU.
Error timeout during normal operation preload C1706
Error cause
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CAPONORD 1200
•
Electrical system
Failed preload motor movement after a 50 seconds timeout.
Troubleshooting
•
Check the preload motor because it is likely to be mechanically blocked. If the motor is free,
check the connector on the component and the VCU connector: disconnect the two connectors and check the continuity of the cable between the PIN 1 motor - PIN M2 VCU and
between PIN 2 motor - PIN M1 VCU. If all the above-mentioned tests have a positive outcome, replace the motor.
Connectors
EVC (EXHAUST VALVE CONTROL UNIT) (CAPONORD 1200)
EVC pin out key:
A1. Exhaust valve engine "B"
A2. CAN L line
A3. Reference voltage output
A4. Live supply
A5. Exhaust valve TPS signal
A6. A7. A8. B1:. Power from battery 1
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Electrical system
B2:. CAN H line
B3:. B4:. B5:. B6:. B7:. B8:. Power from battery 2
C1. Exhaust valve engine "A"
C2. Analogue ground connection
C3. C4. C5. Power ground connection 1
C6. Power ground connection 2
C7. Power ground connection 3
C8. VCU (VEHICLE CONTROL UNIT) (CAPONORD 1200 TRAVEL PACK)
VCU pin out key:
A1. Battery supply
A2. Pump engine encoder 1
A3. Front pressure sensor
A4. ON/OFF Cruise control
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CAPONORD 1200
CAPONORD 1200
Electrical system
B1:. Front solenoid valve positive
B2:. Pump engine encoder 2
B3:. Rotary sensor signal 1
B4:. Exhaust valve potentiometer signal
C1. Front solenoid valve negative
C2. Front stop switch
C3. Rotary sensor signal 2
C4. D1. Front temperature sensor
D2. Front stop switch
D3. D4. E1:. Rear solenoid valve positive
E2. Rear stop switch
E3. Live supply 1
E4. F1. Rear solenoid valve negative
F2. Rear stop switch
F3. 1 Sensors ground connection
F4. 2 Sensors ground connection
G1. 1 Sensors power supply
G2. G3. G4. Digital ground connection
H1. 2 Sensors power supply
H2. H3. Serial line
H4. J1. J2. CAN H line
J3. J4. K1. K2. CAN L line
K3. K4. -
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Electrical system
ECU
Engine pinout key:
Rear cylinder side spark plug coil control output PIN 1
Front cylinder side spark plug coil control output PIN 2
Rear throttle motor output (+) PIN 3
Analogue ground connection 2 PIN 4
Power ground connection 1 PIN 5
Analogue ground connection 1 PIN 6/17
Cylinder 2 injector control output PIN 8
Rear lambda sensor input (+) PIN 9
Front lambda sensor input (+) PIN 10
Track D hand grip input PIN 11
Water temp. sensor input PIN 12
Track B hand grip input PIN 13
Serial line K for diagnosis PIN 14
Rear throttle motor output (-) PIN 15
Power ground connection 2 PIN 16
Engine speed sensor input (-) PIN 20
Input for rear throttle potentiometer 2 signal PIN 21
Front lambda sensor input (-) PIN 22
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CAPONORD 1200
CAPONORD 1200
Electrical system
Track C hand grip input PIN 23
Front cylinder intake pressure sensor input PIN 24
Reference voltage output + 5 V: tracks A-C, front throttle and pressure sensor PIN 25/51
Reference voltage output + 5V: tracks B-D and rear throttle PIN 26
Rear cylinder central spark plug coil control output PIN 27
Front cylinder central spark plug coil control output PIN 28
Front throttle motor output (-) PIN 29
SAFETY relay control output PIN 31
Front lambda heating control output PIN 32
Engine speed sensor input (+) PIN 35
Input for rear throttle potentiometer 1 signal PIN 36
Air temperature sensor input PIN 37
Rear lambda sensor input (-) PIN 38
Track A hand grip input PIN 39
Key input PIN 40/42
Front throttle motor output (+) PIN 41
Rear lambda heating control output PIN 44
Rear cylinder 2 injector control output PIN 46
Quick shift switch PIN 47
Input for front throttle potentiometer 1 signal PIN 48
Rear cylinder intake pressure sensor input PIN 49
Input for front throttle potentiometer 2 signal PIN 50
Direct power supply to control unit PIN 52
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Electrical system
Vehicle pinout key:
Front cylinder 1 injector control output PIN 53
Clutch sensor input PIN 56
Analogue ground connection 2 PIN 57
"Start engine" switch input PIN 58
Electric fan relay control output PIN 61
Reference voltage output + 5V: tracks B-D and rear throttle PIN 63
Neutral input PIN 64
Fall sensor input PIN 65
CAN L line (high speed) PIN 66
Rear cylinder 1 injector control output PIN 67
Start-up control output PIN 69
Side stand input PIN 70
Gear input PIN 72
Auxiliary injection relay control output PIN 73
Clutch switch PIN 76
"engine stop" input PIN 78
Vehicle speed input PIN 79
CAN H line (high speed) PIN 80
ELE SYS - 184
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CAPONORD 1200
CAPONORD 1200
Electrical system
Dashboard
Grey-bodied instrument panel pinout key:
1. Live supply
ELE SYS - 185
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Electrical system
2. RH indicator switch
3. 4. High beam warning light
5. 6. Signal SELECT 3 (ENTER)
7. Signal SELECT 2 (DOWN)
8. Signal SELECT 1 (UP)
9. Fuel reserve warning light
10. Fuel level signal
11. Power from battery 1
12. LH indicator switch
13. 14. 15. Signal heated handgrips control
16. Indicators reset
17. Oil pressure warning light
18. 19. 20. Serial line
Black-bodied instrument panel pinout key:
21. Power from battery 2
ELE SYS - 186
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CAPONORD 1200
CAPONORD 1200
Electrical system
22. Power from battery 3
23. 24. Signal aerial "B"
25. Signal aerial "A"
26. CAN H line
27. CAN L line
28. ABS warning light
29. Sensors analogue ground connection 1
30. Sensors analogue ground connection 2
31. LH front indicator
32. RH front indicator
33. LH rear indicator
34. RH rear indicator
35. Light relay
36. LH handgrip control
37. RH handgrip control
38. Power ground connection 1
39. Power ground connection 2
40. Power ground connection 3
ABS Modulator
ELE SYS - 187
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Electrical system
CAPONORD 1200
ABS control unit pin out key:
1. Power ground connection 1
2. Power ground connection 2
3. Vehicle speed signal
4. Live supply
5. CAN H line
6. CAN L line
7. 8. ABS warning light
9. 10. 11. Rear ABS sensor positive
12. Rear ABS sensor negative
13. Front ABS sensor negative
14. Front ABS sensor positive
15. Power ground connection 3
16. Serial line
17. 18. Battery supply
Can line
Function
It allows communication between the Marelli injection ECU and the instrument panel.
Operation / operating principle
CAN SYSTEM ADVANTAGES
A CAN (controller Area network) line is a connection among the vehicle several electronic devices,
organised as a computer network (Internet). The CAN network has greatly simplified the electrical system layout and consequently, its complexity. With this communication line, needless duplication of
several sensors present on the motorbike has been obviated. The sensor signals are shared by the two
electronic 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 (FaultsConfination).
•
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 - 188
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CAPONORD 1200
•
Electrical system
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 "collision" (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, reception 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).
Level in electrical circuit diagram:
CAN line
Electrical specifications:
•
between PIN 66 and 80 of the control unit: approximately 130 Ohm
•
between PIN 26 and 27 of the instrument panel: approximately 120 Ohm
Pin out:
•
Line L: Orange cable between Marelli control unit PIN 66 and the black-bodied connector
PIN 27 of the instrument panel.
•
Line H: White/Black cable between Marelli control unit PIN 80 and the black-bodied connector PIN 26 of the instrument panel.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
CAN line "Mute Node" U1601
•
Mute Node.
Error cause
•
The injection ECU cannot send CAN signals; it receives signals from the instrument panel
and the ABS control unit (if any): the control unit may need replacing.
Troubleshooting
ELE SYS - 189
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Electrical system
•
CAPONORD 1200
Replace the Marelli control unit.
CAN line without signals U1602
•
Bus Off.
Error cause
•
No communication on CAN line (PIN 66 and/or PIN 80): problem on the whole network (for
example, battery cut-off or short circuited or shorted to ground).
Troubleshooting
•
Check the Marelli control unit VEHICLE connector: if not OK, restore; if OK, check the ground
insulation of the two CAN lines from PIN 66 and PIN 80 of the VEHICLE connector: if not
OK, restore cable harness; if OK, check the continuity of the two CAN lines from Marelli
control unit VEHICLE connector to the instrument panel connector: if not OK, restore the
cable harness; if OK, check that the two lines are not shorted to positive testing each of the
2 connectors (Marelli control unit and instrument panel connector) with 1 connector disconnected at a time and by setting the key to ON: If not OK, restore; if OK, replace the Marelli
control unit.
CAN line towards instrument panel U1701
•
no signal.
Error cause
•
No signal is received from the instrument panel.
Troubleshooting
•
Check the connector of the instrument panel: if not OK, restore; if OK, check the continuity
of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli
control unit: if not OK, restore the cable harness; if OK, replace the instrument panel.
DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS
CAN line towards instrument panel U1702 - Intermittent signal or communication error
Error cause
•
Probable bad contact in the CAN line.
Troubleshooting
•
Check the pins 66 and 80 and the Vehicle connector of the Marelli control unit. If not OK,
restore. If OK, check pins 26 and 27 and the instrument panel connector. If not OK, restore.
If OK, check overall operation of the Marelli control unit and instrument panel: replace the
affected component if you find any fault
CAN line towards ABS control unit U1712 - Intermittent signal or communication error
Error cause
•
Probable bad contact in the CAN line
Troubleshooting
ELE SYS - 190
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CAPONORD 1200
•
Electrical system
Check the pins 66 and 80 and the Vehicle connector of the Marelli control unit. If not OK,
restore. If OK, check pins 5 and 6 and the ABS control unit connector. If not OK, restore. If
OK, check overall operation of the Marelli control unit and ABS control unit: replace the
affected component if you find any fault.
DIAGNOSTICS INSTRUMENT: LOGIC ERRORS
CAN line towards ABS control unit U1711 - No signal/Configuration error
Error cause
•
If there is no signal, no signal is received from the ABS control unit. In case of configuration
error, some devices are present (e.g. ABS) that were not foreseen in the vehicle configuration stored in the control unit.
Troubleshooting
•
Open the diagnosis tool devices status page to check if the control unit setting is actually
consistent with the motorcycle setting. Example: if the bike has an ABS system the correct
state that should be found in the diagnostics instrument device status screen will be: Aprilia
Traction Control present. In the event of a bike with ABS system present and indication of
the diagnostics instrument of: Aprilia Traction Control not present, update the control unit.
VCU ERRORS
Failed CAN reception from motor ECU C1300
Error cause
•
The VCU does not receive the signal from the motor control unit.
Troubleshooting
•
Check the continuity of the cable between PIN K2 VCU - PIN 66 VEHICLE motor control
unit and between PIN J2 VCU - PIN 80 VEHICLE motor control unit. The error is automatically memorised when the communication between the two control units is restored. To exit
the diagnosis status and allow the VCU to resume operation in normal conditions, it is however necessary to switch from «OFF» to «ON».
Failed CAN reception from instrument panel C1301
Error cause
•
The VCU does not receive the signal from the instrument panel.
Troubleshooting
•
Check the continuity of the cable between the PIN K2 VCU - PIN 27 instrument panel (black
connector) and PIN J2 VCU - PIN 26 instrument panel (black connector). The error is automatically memorised when the communication between the two control units is restored.
To exit the diagnosis status and allow the VCU to resume operation in normal conditions, it
is however necessary to switch from «OFF» to «ON».
Failed CAN reception from ABS C1303
ELE SYS - 191
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Electrical system
CAPONORD 1200
Error cause
•
The VCU does not receive the signal from the ABS control unit.
Troubleshooting
•
Check the continuity of the cable between PIN K2 VCU - PIN 6 ABS control unit and between
PIN J2 VCU - PIN 5 ABS control unit. The error is automatically memorised when the communication between the two control units is restored. To exit the diagnosis status and allow
the VCU to resume operation in normal conditions, it is however necessary to switch from
«OFF» to «ON».
Error Frame Counter motor control unit C1306
Error cause
•
Failed synchronisation between VCU and motor control unit on data packets sent/received
(for each packet sent, the VCU increases by 1 its internal counter, and when it reaches 15
it resets itself).
Troubleshooting
•
Possible contact or interruption of the cable that must be checked: Check the continuity of
the cable between PIN K2 VCU - PIN 66 VEHICLE motor control unit and between PIN J2
VCU - PIN 80 VEHICLE motor control unit. Check also the insulation of the two cables
between themselves, from supply and ground.
Error Frame Counter ABS C1307
Error cause
•
Failed synchronisation between VCU and ABS control unit on data packets sent/received
(for each packet sent, the VCU increases by 1 its internal counter, and when it reaches 15
it resets itself).
Troubleshooting
•
Possible contact or interruption of the cable that must be checked: Check the continuity of
the cable between PIN K2 VCU - PIN 6 ABS control unit and between PIN J2 VCU - PIN 5
ABS control unit. Check also the insulation of the two cables between themselves, from
supply and ground.
Error Frame Counter instrument panel C1308
Error cause
•
Failed synchronisation between VCU and instrument panel on data packets sent/received
(for each packet sent, the VCU increases by 1 its internal counter, and when it reaches 15
it resets itself).
Troubleshooting
•
Possible contact or interruption of the cable that must be checked: Check the continuity of
the cable between the PIN K2 VCU - PIN 27 instrument panel (black connector) and PIN J2
ELE SYS - 192
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CAPONORD 1200
Electrical system
VCU - PIN 26 instrument panel (black connector). Check also the insulation of the two cables
between themselves, from supply and ground.
ELE SYS - 193
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INDEX OF TOPICS
ENGINE FROM VEHICLE
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ENG VE
CAPONORD 1200
Engine from vehicle
FRONT CHASSIS
pos.
1
2
3
4
5
Description
TCEI screw fastening shock absorber counterplate to RH frame bracket
Flanged nut fastening Trellis to frame
side panels
Flanged TE screw fastening chain
roller bracket to LH plate
Flanged TE screw fastening chain
roller to chain roller bracket
Screw fastening chain roller bracket
to LH plate
Type
M10x30
Quantity
1
Torque
50 Nm (36.88 lbf ft)
Notes
-
M12
4
80 Nm (59 lbf ft)
-
M8x35
1
25 Nm (18.44 lbf ft)
Loctite 243
M8x45
1
25 Nm (18.44 lbf ft)
Loctite 243
M8x20
1
25 Nm (18.44 lbf ft)
Loctite 243
ENG VE - 195
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CAPONORD 1200
Engine from vehicle
CENTRE FRAME
pos.
1
Description
Flanged nut fastening side panels to
engine
Type
M12
Quantity
3
Torque
80 Nm (59 lbf ft)
Notes
-
Torque
50 Nm (36.88 lbf ft)
Notes
Loctite 270
ENGINE
pos.
1
Description
Flanged TE screw fastening pinion
ENG VE - 196
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Type
M10x1.25
Quantity
1
CAPONORD 1200
pos.
Description
TCEI screw fastening Pin to gearbox
lever and Gearbox Lever to knurled
shaft
LH lock nut for ball joint
RH lock nut for ball joint
RH ball joint on gearbox control lever
Pinion protector fixing screw
LH ball joint on gearbox control lever
Fastener for positive cable on engine
TE screw fastening negative cable to
engine
2
3
4
5
6
7
-
Engine from vehicle
Type
M6x16
Quantity
2
Torque
12 Nm (8.85 lbf ft)
Notes
-
M6
M6
M6
M6x12
M6
M6x12
1
1
1
2
1
1
1
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
-
Vehicle preparation
•
Remove the battery.
•
Remove the fuel tank.
•
Remove the water radiator and oil radiator.
•
Remove the air filter box.
See also
Fuel tank
Removing the
radiator
Engine oil cooler
Air box
•
Disconnect the engine oil pressure
sensor connector.
•
Disconnect the starter motor power
supply cable.
•
Remove the ABS control unit and disconnect the control unit connector.
ENG VE - 197
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Engine from vehicle
•
Slide out bushing and O-ring from
gearbox secondary shaft.
•
Disengage the spring.
•
Unscrew and remove the three nuts
from the front exhaust manifold
ENG VE - 198
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CAPONORD 1200
CAPONORD 1200
•
Engine from vehicle
Disengage the spring joining the central exhaust manifold to the rear exhaust manifold.
•
Remove the front exhaust manifold,
moving the central exhaust manifold.
•
Unscrew and remove the catalytic converter mounting screw
•
Unscrew and remove the three nuts
from the rear exhaust manifold.
•
Remove the exhaust manifold.
ENG VE - 199
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Engine from vehicle
•
Unscrew and remove the three screws.
•
Remove the clutch control cylinder.
•
Lock the plunger using a clamp.
•
Undo and remove the two screws and
remove the pinion protection case.
•
Unscrew and remove the two clutch
support screws.
ENG VE - 200
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CAPONORD 1200
CAPONORD 1200
•
Engine from vehicle
Disconnect the side stand sensor connector.
•
Disconnect the gear in neutral sensor
connector.
•
Slacken the gearing chain tension.
•
Unscrew and remove the screw; collect the washer and the spacer.
•
Slide off the pinion from the chain and
remove.
ENG VE - 201
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Engine from vehicle
•
Loosen the screw and slide off the gear
transmission connecting rod keeping it
linked to the gear shift lever through the
rod.
Removing the engine from the vehicle
•
Carry out the operations described under Vehicle preparation.
•
Support the engine by means of belt
and hoist.
•
Working on the left side, unscrew and
remove the three nuts.
See also
Vehicle preparation
ENG VE - 202
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CAPONORD 1200
CAPONORD 1200
•
Engine from vehicle
Unscrew and remove the rear coil fixing screws.
•
Slide out the rear coils.
•
Slide off the rear top pin and collect the
washer.
•
Remove the two spacers. The thinner
spacer is on the right.
ENG VE - 203
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Engine from vehicle
•
Slide off the rear bottom pin and collect
the washer.
•
Remove the bottom spacer on the right
side.
•
Slide off the front pin and collect the
washer.
•
Remove the bottom spacer on the right
side.
ENG VE - 204
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CAPONORD 1200
CAPONORD 1200
•
Unscrew and remove the screw.
•
Release the ground points.
•
Unscrew and remove the two screws
Engine from vehicle
of the ECU.
•
Move the ECU aside but keep it connected to the wiring harness.
•
Loosen the two clamps.
ENG VE - 205
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Engine from vehicle
•
Lift the throttle body but keep it connected to the wiring harness.
•
Disconnect the engine temperature
sensor from the front cylinder.
•
Disconnect the alternator connectors.
ENG VE - 206
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CAPONORD 1200
CAPONORD 1200
•
Engine from vehicle
Disconnect the throttle body and fasten
it using an elastic band.
•
Unscrew and remove the screws, sliding out the front coils.
•
Lower the engine and take it out of the
chassis.
Installing the engine to the vehicle
•
Place the engine on a suitable lower stand.
•
Lift the engine.
•
Place the engine so that the rear attachments on the chassis are aligned.
ENG VE - 207
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Engine from vehicle
•
Working on the right side, insert the
three bolts with their washers.
•
Working on the right side, place the
spacers on the three bolts between the
engine block and the chassis.
CAUTION
THE SPACERS HAVE DIFFERENT SIZES. REFIT THEM IN
THE SAME WAY THEY WERE BEFORE BEING REMOVED.
•
Working from the left side, tighten the
three nuts.
•
Release the engine from the belt and
the hoist.
•
Refit the pinion and restore the gearing
chain clearance.
•
Reconnect the electric connections
and clamp the cable harnesses.
•
Carry out the vehicle preparation operations but in reverse order, restore the
correct level of all fluids and carry out
the adjustments that may be required.
ENG VE - 208
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CAPONORD 1200
CAPONORD 1200
Engine from vehicle
See also
Vehicle preparation
Adjusting
ENG VE - 209
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INDEX OF TOPICS
ENGINE
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ENG
CAPONORD 1200
•
Engine
Use the special plate to duly support
the engine during the servicing operations.
CAUTION
TAKE PARTICULAR CARE TO ENSURE THAT THE ENGINE AND ENGINE MOUNTING ARE STABLE AND ENSURE THAT THE ENGINE IS SECURELY FASTENED TO
THE MOUNTING PLATE.
Specific tooling
020710Y Engine plate
AP8140187 Engine support stand
Gearbox
Diagram
Key
1. Complete gear shaft and spring
2. Selector lock
3. Selector sprocket wheel
4. M5x16 Screw
5. Sprocket wheel pawl
6. Spring
7. Pin for spring
ENG - 211
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Engine
8. Complete transmission gear shaft
9. Forks
10.Fork shaft
11.Gear selector
12.Fork shaft
13.Fork
14.Gear selector drum
15.M8x1.25 threaded pin
16.Selector locking plate
17.Complete main gear shaft
18.TE flanged screw, M6x15
19.Complete index lever
20.Spring
21.Nut
22.Threaded pin
Gearbox shafts
Gearbox shafts diagram
key:
1. Main gear shaft Z=14
ENG - 212
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CAPONORD 1200
CAPONORD 1200
Engine
2. 2nd gear on primary Z=17
3. 3rd - 4th gear on secondary Z=20/22
4. 5th gear on primary Z=23
5. 6th gear on primary Z=24
6. Thrust washer
7. Circlip
8. Thrust washer
9. Thrust washer
10.Circlip
11.Transmission shaft
12.1st gear on primary Z=36
13.2nd gear on secondary Z=32
14.3rd gear on secondary Z=30
15.4th gear on secondary Z=28
16.5th gear on secondary Z=26
17.6th gear on secondary Z=25
18.Thrust washer
19.Circlip
20.Thrust washer
21.Thrust washer
22.Thrust washer
23.Floating bushing
24.Floating bushing
25.Floating bushing
Disassembling the gearbox
•
Open the crankcase halves.
•
Slide off the gearbox lubrication diffuser pipe.
•
Remove the two bolts of the forks.
ENG - 213
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CAPONORD 1200
Engine
See also
Splitting the
crankcase halves
•
Slide off the desmodromic drum control.
•
Remove the three gear selection forks.
CAUTION
THE MAIN SHAFT FORK IS SMALLER THAN THOSE OF
THE SECONDARY SHAFT.
ALL THE SECONDARY SHAFT FORKS ARE THE SAME
SIZE.
ENG - 214
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CAPONORD 1200
•
Carefully rotate the engine support.
•
Carefully slide off the whole gear unit.
•
Repeat the removal operations but in
Engine
reverse order.
ENG - 215
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CAPONORD 1200
Engine
Gear selector
GEAR SELECTOR
pos.
1
2
3
4
5
6
7
Description
Gear retainer pawl fastener screw
Selector plate fastener screw
Type
M6
M5
Quantity
1
3
Torque
12 Nm (8.85 lb ft)
5.50 Nm (4.06 lb ft)
Screw fastening Desmodromic selector drum / Selector sprocket
Gear sensor fastener screw
Selector pin fastener onto clutch side
crankcase half
Gear retainer pawl fastener pin
M8
1
20 Nm (14.75 lb ft)
M5
M10x1.5
2
1
5.50 Nm (4.06 lb ft)
16 Nm (11.80 lb ft)
-
1
-
1
11-13 Nm (8.11-9.59 lb
ft)
10-12 Nm (7.38-8.85 lb
ft)
Gear retainer pawl fastener flanged
nut
Removing the gear selector
Remove the clutch.
Remove the selector shaft.
See also
ENG - 216
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Notes
Loctite dry loc 2040
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
Loctite 270
Loctite 242
-
CAPONORD 1200
Engine
Disassembling the
clutch
Collect the washer.
NOTE
REPLACE THE WASHER ON EVERY SERVICING
•
Heat the screws of the gearbox selector mounting plate.
•
Unscrew and remove the three screws
fastening the gearbox selector mounting plate.
•
Remove the plate complete with selector
ENG - 217
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Engine
CAPONORD 1200
Checking the gear selector
Selector spring
In the position shown, ensure that the gap between
spring ends is +/- 0.4 mm (0.016 in), compared to
the same gap measured at the corresponding
teeth.
Pawl
Make sure that both pawl tips run free, without
jamming
Reassembling the gear selector
CAUTION
ON REASSEMBLY, ENSURE THAT THE REFERENCE
MARKS ON GEARBOX SHAFT AND SELECTOR SPROCKET ARE ALIGNED
CAUTION
QUALORA SIA NECESSARIO SOSTITUIRE GLI ELEMENTI DI FISSAGGIO DELLA LEVA INDEX,
ACCERTARSI DI ORDINARE I COMPONENTI CORRETTI. ESISTONO DUE VERSIONI NON INTERCAMBIABILI TRA LORO.
ENG - 218
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CAPONORD 1200
Engine
Gearbox Selector Shaft
Removal
•
Place the left hand crankcase in a
press and extract the roller cage with
the specific tool.
NOTE
REPEAT THE SAME OPERATION FOR THE RIGHT HAND
CRANKCASE HALF.
Specific tooling
020724Y Gear control rod roller cage punch
INSTALLATION
•
Place the left hand crankcase in a
press and install the roller cage with the
specific tool.
CAUTION
TO INSTALL THE ROLLER CAGE IN THE RIGHT HAND
CRANKCASE HALF, WORK WITH THE CYLINDER ON THE
SIDE OF THE 1 mm (*) STEP ON THE TOOL TURNED TOWARD THE ROLLER CAGE, WHEREAS TO INSTALL THE
CAGE IN THE LEFT HAND CRANKCASE HALF, USE THE
CYLINDER ON THE SIDE OF THE 2 mm (**) STEP ON THE
TOOL.
Specific tooling
020724Y Gear control rod roller cage punch
Starter motor
ENG - 219
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CAPONORD 1200
Engine
Removing the starter motor
•
Disconnect the starter motor power
supply cable.
•
Unscrew and remove the two screws
and remove the starter motor.
ENG - 220
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CAPONORD 1200
Engine
Generator side
IGNITION
pos.
1
2
3
3
4
5
6
7
8
9
Description
Spark plug
Freewheel Ring fastener screw
Type
M6
Quantity
4
6
Torque
11 Nm (8.11 lb ft)
14 Nm (10.33 lb ft)
Notes
3M SCOTCH GRIP
2353
-
Screw fixing rotor - Crankshaft - (12
mm - 0.47 in)
Screw fixing rotor - Crankshaft - (14
mm - 0.55 in)
Screw fastening Stator / Flywheel
Cover
Screw fastening pick-up / Flywheel
cover
Flywheel cover fastener screw
Screw fastening starter motor bracket to motor and crankcase
Crankshaft access cap
Retainer plate fastener screw
M12x1.25
1
130 Nm (95.88 lb ft)
M12x1.25
1
-
M6
3
190-200 Nm
(140.14-147.51 lb ft)
9 Nm (6.64 lb ft)
M5
2
3.50 Nm (2.58 lb ft)
Loctite 270
M6
M6
10
4
Loct. 242
M6
1
1
13 Nm (9.59 lb ft)
6.86-7.84 Nm
(5.06-5.78 lb ft)
4 Nm (2.95 lb ft)
8 Nm (5.90 lb ft)
-
3M SCOTCH GRIP
2353
ENG - 221
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CAPONORD 1200
Engine
Removing the flywheel cover
•
Remove the flywheel cover inspection
cap.
•
Unscrew and remove the ten screws.
•
Remove the flywheel cover using the
specific tool.
Specific tooling
020712Y Handle for Flywheel cover removal
•
Collect the gasket and the two dowel pins.
ENG - 222
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CAPONORD 1200
Engine
Removing the flywheel cover components
•
Remove the two pick-up fixing screws.
•
Remove the three stator fixing screws.
CAUTION
THE PICK-UP AND STATOR SHALL BE REMOVED SIMULTANEOUSLY AS THEY ARE PART OF THE SAME ELECTRICAL BRANCH.
Magneto flywheel removal
•
Remove the flywheel cover.
•
Unscrew and remove the screw and
remove the retention plate.
•
Heat the magneto flywheel with the
specific heater.
•
Lock the flywheel using the specific
tool and loosen the screw.
Specific tooling
020713Y Flywheel extractor
ENG - 223
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CAPONORD 1200
Engine
•
Screw the anticlockwise bolt of the
special tool on the external body.
•
Keeping the external body blocked and
gripping the key, screw the anticlockwise bolt so as to remove the flywheel
from the crankshaft.
Specific tooling
020713Y Flywheel extractor
•
Unscrew and remove the anticlockwise bolt of the special tool from the external body.
•
Unscrew the screw from the crankshaft.
Specific tooling
020713Y Flywheel extractor
•
Remove the flywheel together with the
freewheel.
•
Remove the start-up transmission
gear.
•
Check dimensions of the supports of
transmission gear on crankcase and
cover: the limit is 12.005 mm (0.4726
in) for both supports
•
In case of malfunction, the start-up
transmission gear cannot be overhauled. Therefore, the complete transmission gear should be replaced.
ENG - 224
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CAPONORD 1200
•
Engine
Collect the crankshaft woodruff key.
Freewheel removal
•
Remove the flywheel.
•
Remove the freewheel gear.
•
Heat the magneto flywheel with the
specific heater.
•
Unscrew and remove the six screws.
•
Remove the bearing retainer and bearing from the magneto flywheel.
See also
Magneto flywheel removal
ENG - 225
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CAPONORD 1200
Engine
Installing the flywheel
•
Insert the woodruff key on the crankshaft.
•
Insert the start-up transmission gear
after applying a layer of grease.
•
Insert the flywheel on the crankshaft.
•
Screw the screw together with the
washer but without tightening.
•
Place the appropriate tool for locking
the flywheel.
•
Locking the flywheel in position, using
the specific tool, tighten the screw on
the crankshaft.
WARNING!:
TO APPLY THE CORRECT TIGHTENING TORQUE, CHECK THE MEASUREMENT OF THE
SCREW THAT MAY BE M12 OR M14.
•
Remove the special tool.
ENG - 226
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CAPONORD 1200
Engine
Specific tooling
020713Y Flywheel extractor
•
Place the retention plate.
•
Tighten the screw.
Clutch side
WATER PUMP
pos.
1
2
3
4
5
6
7
Description
Clutch side cover fastener screw
Fastener screw for Pump Cover /
Clutch side cover
Screw fastening Pump Cover /
Clutch Cover / clutch side crankcase
half
Nut fastening water pump drive gear
sprocket
Water pump rotor
Screw fastening chain tensioner slider to water pump
Water pump support fixing screw
Type
M6
M6
Quantity
11
3
Torque
13 Nm (9.59 lbf ft)
13 Nm (9.59 lbf ft)
Notes
-
M6
2
13 Nm (9.59 lbf ft)
-
M6
1
12 Nm (8.85 lbf ft)
-
M6
1
1
-
M6
3
4.50 Nm (3.32 lbf ft)
8-10 Nm (5.90-7.38 lbf
ft)
12 Nm (8.85 lbf ft)
-
ENG - 227
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CAPONORD 1200
Engine
pos.
Description
Water pump support plug
8
•
Type
M6x10
Unscrew and remove the thirteen
screws in a cross pattern (the two
screws also retaining the water pump
cover are longer than the other eleven
ones).
•
Drain the engine oil.
•
Detach clamp retaining water pump
pipe.
•
Collect the gasket.
ENG - 228
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Quantity
1
Torque
6.5 Nm (4.79 lbf ft)
Notes
3M SCOTCH GRIP
2353
CAPONORD 1200
Engine
Removing the clutch cover
CLUTCH COVER
pos.
Description
Screw fastening Clutch Cover / intermediate Clutch side cover
Clutch fastener nut
Fastening oil filler plug on Clutch cover
Screw fastening fixing Plate / Clutch
control Mounting
Screw fastening clutch control
mounting on flywheel side crankcase
half
1
2
3
4
5
•
Type
M6
Quantity
6
Torque
13 Nm (9.59 lbf ft)
Notes
-
M24x1
-
1
1
170 Nm (125.38 lbf ft)
2 Nm (1.48 lbf ft)
Chamfer
-
M5
3
5.50 Nm (4.06 lbf ft)
Loctite 242
M6
2
8 Nm (5.90 lbf ft)
-
Unscrew and remove the six perimeter
fastener screws.
•
Remove the clutch cover.
•
Remove the gasket
ENG - 229
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CAPONORD 1200
Engine
Removing the clutch cover alone is only recommended when replacing the clutch plates. When
removing the entire clutch assembly, removing the
clutch side cover is recommended.
However, removing the entire clutch assembly is
possible by removing the clutch cover alone. In this
case, proceed as follows:
•
measure the projection of the clutch
housing from the crankcase before disassembling;
•
when refitting, check that the projection
has not changed before tightening the
clutch nut. If the projection has
changed, rotate the crankshaft to correctly engage the engine oil pump drive
gear on the clutch housing with the oil
pump driven gear.
Disassembling the clutch
CLUTCH
pos.
1
Description
Clutch spring fastener screw
ENG - 230
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Type
M6
Quantity
6
Torque
11 Nm (8.11 lbf ft)
Notes
-
CAPONORD 1200
•
Remove the clutch-side cover.
•
Unscrew and remove the six screws by
Engine
loosening them 1/4 of a turn at a time;
operate in stages and diagonally, and
retrieve the washers and the clutch
springs.
•
Remove the thrust plate, the plates and
belleville washer.
•
Remove the mushroom head clutch
control rod.
•
Working on the flywheel side, push the
clutch control rod so that it comes out
on the other side.
ENG - 231
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CAPONORD 1200
Engine
•
Remove the clutch control rod.
•
Fasten the clutch housing using the
specific tool.
Specific tooling
9100896 Clutch housing locking tool
•
Unscrew and remove the clutch hub
nut.
•
Remove the washer to be chamfered.
ENG - 232
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CAPONORD 1200
•
Remove the clutch hub.
•
Collect the washer between the clutch
Engine
hub and the housing.
•
Collect the clutch housing.
•
Collect the spacer and the needle
bearings.
ENG - 233
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CAPONORD 1200
Engine
•
Collect the special shim featuring two
thicknesses.
Checking the clutch plates
•
Lay the friction discs and steel discs on
a level surface and check them for
cracks and potential distortions.
Maximum distortion allowed: 0.20 mm (0.0079
in)
•
Measure the driving plate thickness at
four positions, replace them all if not
complying with specifications.
CAUTION
THE STEEL DISCS MUST SHOW NO SCORES OR TEMPERING COLOUR.
•
Measure the thickness of the clutch
plates at four positions, replace them if
not complying with specifications.
Minimum thickness of the eleven driving
plates (individually): 2.75 mm (0.11 in).
Minimum thickness of the ten driven plates (individually): 2,75 - 2,85 mm (0.108 ÷ 0.112 in).
MUSHROOM VALVE CHECK
•
Check if the valve slides freely, without
jamming.
•
Blow compressed air into the valve and
check that the lubricating oil passage
holes open.
ENG - 234
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CAPONORD 1200
Engine
Checking the clutch housing
•
Remove the clutch bell.
•
Remove the seeger ring.
•
Remove the oil pump control gear.
UPON REFITTING, THE GEAR COLLAR MUST ALWAYS
BE FACING THE CLUTCH BELL.
•
Remove the rotation locking pin from
the oil pump control gear.
Check the clutch bell for damage and wear that may result in clutch irregular operation. Deburr the teeth
or replace the bell.
MAIN DRIVEN GEAR CHECK
Check the main driven gear for damage and wear and, if necessary, replace the main transmission
driving gear and the clutch bell all together.
Make sure there is not excessive noise during operation; if necessary, replace the main transmission
driving gear and the clutch bell all together.
ENG - 235
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CAPONORD 1200
Engine
Checking the pusher plate
Check the thrust plate and the bearing for damage
and wear. If necessary, replace the parts.
Checking the clutch hub
Check the clutch hub for damage and wear that
may result in clutch irregular operation. If necessary, replace the bell.
Checking the springs
•
Check the springs for damage and, if
necessary, replace the them all together.
•
Measure the clutch spring length when
unloaded; if necessary, replace the
springs all together.
Clutch spring length when unloaded: 69.2 +/- 5
mm (2.72 +/- 0.2 in)
ENG - 236
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CAPONORD 1200
Engine
Assembling the clutch
•
Fit the shim washer.
•
Fit the needle bearing and the spacer.
•
Fit the clutch housing.
•
Make sure that the oil pump control
drive gear of the clutch housing engages correctly with the oil pump driven
gear.
•
Place the washer correctly between
the clutch housing and the hub.
ENG - 237
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CAPONORD 1200
Engine
•
Position the clutch hub.
•
Fit the clutch-side cover.
•
Check that the measurement has not
changed compared with the one carried out upon removal; tighten the
clutch nut afterwards. If the projection
has changed, rotate the crankshaft to
correctly engage the engine oil pump
drive gear on the clutch housing with
the oil pump driven gear.
•
Fit the washer and a new clutch hub
nut.
•
Tighten the clutch hub nut using the
specific tool.
Specific tooling
9100896 Clutch housing locking tool
•
Tighten the nut and proceed to caulk.
CAUTION
BE CAREFUL WITH THE CUPPED RING FITTING SIDE;
THE RING CONE SHALL BE DIRECTED TOWARDS THE
ENGINE.
ENG - 238
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CAPONORD 1200
•
Engine
Insert the cupped ring (1).
CAUTION
BE CAREFUL WITH THE CUPPED RING FITTING SIDE;
THE RING CONE SHALL BE DIRECTED TOWARDS THE
ENGINE.
•
Fit the lathed driven disc (2).
•
Fit the nitrided steel disc (3).
•
Fit the clutch plates. Start with the friction material discs and alternate with
steel discs.
•
Position all friction material discs with
their teeth aligned in one of the long
slots of the clutch housing.
•
Place the control rod.
•
Place the thrust plate.
CAUTION
ENSURE TO ALIGN THE ARROW ON THRUST PLATE
WITH THE MACHINED REFERENCE ON HUB.
•
Fit the clutch springs.
•
Fit the screw washers.
•
Tighten the six screws operating in
stages and diagonally.
•
On reassembly, replace the gasket under clutch cover.
ENG - 239
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CAPONORD 1200
Engine
Installing the clutch cover
CLUTCH-SIDE COVER OIL SEAL INSTALLATION
•
For controlled driving of the oil seal, take a 0.5 mm (0.020 in) thick washer, having an inside
diameter of 12 mm (0.47 in) and outside diameter of 20 mm (0.79 in).
•
Prepare the following tools:
Specific tooling
020376Y Adapter handle
020362Y 12 mm guide
020891Y Adapter 25 mm (0.98 in)
•
Assemble the tool using the washer for
controlled driving then, paying attention to the assembly direction, set the
oil seal in its seat, with marking facing
the operator.
•
Place the oil seal retainer with its flat
side resting against the oil seal.
•
Position the retainer ring.
ENG - 240
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CAPONORD 1200
Engine
Heads
HEAD COVER
pos.
1
2
3
-
Description
Special screw for fastening head
cover
Special screw for fastening head
cover
Oil breather fastener screw
Spark plugs
Type
M6
Quantity
8
Torque
9 Nm (6.64 lbf ft)
Notes
-
M6
2
9 Nm (6.64 lbf ft)
-
M6
-
2
2
5.50 Nm (4.06 lbf ft)
10-12 Nm (7.38-8.85 lbf
ft)
-
ENG - 241
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CAPONORD 1200
Engine
HEAD
pos.
Description
Water Temperature Sensor
Threaded plug for water sensor seat
Head stud bolt fastener nut - pretightening
Type
M12x1.5
M12x1.5
M10x1.25
Quantity
1
1
8
Torque
22 Nm (16.22 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
3
Head stud bolt fastener nut - tightening
M10x1.25
8
13 Nm (9.59 lbf ft) +
135° + 135°
4
Fastener for Head / Cylinder / Outer
side crankcase
Fastener for Head / Cylinder / Inner
side crankcase
Nut fastening Stud Bolts / Head
Nut fastening Stud Bolts / Head
Bleed union fastener screw
M6
2
12 Nm (8.85 lbf ft)
Notes
Loctite Drise AL 506
Lubricate the
threads before tightening
Lubricate the
threads before tightening
-
M6
4
12 Nm (8.85 lbf ft)
-
M6
M8
M5
4
2
4
12 Nm (8.85 lbf ft)
26 Nm (19.18 lbf ft)
5.50 Nm (4.06 lbf ft)
Loctite dry loc 2040
1
2
3
5
6
7
8
Head cover removal
The operations described below are valid for both
heads.
•
Unscrew and remove the five screws
and collect the rubber rings.
•
Remove the head cover.
ENG - 242
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CAPONORD 1200
Engine
HEAD COVER FITTING
•
Installation operations apply to both
head covers.
•
Ensure gasket is in good conditions. If
required, change it and use a gasket
having the same features.
•
Fit the cover.
•
Fit the rubber blocks in their seats.
•
Start and tighten the five screws to the
prescribed torque working diagonally
and in stages.
Front head
Removing camshafts
•
Remove the head cover.
•
Unscrew and remove the two screws.
•
Remove the coolant fitting.
•
Disconnect the coolant breather pipe.
See also
Head cover removal
ENG - 243
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CAPONORD 1200
Engine
•
Remove the cap from flywheel cover.
•
Turn the crankshaft until the front cylinder piston reaches the TDC (combustion).
•
Unscrew and remove the eight cam
tower screws working in a diagonal sequence and in stages.
•
Remove the cam tower.
•
Remove the camshafts with the gears.
Inspecting camshafts
CAMSHAFT TOOTHED WHEEL CHECK
•
Check that the camshaft gear works properly: if it is damaged or does not move smoothly,
replace the timing chain and the camshaft gear.
CAMSHAFT LOBES
•
Check that they do not show blue colouring, cracks or scratches; otherwise, replace the
camshaft, gear and chain.
•
Remove the exhaust camshaft.
•
Position the camshaft on a vice featuring protective shoes.
•
Unscrew and remove the screw and
collect the washer.
ENG - 244
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CAPONORD 1200
•
Engine
Remove the decompression device
housing.
•
Remove the counterweight and decompression device with the relevant
spring.
•
To refit, engage spring on decompression device and preload it by one turn.
•
Install the counterweight and engage
the preloaded device to it.
•
Tighten the counterweight fixing
screw.
Installing camshafts
The camshaft refitting procedure is described in the "Timing" section.
See also
Timing
ENG - 245
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CAPONORD 1200
Engine
Front head removal
•
Remove the clutch assembly.
•
Unscrew and remove the screw and
collect the washer and the internal
spring.
•
Unscrew and remove the two screws.
•
Remove the chain tensioner and collect the gasket.
•
Remove the camshafts with the gears.
See also
Removing camshafts
Disassembling the
clutch
•
Unscrew and remove the two chain
slider screws.
ENG - 246
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CAPONORD 1200
•
Engine
Unscrew and remove the chain intermediate gear pin.
•
Pay attention to avoid damaging the Oring.
•
Remove the primary gear following the
explanation given on crankcase opening.
•
Remove the mobile chain slider.
•
Remove the primary gear following the
explanation given on crankcase opening.
•
Remove the intermediate gear with
chain.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
See also
Splitting the
crankcase halves
•
Unscrew and remove the two external
head fixing screws.
ENG - 247
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CAPONORD 1200
Engine
•
Unscrew and remove the external
screw on the flywheel side.
•
Unscrew and remove the three bottom
head fixing nuts.
•
Unscrew and remove the four nuts,
proceeding in stages and in a diagonal
pattern.
ENG - 248
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CAPONORD 1200
•
Slide head off the stud bolts.
•
Remove the gasket between the head
Engine
and the cylinder.
•
Rimuovere il pattino catena fisso.
Front head check
•
Using a round scraper, clean off any carbon deposits in the combustion chamber.
CAUTION
DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK
PLUG THREADS OR THE VALVE SEATS.
•
Check that cylinder head is not damaged or scratched; replace it if necessary.
•
Check that there are no mineral deposits or rust in the cylinder head water cooled jacket;
remove them if necessary.
•
Check that the tappet covers and the camshaft toothed wheel cover are not damaged or
worn; replace the defective part(s).
Rear head
ENG - 249
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CAPONORD 1200
Engine
Removing camshafts
•
Remove the head cover.
•
Unscrew and remove the two screws.
•
Remove the coolant fitting.
See also
Head cover removal
•
Remove the cap from flywheel cover.
•
Rotate the crankshaft until the rear cylinder piston reaches the TDC.
•
Unscrew and remove the eight cam
tower screws working in a diagonal sequence and in stages.
•
Remove the cam tower.
ENG - 250
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CAPONORD 1200
•
Engine
Remove the camshafts with the gears.
Inspecting camshafts
CAMSHAFT TOOTHED WHEEL CHECK
•
Check that the camshaft gear works properly: if it is damaged or does not move smoothly,
replace the timing chain and the camshaft gear.
CAMSHAFT LOBES
•
Check that they do not show blue colouring, cracks or scratches; otherwise, replace the
camshaft, gear and chain.
•
Remove the exhaust camshaft.
•
Position the camshaft on a vice featuring protective shoes.
•
Unscrew and remove the screw and
collect the washer.
•
Remove the decompression device
housing.
ENG - 251
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CAPONORD 1200
Engine
•
Remove the counterweight and decompression device with the relevant
spring.
•
To refit, engage spring on decompression device and preload it by one turn.
•
Install the counterweight and engage
the preloaded device to it.
•
Tighten the counterweight fixing
screw.
Installing camshafts
The camshaft refitting procedure is described in the "Timing" section.
See also
Timing
Rear head removal
•
Remove the magneto flywheel.
•
Unscrew and remove the screw and
collect the washer and the internal
spring.
ENG - 252
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CAPONORD 1200
•
Unscrew and remove the two screws.
•
Remove the chain tensioner and col-
Engine
lect the gasket.
•
Remove the camshafts with the gears.
See also
Removing camshafts
Magneto flywheel removal
•
Unscrew and remove the two chain
slider screws.
•
Unscrew and remove the chain intermediate gear pin.
•
Pay attention to avoid damaging the Oring.
ENG - 253
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CAPONORD 1200
Engine
•
Remove the primary gear following the
explanation given on crankcase opening.
•
Remove the intermediate gear with
chain.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
•
Remove the mobile chain slider.
See also
Splitting the
crankcase halves
•
Unscrew and remove the two external
head fixing screws.
•
Unscrew and remove the external
screw on the flywheel side.
ENG - 254
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CAPONORD 1200
•
Engine
Unscrew and remove the three bottom
head fixing nuts.
•
Unscrew and remove the four nuts,
proceeding in stages and in a diagonal
pattern.
•
Slide head off the stud bolts.
•
Remove the gasket between the head
and the cylinder.
ENG - 255
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CAPONORD 1200
Engine
•
Remove the fixed chain slider.
NOTE
ON REASSEMBLY, PERFECTLY CLEAN THE MATING
SURFACE OF THE SPECIAL SCREW RETAINING THE
IDLE GEAR AND THE THREE TIMING GEARS AND REPLACE THE ALUMINIUM WASHER.
Rear head check
•
Using a round scraper, clean off any carbon deposits in the combustion chamber.
CAUTION
DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK
PLUG THREADS OR THE VALVE SEATS.
•
Check that cylinder head is not damaged or scratched; replace it if necessary.
•
Check that there are no mineral deposits or rust in the cylinder head water cooled jacket;
remove them if necessary.
•
Check that the tappet covers and the camshaft toothed wheel cover are not damaged or
worn; replace the defective part(s).
Valves
Valve removal
•
Remove the head.
•
Place the head on supporting surface.
•
Number the valves and their bucket tappets in order to position them correctly upon refitting.
•
Remove the bucket tappets and the
adjustment shims using a magnet.
ENG - 256
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CAPONORD 1200
•
Engine
Compress the valve springs with the
specific wrench and with the spring
compressing tool.
Specific tooling
020382Y Tool for removing valve cotters fitted
with part 012
020896Y Bushing for valve removal
•
Remove the cotters using a magnet.
•
Release the valve springs.
•
Remove the valve spring fittings and
the springs.
ENG - 257
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CAPONORD 1200
Engine
•
Remove the valves.
Valve check
CAUTION
REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST
BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL.
VALVE STEM DEVIATION
Lift up the valve approx. 10 mm (0.39 in) from its
seat.
Measure the valve stem deviation in two perpendicular directions and position the dial gauge as
shown in the figure.
If the measured deviation exceeds the specified
limit, determine if the valve or the guide must be
replaced.
Characteristic
Valve stem distortion
0.25 mm (0.0098 in)
If the valve stem, when measured with a micrometer, is worn to its limit and the clearance exceeds the specified limit, replace the valve.
If the valve stem lies within the specific limit, replace the valve guide.
Recheck the clearance after replacing the valve or
the guide.
Characteristic
Intake valve stem diameter
5.987 - 5.973 mm (0.2357 - 0.2352 in)
Exhaust valve stem diameter
5.975 - 5.960 mm (0.2352 - 0.2346 in)
ENG - 258
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CAPONORD 1200
Engine
Support the valve with two "V" blocks as shown
and check the run-out with a dial gauge.
If the run-out exceeds the specified limit, replace
the valve.
Characteristic
Valve stem run-out
0.05 mm (0.0020 in)
Position the dial gauge at a right angle to the valve
head face and measure the eccentricity.
If the eccentricity exceeds the specified limit, replace the valve.
Characteristic
Valve head eccentricity
0.03 mm (0.0012 in)
Spring check
Carry out a measurement and a visual inspection
of the valve springs for damage, distortion or loss
of tension.
Measure the spring length at release position.
Valve springs: minimum wear limit (1) 43.8 mm
(1.724 in).
minimum wear limit (2) 36.7 mm (1.445 in).
ENG - 259
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CAPONORD 1200
Engine
Timing
TIMING SYSTEM
pos.
Description
Camshaft gear fastener nut
Timing drive gear fastener screw
Type
M15x1
M24x1.5
Quantity
4
2
Torque
90 Nm (66.38 lbf ft)
40 Nm (29.50 lbf ft)
Special screw for fastening mobile /
fixed shoes
Cam tower / head fastener screws
M8
4
19 Nm (14.01 lbf ft)
M6
16
12 Nm (8.85 lbf ft)
1
2
3
4
ENG - 260
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Notes
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
-
CAPONORD 1200
pos.
Engine
Type
torx M5
Quantity
8
Torque
8.5 Nm (6.26 lbf ft)
6
Description
Camshaft retainer plate fastener
screw
Decompression device fixing screw
torx M8
2
28.5 Nm (21.02 lbf ft)
7
Fastener screw
M5
2
5.50 Nm (4.06 lbf ft)
5
Notes
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
3M SCOTCH GRIP
2353
Installing the chain tensioner
Refit the removed timing system chain tensioner on the cylinder - head:
•
Fit the timing chain on the crankshaft and on the intermediate gear.
•
Remove the screw and collect the washer and the spring.
•
Fit the chain tensioner body on the cylinder and insert a new paper gasket.
•
Tighten the two screws to the prescribed torque.
•
Insert the spring and tighten the screw together with the washer.
Cam timing
Timing
•
Remove the flywheel.
•
Install the timing chains on the intermediate gears.
•
Install special tool flange on flywheel
side crankcase and fasten it using the
two screws supplied.
Specific tooling
020720Y Timing tool
ENG - 261
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CAPONORD 1200
Engine
•
Fit tool on crankshaft matching the flywheel key.
•
Tighten the screw on the crankshaft.
•
Turn crankshaft until the tool "V" is
positioned at the front cylinder.
•
Tighten the two pins of the tool.
•
Screw without tighten the nuts on camshaft gears.
•
Install the camshafts on front head,
aligning them using the suitable pins.
Specific tooling
020719Y Timing pin
•
Fit cam tower and tighten the eight
screws working in a diagonal sequence and in stages.
•
Pre-tighten the gear nut on the camshaft.
REFIT THE NUT WITH THE MACHINED SURFACE FACING THE GEAR (THE MATERIAL ACRONYM SHOULD BE VISIBLE).
ENG - 262
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CAPONORD 1200
Engine
Locking torques (N*m)
Nut fixing camshaft gears (pre-tightening) - M15x1 (4) 30 Nm (22.13 lb ft)
•
Remove the two pins.
•
Unscrew and remove the eight fixing
screws and remove the cam tower.
•
Remove both camshafts, lock them on
a vice with aluminium jaws, then tighten the gear retaining nut to the prescribed torque.
DO NOT TIGHTEN THE CAMSHAFT GEAR NUT TO THE
ULTIMATE TIGHTENING TORQUE WITH THE SHAFT
MOUNTED ON THE HEAD.
THIS OPERATION WOULD IRRETRIEVABLY DAMAGE
THE HEAD.
Locking torques (N*m)
Nut fixing camshaft gears - M15x1 (4) 90 Nm
(66.38 lb ft)
•
Repeat the fastening operations of the camshafts to the front head.
•
Release the crankshaft from the specific special tool.
•
Rotate the crankshaft in the riding direction until the rear cylinder piston reaches the top
dead centre (270°).
•
Lock the crankshaft with the specific special tool.
•
Carry out the timing operations performed on the front cylinder; please remember that rear
camshaft gear nuts are anticlockwise and cam position is divergent.
Specific tooling
ENG - 263
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CAPONORD 1200
Engine
020720Y Timing tool
Cylinder-piston assembly
CYLINDER
pos.
1
2
Description
Chain tensioner fastener screw
Cylinder plate fastener screw
Type
M6
M6
Quantity
4
4
3
Chain tensioner adjustment screw
M6
2
Removing the cylinder
•
Remove the head
•
Slide cylinder out of stud bolts collecting the base gasket.
ENG - 264
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Torque
13 Nm (9.59 lb ft)
7.84-9.81 Nm
(5.78-7.23 lb ft)
5.50 Nm (4.06 lb ft)
Notes
-
CAPONORD 1200
Engine
See also
Front head removal
Rear head removal
Disassembling the piston
•
Remove the cylinder.
•
Take out the pin locking ring.
•
Lock the connecting rod using the specific tool.
•
Slide out the pin, using the assembly
tool pin, and remove the piston.
Specific tooling
020716Y Connecting rod locking
020894Y Pin snap ring fitting tool
ENG - 265
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CAPONORD 1200
Engine
•
Lock the connecting rod using circlips.
FOR SAFETY REASONS COVER THE CRANKCASE WITH
A CLEAN CLOTH SO THAT THE PARTS DO NOT FALL INTO THE CRANKCASE.
See also
Removing the
cylinder head
Removing the
cylinder
•
Remove the top ring, the intermediate
ring and the three oil scraper rings.
ENG - 266
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CAPONORD 1200
Engine
Checking the cylinder
•
All seal surfaces must be clean and flat.
•
Make sure all threads are in proper conditions.
•
Check cylinder sliding surface for signs of friction and scratches. Also check the seal surfaces for damages.
CAUTION
IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT, REPLACE THE CYLINDER AND
THE PISTON.
•
Clean off lime scales on the cylinder
cooling slots.
•
Measure the cylinder bore at a distance of 10 - 43 - 90 mm (0.39 - 1.69 3.54 in) from the head coupling surface; the highest value should be
considered to estimate wear limits.
Cylinder bore (C): 106.000 mm (4.1732 in) C=
D1 or D2 max
Replace the cylinder, the piston and the piston ring
all together if not complying with specifications.
Checking the piston
•
Measure the piston skirt diameter "P"
with a micrometer (a=10 mm (0.39 in)
from the piston lower border).
•
Calculate the clearance between piston and cylinder as follows:
Piston diameter (P): 106.000 mm (4.1732 in)
Piston - cylinder clearance C = C - P
Piston - cylinder clearance: 0.085 mm (0.00335
in)
•
Replace the cylinder, the piston and
the piston ring all together if not complying with specifications.
ENG - 267
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CAPONORD 1200
Engine
PISTON RINGS
•
Clean off any carbon deposits from the
grooves in the piston rings and from the
rings themselves.
•
Measure the piston ring side clearance
and replace the piston and the piston
rings all together if not complying with
specifications.
Piston ring side clearance:
Top ring (1st slot): with new engine 0.030 0.065 mm (0.0012 - 0.0026 in). Wear limit: 0.075
mm (0.0029 in)
Intermediate ring (2nd slot): with new engine
0.020 - 0.055 mm (0.0008 - 0.0022 in). Wear limit
0.065 mm (0.0026 in)
Oil scraper ring (3rd slot): with new engine
0.010 - 0.045 mm (0.0004 - 0.0018 in). Wear limit
0.055 mm (0.0022 in)
•
Fit the piston ring to the cylinder.
•
Level the installed piston ring with the
piston crown.
•
Measure piston ring port and replace it
if not complying with specifications.
Piston ring end gap:
Top ring: with new engine 0.25 - 0.45 mm
(0.0079 - 0.0177 in). Wear limit: 0.65 mm (0.026
in)
Intermediate ring: with new engine 0.35 - 0.60
mm (0.0138 - 0.0236 in). Wear limit: 0.80 mm
(0.032 in)
Oil scraper ring: with new engine 0.20 - 0.70
mm (0.0079 - 0.0276 in). Wear limit: 0.90 mm
(0.035 in)
PIN
•
Clean off combustion residues from the piston crown and from the area above the top ring.
ENG - 268
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CAPONORD 1200
•
Engine
Check for cracks on the piston and for compression on the piston sliding surface (seizing);
Replace the piston if required.
CAUTION
SMALL STRIATIONS ON THE PISTON LINER ARE ADMISSIBLE.
•
Measure the pin outside diameter (a)
and if not complying with specifications, replace the pin.
Pin outside diameter: 22.00 - 21.97 mm (0.8661
- 0.8650 in) Limit: 21.96 mm (0.8646 in)
•
Measure the pin housing diameter (b)
and replace the piston if not complying
with specifications.
Pin housing diameter (b): 22.010 - 22.015 mm
(0.8665 - 0.8667 in)
•
Calculate the clearance between pin
and pin hole and, if not complying with
specifications, replace both pin and
piston.
Pin - piston clearance: C = b - a
0.010 - 0.045 mm (0.0004 - 0.0018 in)
Limit: 0.060 mm (0.0024 in)
CYLINDER-PISTON COUPLING
Name
Cylinder-piston clearance A - A
Cylinder-piston clearance B - B
Cylinder-piston clearance C - C
Cylinder-piston clearance D - D
Initials
Type A - A
Type B - B
Type C -C
Type D - D
Cylinder
105.990 - 105.997 mm
(4.1728 - 4.1731 in)
105.997 - 106.004 mm
(4.1731 - 4.1734 in)
106.004 - 106.011 mm
(4.1734 - 4.1736 in)
106.011 - 106.018 mm
(4.1736 - 4.1739 in)
Piston
105.928 - 105.935 mm
(4.1704 - 4.1707 in)
105.935 - 105.942 mm
(4.1707 - 4.1709 in)
105.942 - 105.949 mm
(4.1709 - 4.1712 in)
105.949 - 105.956 mm
(4.1712 - 4.1715 in)
Play on fitting
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
0.055 - 0.069 mm
(0.0022 - 0.0027 in)
NOTE
MAXIMUM CLEARANCE AT WEAR LIMIT 0.085 mm (0.0033 in)
Installing the cylinder
•
Fit the stud bolts, if previously removed.
CAUTION
THE STUD BOLTS SHOULD BE FITTED SO THAT THEY PROTRUDE.
ENG - 269
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CAPONORD 1200
Engine
DISTRIBUTE Loctite 270 (high-strength) ON THE THREAD AND SCREW THE STUD BOLT ON
THE CRANKCASE UNTIL THEY PROTRUDE BY 137 mm (5.39 in), THEN MAKE SURE THE Loctite
HAS SET.
•
The piston rings are different and must
be installed with the marking at the top.
•
Fit the lower oil scraper ring on the piston with the gap turned towards the
exhaust side.
•
Install the remaining piston rings on the
piston, offsetting the gaps in the rings
by 90° relative to each other.
•
Fit a new retainer ring on the piston.
•
Insert piston in the cylinder using the
tool.
Specific tooling
020895Y Piston installation ring
•
Install the second pin retainer ring on
the tool guide, as shown in the figure.
•
Insert tool shaft and push retainer ring
inside the guide until reaching the
height shown in the figure.
•
Fit a new base gasket.
•
Fit the piston-cylinder assembly previously assembled on the stud bolts,
aligning pin with connecting rod big
end.
•
Fit the tool in the pin and push shaft to
position the retainer ring in its seat.
Specific tooling
020894Y Pin snap ring fitting tool
ENG - 270
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CAPONORD 1200
Engine
See also
Selecting the base gasket
•
Remove the tool and fully push cylinder
on the stud bolts.
Selecting the base gasket
•
Temporarily, fit the piston to the cylinder, without base or head gasket.
ENG - 271
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CAPONORD 1200
Engine
•
Fit a dial gauge on the specific tool.
•
Set the dial gauge to zero on a reference surface with a medium preload,
e.g. 5 mm (0.2 in). Keeping the zero
setting, fit the tool on the cylinder and
lock it with two nuts (10 Nm - 7.38 lb ft)
as shown in the figure.
Specific tooling
020714Y Dial gauge mounting
•
Rotate the crankshaft up to the TDC
(the reversal point of the dial gauge rotation).
•
Lock the crankshaft at TDC using the
specific tool.
•
Calculate the difference between the
two measurements: using the chart below, identify the thickness of the cylinder base gasket to be used upon
refitting. By correctly identifying the cylinder base gasket thickness, an adequate compression ratio can be maintained
•
Remove the specific tool and the cylinder.
Specific tooling
020720Y Timing tool
BASE GASKET
Specification
Measured protrusion -0.10 / + 0.0 mm (- 0.0039 / 0.0000 in)
Measured protrusion 0.05 / 0.10 mm (0.0020 / 0.0039 in)
Measured protrusion 0.15 / 0.30 mm (0.0059 / 0.0118 in)
See also
Installing the
cylinder
ENG - 272
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Desc./Quantity
Gasket 0.4 mm (0.0157 in)
Gasket 0.5 mm (0.0197 in)
Gasket 0.6 mm (0.0236 in)
CAPONORD 1200
Engine
Crankcase - crankshaft
CRANKCASE 1
pos.
1
2
3
4
Description
Bearing retainer fastener screw
Piston oil jet fastener screw
Tapered plug for crankshaft main
bearing lubrication
Calibrated Brass dowel fixed to complete crankcase
Type
M6
M5
M8x1
Quantity
3
2
4
Torque
10 Nm (7.38 lbf ft)
5.50 Nm (4.06 lbf ft)
15 Nm (11.06 lbf ft)
Notes
Loctite 270
Loctite 242
-
M8
2
5.50 Nm (4.06 lbf ft)
-
ENG - 273
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CAPONORD 1200
Engine
CRANKCASE 2
pos.
Description
Engine speed sensor fixing screw
Screw fastening flywheel side /
clutch side crankcase halves
Screw fastening flywheel side /
clutch side crankcase halves
Special calibrated screw for gearbox
lubrication
1
2
3
4
Type
M6
M6
Quantity
1
8
Torque
13 Nm (9.59 lbf ft)
13 Nm (9.59 lbf ft)
Notes
Loctite 243
-
M8
9
29 Nm (21.39 lbf ft)
-
-
1
18 Nm (13.28 lbf ft)
-
Splitting the crankcase halves
•
Fit the special tool, tightly fastening the
three screws securing the tool onto the
crankcase.
•
Unscrew and remove the crankshaft
fastener nut anticlockwise using the
special tool, retrieving the washer and
the water pump drive gear.
Specific tooling
020850Y Primary gear lock
•
Remove the clutch.
•
Remove the complete flywheel.
•
Remove the selector.
•
Remove the starter motor.
ENG - 274
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CAPONORD 1200
•
Remove the oil filter.
•
Using a heating gun, heat the area
Engine
shown in the figure then remove the
crankshaft gear with a commercially
available extractor.
See also
Disassembling the
clutch
Magneto flywheel removal
•
Remove the head-cylinder assemblies.
•
Remove the gear sensor loosening the
two fixing screws.
ENG - 275
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CAPONORD 1200
Engine
•
Collect the O-ring.
See also
Removing the
cylinder
•
Unscrew and remove the selector
drum fastener screw.
•
Unscrew and remove the nine flywheel
side M8 screws.
•
Unscrew and remove the eleven flywheel side M6 screws.
•
Turn the engine into horizontal position.
ENG - 276
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CAPONORD 1200
•
Engine
Unscrew and remove the two engine
support nuts.
•
Open the crankcase halves.
Removing the crankshaft
CRANKSHAFT
pos.
1
Description
Crankshaft primary gear fastener nut
Type
M24x1.5
Quantity
1
Torque
300 Nm (221.27 lbf ft)
Notes
Anticlockwise nut
ENG - 277
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CAPONORD 1200
Engine
pos.
Description
Connecting rod screw
2
•
Open the crankcase halves.
•
Remove the crankshaft.
Type
M10
Quantity
4
Torque
Notes
15 + 30 Nm (11.06 +
Lubricate the
22.13 lbf ft) + 50° ± 2°, threads before tightfinal control torque 65 ening
78 Nm (47.94 - 57.53 lbf
ft)
See also
Splitting the
crankcase halves
Inspecting the crankcase halves
BEARINGS AND OIL SEAL CHECK
Thoroughly clean the two sections of the crankcase, the ball bearings, the threads of the crankcase
fixing screws and the bearing seats with a non-aggressive solvent. Clean the seal surfaces and check
that they are not damaged.
CAUTION
TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE.
Check that both crankcase halves are not cracked or damaged.
Check that all threads are in proper conditions.
Check that all oil seals remaining in their position are not worn or damaged.
Check all ball bearings for clearance, smoothness and potential distortions.
CAUTION
LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING.
If the internal ring does not rotate smoothly and silently or if there is some noise while it turns, it means
that the bearing is faulty and must be replaced.
OIL FILTER AND OIL DELIVERY PIPE CHECK
Check the oil filter for damage. If necessary, replace the part.
Clean the oil net with petrol and inspect the net links for potential damage.
ENG - 278
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CAPONORD 1200
Engine
CHECK THE ENGINE OIL FILTER O-RING.
LUBRICATION CHECK
•
Working on both crankcase halves, remove and thoroughly clean the nozzle
that lubricates the piston crown.
REPLACE THE SPRAY NOZZLE O-RING IF NECESSARY.
•
Replace the O-Rings on oil ducts.
Before refitting
UPON REFITTING THE CRANKSHAFT, GREASE THE SHAFT BUSHING-CONNECTING ROD
COUPLING.
ENG - 279
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CAPONORD 1200
Engine
Inspecting the crankshaft components
Crankshaft axial clearance check
•
The shaft axial clearance on the crankcase should be checked with a dial
gauge mounted on the specific dial
gauge support.
•
The clearance should be between 0.1
- 0.26 mm (0.0039 - 0.0102 in).
•
If the clearance is beyond tolerance,
check the reference surfaces.
Specific tooling
020714Y Dial gauge mounting
Removal
•
Mark the position of the original semi-bushings on the crankcase.
•
To reduce the installation force necessary, score an incision approximately
0.5 mm (0.02 in) deep (without cutting
into the steel shell) in each semi-bushing in the area indicated in the figure.
•
Remove the bushings with the crankcase cold, using a press and the specific tool and pushing inward from the
outside of the crankcase.
Specific tooling
020726Y Extractor for bushings
ENG - 280
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CAPONORD 1200
Engine
Installing
•
The orientation of the semi-bushings
must match the specifications indicated in the drawing as closely as possible.
NOTE
WHEN REPLACING THE SEMI-BUSHINGS ALONE, THE
NEW COMPONENTS MUST BE THE SAME COLOUR AS
THE REMOVED COMPONENTS. IF THE COLOUR OF THE
OLD COMPONENTS IS NO LONGER VISIBLE, USE THE
TABLE TO IDENTIFY THE CORRECT COMPONENTS, REFERRING TO THE CRANKCASE AND CRANKSHAFT
CLASSES.
Key:
* Semi-bushing joint line.
•
Fit the new bushings with the crankcase cold, using a press and the specific tool and pushing outward from the
inside of the crankcase, until the punch
comes into contact with the crankcase
surface.
Specific tooling
020727Y Punch for bushings
Assembling the connecting rod
CAUTION
TO FIT THE CONNECTING RODS, CHECK THE COUPLING TYPES INDICATED IN THE "CRANKCASE- CRANKSHAFT CONNECTING ROD" SECTION, IN THE "CHARACTERISTICS" CHAPTER
OF THE WORKSHOP MANUAL.
Installing the crankshaft
•
Place the left side crankcase half on
the engine support adequately.
•
Place the crankshaft on the seat of the
crankcase half with caution.
ENG - 281
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CAPONORD 1200
Engine
Refitting the crankcase halves
•
Fit the strum box, if previously removed.
•
Tighten the two strum box fixing
screws.
•
Turn the engine support into horizontal position.
•
Place the left crankcase half on the engine support, fitting it on the engine support plate pins.
CAUTION
TAKE PARTICULAR CARE TO ENSURE THAT THE ENGINE AND ENGINE MOUNTING ARE STABLE AND ENSURE THAT THE ENGINE IS SECURELY FASTENED TO THE MOUNTING PLATE.
•
Install the complete gearbox assembly and the gearbox lubrication diffuser pipe, checking
O-ring conditions.
•
Apply black sealing paste (Threebond)
on the left crankcase half.
CAUTION
BE CAREFUL NOT TO APPLY THREEBOND IN EXCESS AS
IT MAY BLOCK OIL DUCTS THROUGH THE CRANKCASE
HALVES.
•
Place the right crankcase half with the
aid of a rubber hammer.
ENG - 282
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CAPONORD 1200
•
Tighten the two fixing pins.
•
Rotate the engine and the engine support into vertical position.
•
Working on the left side, place the elev-
Engine
en M6 screws fixing the crankcase.
•
Working on the left side, place the nine
M8 screws fixing the crankcase.
•
Tighten all the crankcase fixing
screws, both M6 and M8 type.
ENG - 283
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CAPONORD 1200
Engine
•
Tighten the two screws fixing the selector drum.
•
Fit a new O-ring in the seat.
•
Position the gear sensor and screw the
two fixing screws.
•
Refit both head-cylinder assemblies.
•
Position the crankshaft gear.
ENG - 284
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CAPONORD 1200
•
Engine
Fit the special tool, tightly fastening the
three screws securing the tool onto the
crankcase.
Specific tooling
020850Y Primary gear lock
•
Position the water pump drive gear, the
washer and crankshaft fastener nut
and tighten it to the specified torque.
ENG - 285
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CAPONORD 1200
Engine
Lubrication
OIL RADIATOR
pos.
1
Description
Fastening nipple to oil radiator
Type
M16x1.5
2
Oil radiator tubes fastening
M16x1.5
3
Fastening nipple to engine
M16x1.5
ENG - 286
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Quantity
Torque
2
20 ± 3 Nm (14.75 ± 2.21 lb
ft)
4
15 ± 2.25 Nm (11,06 ± 1.66
lb ft)
2
42 ± 6.3 Nm (30.97 ± 4.64
lb ft)
Notes
-
CAPONORD 1200
Engine
Oil pump
OIL PUMP
pos.
Type
M16x1.5
-
Quantity
1
1
Torque
19 Nm (14.01 lbf ft)
13 Nm (9.59 lbf ft)
Notes
-
-
1
20 Nm (14.75 lbf ft)
-
4
5
6
Description
Oil drainage plug
Fastening oil sensor on clutch side
crankcase half
Fastening oil filter union on clutch
side crankcase half
Oil filter
Oil pressure regulator valve
Oil pump fixing screw
M18x1.5
M6
1
1
2
7
8
9
10
Rose pipe fixing screw
Oil pump driven gear fastener nut
By-Pass plate fastener screw
Oil cooling radiator nipple
M6
M6
M5
M16x1.5
2
1
2
2
1
2
3
14 Nm (10.33 lbf ft)
42 Nm (30.98 lbf ft)
5-6 Nm (3.69-4.42 lbf ft) 3M SCOTCH GRIP
2353
12 Nm (8.85 lbf ft)
11 Nm (8.11 lbf ft)
5.50 Nm (4.06 lbf ft)
Loctite 242
42.5 Nm (31.35 lbf ft)
-
Removing
•
Remove the clutch.
•
Bend the chamfering tongue.
ENG - 287
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CAPONORD 1200
Engine
•
By means of a calliper spanner lock out
gear rotation and loosen the nut to remove it.
See also
Disassembling the
clutch
•
Collect the washer.
•
Collect the gear.
•
Collect the spacer.
ENG - 288
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CAPONORD 1200
•
Engine
Unscrew and remove the two nuts fixing the protection.
•
Collect the protection.
•
Remove the oil pump.
Inspection
•
Undo and remove the two fixing
screws.
•
Using a thickness gauge check clearance between rotor and stator and replace the rotor / stator unit if necessary.
clearance between rotor and stator: 0.04 ± 0.10
mm (0.0016 in - 0.0039 in).
ENG - 289
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CAPONORD 1200
Engine
•
Slide off the shaft with the cover.
•
Collect the lock pin from the shaft.
•
Remove the oil pump rotor.
•
Remove the oil pump stator.
CAUTION
CHECK THAT THE ROTOR AND STATOR ARE NOT DAMAGED (NO EVIDENT ABRASIONS, SCORES OR ANY OTHER MARKS).
ENG - 290
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CAPONORD 1200
Engine
Installing
NOTE
PAY ATTENTION TO ALIGN THE REFERENCES ON STATOR AND ROTOR DURING INSTALLATION AND CHECK
CLEARANCE WITH A FEELER GAUGE.
IF REQUIRED, REPLACE THE STATOR / ROTOR UNIT.
•
Fit the oil pump.
•
Fit the protection and tighten the two
retaining screws.
ENG - 291
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CAPONORD 1200
Engine
•
Fit the spacer.
•
Fit the gear.
•
Place the washer.
•
By means of a calliper spanner lock out
gear rotation and tighten the retaining
nut.
ENG - 292
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CAPONORD 1200
•
Bend the chamfering tongue.
•
Refit the clutch.
Engine
See also
Assembling the
clutch
Blow-by
The Blow By system allows for oil vapours to be recycled. The law requires that these gas and oil
vapours cannot be released into the atmosphere for environmental reasons. Therefore, there are systems for the recirculation of these gas-oil vapours inside the intake ducts to burn them in the subsequent
active phases of the engine. This system separates the engine oil into oil vapour.
The oil vapours coming from the joints (1) and (2), are filtered and enter into the filter box through the
joint (4).
ENG - 293
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INDEX OF TOPICS
POWER SUPPLY
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P SUPP
CAPONORD 1200
Power supply
Fuel pump
Injection
P SUPP - 295
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INDEX OF TOPICS
SUSPENSIONS
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SUSP
CAPONORD 1200
Suspensions
Front
FRONT WHEEL
pos.
1
Description
Wheel axle
Type
-
Quantity
Torque
1
80 ± 12 Nm (59 ± 8.85 lb ft)
Notes
-
Removing the front wheel
•
Hold the vehicle front part.
•
Unscrew the screws fixing the front pliers and slide them off the disc.
SUSP - 297
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Suspensions
•
Remove the wheel axle fixing nut.
•
Retrieve the sealing washer.
•
Loosen the screws on the wheel axle
CAPONORD 1200
clamps.
•
Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is
exposed.
•
Remove the wheel axle by inserting a screwdriver in the holes on the pin.
•
During extraction, support the wheel
and then remove it.
•
Collect the spacer from the front wheel
right side.
SUSP - 298
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CAPONORD 1200
Suspensions
Checking the front wheel
FRONT WHEEL BEARINGS
Carry out the check with the bearings fitted on the wheel.
CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOLLOWS.
ROTATION CHECK
•
Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and
noiseless.
If one or both bearings do not fall within the control parameters:
•
Replace both wheel bearings.
RADIAL AND AXIAL CLEARANCE CHECK
•
Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed.
Radial clearance: 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 OTHERS OF THE SAME TYPE.
GASKETS
•
Check that the gaskets are in good conditions; replace them if they show signs of damage
or excessive wear.
ALWAYS REPLACE BOTH GASKETS.
ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE.
WHEEL AXLE
•
Use a dial gauge to check the wheel
axle eccentricity. Replace the wheel
axle if the eccentricity exceeds the limit
value.
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
SUSP - 299
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CAPONORD 1200
Suspensions
•
Using a dial gauge, check that the radial (A) and the axial (B) eccentricities
of the rim do not exceed the limit value.
An excessive eccentricity is usually
caused by worn or damaged bearings.
Replace the rim if, after replacing the
bearings, the value is not within the
specified limit.
Characteristic
Maximum radial and axial eccentricity:
2 mm (0.0079 in)
Handlebar
HANDLEBAR
pos.
1
2
3
4
5
Description
TCEI screw fastening counterweight
to handlebar end
Stainless steel TCC screw fastening
upper U-bolt to lower clamp
Screws fastening light switch assembly
Anti-vibration weight terminal
TBEI screw
SUSP - 300
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Type
M6x50
Quantity
2
Torque
10 Nm (7.37 lbf ft)
Notes
-
M8x25
4
25 Nm (18.44 lbf ft)
-
-
2+2
1.5 Nm (1.11 lbf ft)
-
M18
M6x16
2
2
20 Nm (14.75 lbf ft)
12 Nm (8.85 lbf ft)
-
CAPONORD 1200
Suspensions
Front fork
FRONT FORK
Pos.
1
2
3
4
Description
TEFL screw (fasten onto Fork Hubs)
Screw (Pumping member pin fixing
to the stem base)
Upper cover
Upper cover locking nut
Type
M6x40
-
Quantity
4
2
Torque
10 Nm (7.37 lb ft)
30 Nm (22.13 lb ft)
Notes
-
-
2
2
20 Nm (14.75 lb ft)
20 Nm (14.75 lb ft)
-
ADD Version
SUSP - 301
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CAPONORD 1200
Suspensions
FRONT FORK ADD
Pos.
1
2
3
4
Description
Sensor upper cover screw
Sensor lower cover screw
Screw (Pumping member pin fixing
to the stem base)
Upper cover
Diagram
SUSP - 302
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Type
M6x20
M6x12
-
Quantity
1
2
2
Torque
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
30 Nm (22.13 lb ft)
Notes
-
-
2
20 Nm (14.75 lb ft)
-
CAPONORD 1200
Suspensions
STEERING
Pos.
1
Description
Headstock ring nut - pre-tightening
Type
M25x1
Quantity
1
Torque
60 Nm (44.25 lb ft)
1
Headstock ring nut - tightening
M25x1
1
2
3
Headstock cap
TCEI screw fastening fork legs to
bottom yoke
TCEI screw fastening U-bolt onto
fork yoke
TCEI screw fastening fork legs to top
yoke
Headstock counter-lock ring
M22x1
M8x35
1
4
50 +/- 5 Nm (36.88 +/3.69 lb ft)
100 Nm (73.75 lb ft)
25 Nm (18.44 lb ft)
M10x60
2
50 Nm (36.88 lb ft)
-
M8x30
2
25 Nm (18.44 lb ft)
-
M25x1
1
-
Manually screw
4
5
6
Notes
Unscrew after pretightening
-
Removing the fork legs
•
Remove the front wheel.
•
Support the stanchion and loosen the
screws on the upper and then the lower
plate.
•
Remove the stanchion.
FOR THE ADD VERSION, THE PRESSURE
SENSOR MUST BE DISCONNECTED BEFORE
REMOVING THE LEFT STEM.
•
Undo and remove the sensor fixing
screw located on the fork head.
CAUTION
TO AVOID OIL LEAKAGE FROM THE STEM WHEN REMOVING THE PRESSURE SENSOR, REPLACE IT WITH A
CAP. AS AN ALTERNATIVE, DO NOT PLACE THE STEM
HORIZONTALLY.
SUSP - 303
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Suspensions
•
CAPONORD 1200
Undo and remove the sensor base fixing screw located above the fork.
•
Disconnect the connector.
•
Remove the cable guide, making sure
that you do not damage the cable itself.
At this point the stem can be removed from the
plate.
WARNING
USING APPROPRIATE EQUIPMENT, ACCESS THE SPACE
BETWEEN THE CABLE GUIDE AND THE CABLE, THEN
LEVERAGE MAKING SURE THAT YOU DO NOT DAMAGE
THE CABLE.
Disassembling the fork
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
SUSP - 304
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CAPONORD 1200
•
Suspensions
Using the appropriate tool fasten the
stem in the vice.
Specific tooling
AP8140149 Protection for fitting operations
•
Operating on the upper screw, unload
the spring.
•
Loosen the cover without unscrewing it
completely, using the suitable equipment.
Specific tooling
020957Y Key for upper fork nut
NOTE
THE OPERATIONS REPORTED BELOW ARE VALID FOR BOTH CAPONORD 1200 STANCHIONS,
AND THE RH STANCHION OF CAPONORD 1200 aDD VERSION.
•
Put the stem upright and using the appropriate tool fasten the stem in the
vice.
•
Completely unscrew the plug.
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 305
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Suspensions
•
Using the specific tool, fixed to the preloading pipe, compress the spring.
•
Insert a spanner in the lock nut of the
cover.
Specific tooling
020888Y Pliers for pre-fill pipe
•
Unscrew the cap and remove it.
•
Remove the spring preload pipe.
•
Remove the lock nut and the washer.
SUSP - 306
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CAPONORD 1200
CAPONORD 1200
•
Suspensions
Remove the spring paying attention to
drain the oil correctly.
•
Drain the oil into a container of suitable
capacity to collect fluids.
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND
TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED
OIL COLLECTION CENTRE.
•
Discharge the fork, remove the internal
dipstick of the pumping member pin (1)
and the washer (2).
•
Operate repeatedly on the pumping
member pin (3) so as to drain completely the oil from inside.
•
Slide off the dust scraper from the
sleeve using a screwdriver as a lever.
•
During this operation, pay attention not
to damage the sleeve rim.
SUSP - 307
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Suspensions
CAPONORD 1200
•
Remove the retainer ring.
•
Take out the sleeve from the stem using the stem as a hammer puller.
•
Remove the fixed bushing (1), the
movable bushing (2), the ring (3) and
the oil seal (4) from the stem.
•
Remove the lock seeger ring of the
spring guide.
•
Remove the spring guide.
•
Using a hook spanner lock the pumping member pin
•
Remove the stem bottom screw.
Specific tooling
020889Y Pumping member ring nut locking
spanner
SUSP - 308
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CAPONORD 1200
•
Suspensions
Remove the pumping member pin.
THE FOLLOWING PROCEDURE APPLIES TO
aDD VERSION OF THE LH STEM.
•
Using the appropriate tool fasten the
stem in the vice.
•
Undo completely the sleeve cap using
the special tool.
NOTE
THE STEMS ARE DIFFERENT.
Specific tooling
AP8140149 Protection for fitting operations
•
Drain the oil into a container of suitable
capacity to collect fluids.
DO NOT DISPOSE OF OIL INTO 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 SERVICING THE VEHICLE.
SUSP - 309
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Suspensions
•
Unscrew and remove the bottom screw
and collect the washer.
•
Remove the pumping member pin.
•
Slide off the dust scraper from the
sleeve using a screwdriver as a lever.
•
During this operation, pay attention not
to damage the sleeve rim.
•
Remove the retainer ring.
•
Take out the sleeve from the stem using the stem as a hammer puller.
SUSP - 310
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CAPONORD 1200
CAPONORD 1200
•
Suspensions
Remove the fixed bushing (1), the
movable bushing (2), the ring (3) and
the oil seal (4) from the stem.
•
remove the ring and the dust guard.
THE FOLLOWING PROCEDURE APPLIES TO
THE ADD VERSION.
•
Lock the pumping member in a vice
using the special tool.
•
Lubricate the sliding edges with fork oil
or sealing grease.
•
Using the special key, unscrew the cap
and remove the spring.
•
Pay attention to place the key in the
lower seat of the "lock nut".
Specific tooling
020957Y Key for upper fork nut
020958Y Fork cartridge protection
•
Before removing the cap (1) from the pumping member, the electric cable harness must be
released. To do this, loosen the ring nut (2) and remove the sleeve (3) by unscrewing it.
SUSP - 311
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Suspensions
CAPONORD 1200
NOTE
DURING THE ASSEMBLY PHASE REMEMBER TO REPLACE THE CABLE GUIDE WITH A NEW
ONE.
WARNING
DURING THE REASSEMBLY PHASE TIGHTEN THE RING NUT (2) AND THE SLEEVE (3) TO THE
TORQUE 20 Nm (14.75 lb ft)
•
Remove the cap from the pumping
member and finally the spring.
Checking the components
Stem
Check the sliding surface for scorings and/or scratches.
These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
If the scorings are deep, replace the stem.
Use a dial gauge to check that the stem bending is below the limit value.
If over the value, replace the stem.
CAUTION
SUSP - 312
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CAPONORD 1200
Suspensions
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE
WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
Bending limit:
0.2 mm (0.00787 in)
Sleeve
Check that there are no damages and/or cracks; otherwise, replace it.
Spring
Check the spring is in good conditions.
Check that the following components are in good
conditions:
•
upper bushing;
•
lower bushing;
•
piston.
If there are signs of excessive wear or damage,
replace the affected component.
CAUTION
REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING
CARE NOT TO SCRATCH THEIR SURFACE.
SUSP - 313
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Suspensions
CAPONORD 1200
Replace the following components with new ones:
•
seal ring;
•
dust gaiter;
•
O-Ring on the cap.
Reassembling the fork
NOTE
THE OPERATIONS REPORTED BELOW ARE VALID FOR BOTH CAPONORD 1200 STANCHIONS,
AND THE RH STANCHION OF CAPONORD 1200 aDD VERSION.
•
Lock the stem in a vice without damaging the surface.
•
Protect the bearing tube end with adhesive tape.
•
Lubricate the sliding edges with fork oil
or sealing grease.
•
Fit the dust gaiter, the retainer ring and
the dust scraper on the stem.
SUSP - 314
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CAPONORD 1200
•
Suspensions
Fit the ring, the movable bushing and,
after removing the tape, fit the fixed
bushing.
•
Fit the sleeve on the stem and set the
oil seal into position with the aid of the
specific tool.
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
AP8140146 Weight
•
Insert the retainer ring in its position.
SUSP - 315
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Suspensions
•
Fit the dust gaiter with the specific tool.
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
AP8140146 Weight
•
Insert the pumping member pin in the
stem.
•
Using a hook spanner lock the pumping member pin and tighten the fixing
screw on the fork end to the prescribed
torque.
Specific tooling
020889Y Pumping member ring nut locking
spanner
•
Insert the spring guide and lock it by the appropriate seeger.
•
Place the fork vertically.
•
Insert the washer.
SUSP - 316
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CAPONORD 1200
CAPONORD 1200
•
Suspensions
Refill the fork with oil according to the
prescribed quantity.
•
Fit the spring.
CAUTION
BE CAREFUL WHEN INSERTING THE SPRING SINCE THE
COMPRESSED SPIRAL PART MUST BE PLACED DOWNWARDS.
See also
Filling oil
•
Insert the washer that will be supported
on the spring
•
Insert and hand tighten the nut on the
pumping member pin
•
Place the preload pipe.
•
Tighten the appropriate tool on the
pumping member pin rod and keep it
raised to allow, inserting a wrench in
the nut by compressing the spring.
Specific tooling
020890Y Pumping member stanchion support
rod
AP8140147 Spacer tool
SUSP - 317
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Suspensions
•
Tighten the nut as much as possible.
•
Insert the cover and tighten until it
stops.
•
Remove the specific tools.
•
Screw the cover in the sleeve to the
prescribed torque.
THE FOLLOWING PROCEDURE APPLIES TO
THE ADD VERSION.
•
Lock the pumping member in a vice
using the special tool.
•
Lubricate the sliding edges with fork oil
or sealing grease.
•
Using the special key, unscrew the cap
and remove the spring.
•
Pay attention to place the key in the
lower seat of the "lock nut".
Specific tooling
020957Y Key for upper fork nut
020958Y Fork cartridge protection
SUSP - 318
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CAPONORD 1200
CAPONORD 1200
•
Suspensions
With the key hold, turn the spring clockwise until the ring nut is fully uncovered
and manually tighten the ring nut
against the cap.
•
Insert the key on the ring nut seat.
•
Using a wrench and the special tool,
tighten the cap and the ring nut to the
prescribed torque.
•
Protect the bushing seat with adhesive
tape.
SUSP - 319
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Suspensions
•
Install first the dust scraper (1), then
the oil seal (2), the ring (3) and the
movable bushing.
•
When inserting the above listed elements, pay attention not to damage
them passing over the hole on the
stem.
•
Remove the adhesive tape.
•
Install the fixed bushing on the stem.
•
Fit the sleeve on the stem and set the
oil seal into position with the aid of the
specific tool.
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
AP8140146 Weight
SUSP - 320
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CAPONORD 1200
CAPONORD 1200
•
Insert the retainer ring in its position.
•
Fit the dust gaiter with the specific tool.
Suspensions
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
AP8140146 Weight
•
Fit the pumping member inside the
stem, paying attention that it is placed
inside the seat of the stem.
CAUTION
PAY PARTICULAR ATTENTION TO THE CORRECT INSERTION OF THE PUMPING MEMBER INSIDE THE STEM. IN
THE RIGHT POSITION, THE PUMPING MEMBER SHOULD
NOT TURN. ALSO DURING THE SCREW TIGHTENING ALWAYS CHECK THAT THE PUMPING MEMBER IS NOT
TURNING.
Filling oil
•
Place the sleeve upright in a vice fitted with protection shoes.
•
Compress the sleeve in the stem. Place a support under the stem in order to leave it compressed.
SUSP - 321
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Suspensions
•
Pour part of the fork oil into the sleeve.
•
Wait some minutes until the oil fills all the ducts.
•
Pour the remaining oil.
•
Pump out oil a few times.
•
Measure the air gap between the oil level and the rim.
CAPONORD 1200
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
AP8140149 Protection for fitting operations
Oil level: 135 mm (5.31 in) (from the sleeve
edge, without a spring and with preload pipe).
Characteristic
Fork oil (check also the correct air level in the
stem)
441 cm³ (26.91 cu.in) (for each stanchion)
ADD Version
Oil level LH stem: 130±2mm (5.12±0.08 in)
(from sleeve rim, without spacer spring and total cap).
Oil level RH stem: 120±2mm (4.72±0.08 in)
(from sleeve rim, without spacer spring and total cap).
Characteristic
Fork oil LH stem
119±5 cm³ (7.26±0.30 cu in) (Fork oil)
Fork oil RH stem
449±5 cm³ (27.40±0.30 cu in) (Fork oil)
SUSP - 322
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CAPONORD 1200
Suspensions
Steering bearing
STEERING
Pos.
1
Description
Headstock ring nut - pre-tightening
Type
M25x1
Quantity
1
Torque
60 Nm (44.25 lb ft)
1
Headstock ring nut - tightening
M25x1
1
2
3
Headstock cap
TCEI screw fastening fork legs to
bottom yoke
TCEI screw fastening U-bolt onto
fork yoke
TCEI screw fastening fork legs to top
yoke
Headstock counter-lock ring
M22x1
M8x35
1
4
50 +/- 5 Nm (36.88 +/3.69 lb ft)
100 Nm (73.75 lb ft)
25 Nm (18.44 lb ft)
M10x60
2
50 Nm (36.88 lb ft)
-
M8x30
2
25 Nm (18.44 lb ft)
-
M25x1
1
-
Manually screw
4
5
6
Notes
Unscrew after pretightening
-
Adjusting play
•
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 400 ± 150 g (0.88 ± 0.33 lb) in both directions.
•
Adjust if clearance is detected.
SUSP - 323
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Suspensions
•
CAPONORD 1200
Unscrew and remove the U-bolt four
fixing screws.
•
Remove the U-bolt.
•
Remove the handlebar and place it
paying attention that oil in the clutch
and front brake tanks does not spill out.
•
Unscrew and remove the upper plug
from steering yoke pin and collect the
washer.
•
Operating from both sides, loosen the
screws fixing the stanchions to the upper plate.
•
Undo and remove the two screws fixing
the instrument panel support to the fork
upper plate.
•
Slide off the fork upper plate by moving it towards the instrument panel.
SUSP - 324
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CAPONORD 1200
•
Suspensions
Straighten the safety plate (1) on the
counter-lock ring (2) and remove it
from steering yoke pin.
•
Take the suitable tool for working on
the steering ring nuts.
•
Loosen the counter-lock ring (2) and
remove it together with the rubber
spacer (3) from the steering yoke pin.
Specific tooling
020884Y 46 mm wrench for steering ring nut
Carry out the following operations:
- carry out a first tightening of the ring nut to the
indicated tightening torque for the settlement of the
steering package.
- turn the steering completely from both sides, for
several times.
Loosen the ring nut completely.
- carry out the final tightening of the ring nut to the
indicated tightening torque.
STEERING RING NUT
pos.
Description
Type
1
Headstock ring nut - pre-tightening
M25x1
Qua
ntit
y
1
1
Headstock ring nut - tightening
M25x1
1
•
Install the rubber spacer (3).
•
Hand screw counter-lock ring (2) until
Torque
Notes
60 Nm (44.25 lb
ft)
50 +/- 5 Nm
(36.88 +/- 3.69 lb
ft)
Unscrew after pre-tightening
-
against spacer (3).
•
Install a new safety plate (1) and bend
it on the ring nuts.
SUSP - 325
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CAPONORD 1200
Suspensions
•
Fit the entire fork upper plate, adjusting
with short taps with a rubber hammer
•
Fit the washer and tighten the upper
plug to the specified tightening torque.
STEERING UPPER PLATE
pos.
Description
Headstock cap
TCEI screw fastening fork legs to
bottom yoke
TCEI screw fastening U-bolt onto
fork yoke
TCEI screw fastening fork legs to top
yoke
Headstock counter-lock ring
2
3
4
5
6
•
Type
M22x1
M8x35
Quantity
1
4
Torque
100 Nm (73.75 lb ft)
25 Nm (18.44 lb ft)
Notes
-
M10x60
2
50 Nm (36.88 lb ft)
-
M8x30
2
25 Nm (18.44 lb ft)
-
M25x1
1
-
Manually screw
Tighten the fixing screws of the upper
plate to the prescribed tightening torque.
When refitting the U-bolt, position the two references facing the front part of the vehicle.
SUSP - 326
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CAPONORD 1200
Suspensions
Assembling
•
Grease the lower and upper bearing
rollers
•
Prefit the shim, dust gaiter and lower
bearing on the steering yoke as shown
in the figure.
Recommended products
AGIP MP GREASE Grease for bearings, joints,
couplings and linkages
As an alternative to the recommended product,
use top brand grease for roller bearings with an
operating temperature range of -22°F to +284°F
(-30°C to +140°C), drop point between 302ºF to
446°F (150°C to 230°C), high corrosion protection
qualities and good water and rust resistance.
•
Install the upper bearing on the steering yoke pin as shown in the figure,
with the conical part facing downward.
•
After inserting, the bearing must slide
freely on the steering pin till matching
with the steering bearing conic in the
frame.
•
Ensure the bearing mating in its seat,
using a teflon buffer from a suitable diameter.
SUSP - 327
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Suspensions
•
Fit the specific upper seal ring with the
lip placed upwards and the surface
with the words downwards.
•
Fit it on the pin and place it on the upper
rim of the headstock.
•
Finish inserting, until the stop, with the
teflon buffer and rubber hammer.
•
Pass with a brush on the seal ring to
lay down potential grease storage.
•
Install dust gaiter (4) on frame headstock.
•
Place the tightening ring nut (5) with
the indicated rim placed downwards.
•
Carry out the steering bearings clearance adjustment.
See also
Assembling
SUSP - 328
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CAPONORD 1200
CAPONORD 1200
Suspensions
Rear
REAR WHEEL
pos.
1
2
Description
Fastening screws flexible coupling
Rear wheel axle
Type
M10
-
Quantity
5
1
Torque
●
120 ± 18 Nm (88.50 ±
13.27 lb ft)
Notes
-
Removing the rear wheel
•
Place the vehicle on its rear service
stand.
•
Fasten the vehicle handlebar to the
bench using belts.
•
To facilitate operations, it is advisable
to remove the chain protection by unscrewing the two screws.
SUSP - 329
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Suspensions
CAPONORD 1200
CAUTION
RIMUOVERE IL SENSORE VELOCITA' PRIMA DI PROCEDERE CON LA RIMOZIONE DELLA
RUOTA POSTERIORE EVITANDO QUINDI DI DANNEGGIARLO
•
Fully slacken the gearing chain tension.
•
Make the wheel move forward and release the gearing chain from the
sprocket.
•
Unscrew and remove the nut on the
wheel axle.
•
Collect the thrust washer and the right
chain tensioner slider.
See also
Adjusting
•
Working on the left side, hit the wheel
axle lightly so as to take out the head
from its housing.
•
Working on the right side, slide off the
wheel axle together with the chain
guide slider.
•
Remove the wheel by freeing the disc
from the brake calliper.
SUSP - 330
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CAPONORD 1200
•
Collect the rear wheel spacer.
•
Working from the left side, unscrew
Suspensions
and remove the five nuts and remove
the sprocket and the bolts.
•
Unscrew and remove the five screws
and remove the anti-vibration buffer
holder.
•
Check the flexible couplings according
to the routine maintenance table.
See also
Adjusting
Checking the rear wheel
CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOLLOWS.
REAR WHEEL BEARINGS
Carry out the check with the bearings fitted on the wheel.
ROTATION CHECK
•
Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and
noiseless.
If one or both bearings do not fall within the control parameters:
SUSP - 331
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Suspensions
•
CAPONORD 1200
Replace both wheel bearings.
ALWAYS REPLACE BOTH BEARINGS.
ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE.
•
Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed.
Radial clearance: none.
If one or both bearings do not fall within the control parameters:
•
Replace both wheel bearings.
REAR WHEEL GASKETS
•
Check that the gaskets are in good conditions; replace them if they show signs of damage
or excessive wear.
ALWAYS REPLACE BOTH GASKETS.
ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE.
REAR WHEEL AXLE
•
Use a dial gauge to check the wheel
axle eccentricity (1). Replace the
wheel axle if the eccentricity exceeds
the limit value (1).
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
REAR WHEEL RIM
•
Using a dial gauge, check that the radial (A) and the axial eccentricity (B) of
the rim (2) do not exceed the limit value.
An excessive eccentricity is usually caused by
worn or damaged bearings. Replace the rim (2) if
after replacing the bearings, the value is not within
the specified limit.
Characteristic
Maximum radial and axial eccentricity:
2 mm (0.0079 in)
SUSP - 332
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CAPONORD 1200
Suspensions
Shock absorbers
REAR SUSPENSION
Pos.
1
2
Description
Upper TCEI mounting screw
Lower TCEI mounting screw
Type
M10x50
M10x80
Quantity
1
1
Torque
50 Nm (36.88 lb ft)
50 Nm (36.88 lb ft)
Notes
-
ADD Version
SUSP - 333
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CAPONORD 1200
Suspensions
REAR SUSPENSION ADD
Pos.
Description
Upper TCEI mounting screw
Lower TCEI mounting screw
1
2
Type
M10x50
M10x80
Quantity
1
1
Torque
50 Nm (36.88 lb ft)
50 Nm (36.88 lb ft)
Removing
THE FOLLOWING PROCEDURE APPLIES TO THE ADD VERSION
•
Disconnect the electric motor connector (1).
•
Release the elastic that keeps the electric motor in position.
•
Unscrew and remove the shock absorber upper fixing screw.
•
Unscrew and remove the shock absorber lower fixing screw.
SUSP - 334
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Notes
-
CAPONORD 1200
•
Disconnect the shock absorber valve.
•
When removing the shock absorber
Suspensions
pay attention to the electric motor, it
must be removed from the frame taking
care not to damage it.
Revision
•
Disconnect the cabling from the support bracket
SUSP - 335
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Suspensions
•
After removing the two fastening
screws of the support bracket, remove
it
•
Put the shock absorber in the special
tool for the spring compression
CAUTION
MAKE SURE NOT TO DAMAGE THE CABLE HARNESS
AND THE TUBE BETWEEN THE MOTOR AND THE SHOCK
ABSORBER
•
Compress the shock absorber spring
•
Remove the retainer ring.
SUSP - 336
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CAPONORD 1200
CAPONORD 1200
•
Suspensions
Discharge the spring and remove the
suspension from the specific tool
•
Remove the lock plate of the spring
making sure not to damage the cable
harness
•
Remove the spring making sure not to
damage the cable harness
BLEEDING
•
It is possible to carry out a bleeding and replace the oil in the suspension using a special
pump.
•
Loosen the bleeding valve from suspension
SUSP - 337
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Suspensions
•
Insert and tighten the special joint
•
Connect the tube for the oil bleeding/
filling to the joint
•
Connect the tube for the oil bleeding/
filling to the tool
•
After the bleeding and the oil filling remove the tube from the joints
•
Remove the joints
•
Insert and tighten the screw for bleeding the suspension
SUSP - 338
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CAPONORD 1200
INDEX OF TOPICS
CHASSIS
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CHAS
CAPONORD 1200
Chassis
Swinging arm
SWINGARM
pos.
1
2
3
4
5
6
7
8
Description
Swingarm Pin adjustment bushing
Swingarm pin ring nut
Swingarm pin nut
TPSI screw fastening rear stand
bushing
TBEI screw fastening chain guard to
swingarm
TBEI Chainguard fixing screw
TBEI screw fastening chain guide to
swingarm
Flanged TBEI screw fastening chain
slider
Type
M6x40
Quantity
1
1
1
2
Torque
12 Nm (8.85 lb ft)
60 Nm (44.25 lb ft)
90 Nm (66.38 lb ft)
10 Nm (7.37 lb ft)
Notes
-
M5x9
1
6 Nm (4.42 lb ft)
Loctite 243
M5x9
M5x9
1
2
4 Nm (2.95 lb ft)
6 Nm (4.42 lb ft)
Loctite 243
M5x9
2
6 Nm (4.42 lb ft)
-
Removing
•
Remove the exhaust system.
•
Support the vehicle by means of the engine service stand and a hoist with belts fastened to
the rear section of the frame.
•
Remove the rear wheel.
CHAS - 340
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CAPONORD 1200
•
Cut the clamp.
•
Slide off the rear calliper holding plate,
Chassis
keeping it linked to the brake pipe.
CAUTION
DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER
REMOVING THE WHEEL. OTHERWISE, THE CALLIPER
PLUNGERS COULD GO OUT OF THEIR SEAT, RESULTING
IN BRAKE FLUID LEAKAGE.
•
Unscrew and remove the shock absorber lower screw and collect the nut.
•
Fasten the shock absorber to the chassis.
•
With the specific box-spanner, unscrew and remove the locking ring nut.
CHAS - 341
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CAPONORD 1200
Chassis
•
Working from the left side, unscrew
and remove the nut and collect the
washer.
REMOVAL SHOULD BE CARRIED OUT WITH UTMOST
CAUTION.
SUPPORT THE SWINGARM FROM THE FRONT TO AVOID
ACCIDENTAL FALLS.
PLACE A WOODEN SUPPORT UNDER THE FRONT PART
OF THE REAR SWINGARM TO PREVENT IT FROM LOWERING AND TO KEEP IT UPRIGHT.
•
Working on the right side, unscrew and
remove the swingarm bolt.
UPON REMOVING THE REAR SWINGARM PAY ATTENTION NOT TO JAM THE GEARING CHAIN.
See also
Removing the
rear wheel
Drive chain
Adjusting
The vehicle is fitted with an endless chain, without master link.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
To check clearance:
•
Shut off the engine.
•
Rest the vehicle on its stand.
•
Engage neutral gear.
•
Check that the vertical oscillation at a
point between the pinion and the
sprocket on the lower branch of the
chain is approx. 25 - 30 mm (0.98 - 1.18
in).
CHAS - 342
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CAPONORD 1200
•
Chassis
Move the vehicle forward so as to
check vertical oscillation of the chain in
other positions too. clearance should
remain constant at all wheel rotation
phases.
•
If clearance is uniform but over 30 mm
(1.18 in) or below 25 mm (0.98 in), adjustment is necessary.
ADJUSTMENT
CAUTION
GET A SPECIFIC REAR SERVICE STAND (OPT) TO ADJUST THE CHAIN.
If you need to adjust chain tension after the check:
•
Place the vehicle on its rear service
stand (OPT).
•
Loosen the nut (1) completely.
•
Loosen both lock nuts (4).
•
Actuate on the adjuster screws (5) and
adjust the chain clearance checking
that the references (2-3) match on both
sides of the vehicle.
•
Tighten both lock nuts (4).
•
Tighten the nut (1).
•
Check chain clearance.
CAUTION
TO ENSURE THAT THE WHEEL IS CORRECTLY CENTRED, THERE ARE FIXED REFERENCE MARKINGS (2-3)
INSIDE THE CHAIN TENSIONER SLIDER SEATS ON THE
SWINGARMS, IN FRONT OF THE WHEEL AXLE.
CHECKING THE CHAIN, THE PINION AND THE SPROCKET FOR WEAR
Furthermore, check the following parts and make sure the chain, the pinion and the sprocket do not
show:
•
damaged rollers;
•
loosened pins;
•
dry, rusty, flattened or jammed chain links;
•
excessive wear;
•
missing sealing rings;
•
excessively worn or damaged pinion or sprocket teeth.
CHAS - 343
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CAPONORD 1200
Chassis
IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSE AND/OR THE SEAL RINGS
ARE MISSING OR DAMAGED, THE WHOLE CHAIN UNIT (PINION, SPROCKET AND CHAIN)
SHOULD BE REPLACED.
LUBRICATE THE CHAIN ON A REGULAR BASIS, PARTICULARLY IF YOU DETECT DRY OR
RUSTY PARTS.
FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING
CONDITIONS RESTORED.
THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE
INSIDE.
ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION.
CLEANING AND LUBRICATION
Do not wash the chain with water jets, steam jets, high-pressure water jets and highly flammable solvents.
•
Wash the chain with fuel oil or kerosene. Maintenance operations should be more frequent
if there are signs of quick rust.
Lubricate the chain at the intervals specified on the routine maintenance table and whenever necessary.
•
Wash the chain, allow to dry and lubricate with spray grease for sealed chains.
Stand
STAND
pos.
1
2
Description
Fixing screw protection
Plate fastening screws
CHAS - 344
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Type
M6x16
M8x30
Quantity
Torque
3
5 ± 1 Nm (3.68 ± 0.74 lb ft)
3
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
Notes
Loctite 243
CAPONORD 1200
pos.
3
4
Chassis
Description
Stand screw
Type
M10
Stand nut
M10x1.25
Quantity
Torque
1
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
1
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
Notes
Loctite 243
Loctite 243
Centre stand
WHERE CONTEMPLATED
•
Working on the left side, unscrew and
remove the central stand fixing screw.
•
Working on the left inside, unscrew and remove the central stand fixing screw.
•
Working on the right side, unscrew and
remove the central stand fixing screw.
CHAS - 345
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CAPONORD 1200
Chassis
•
Remove the centre stand.
Side stand
•
Remove the gearshift lever first.
•
Disconnect the stand sensor.
•
Unscrew and remove the three fixing
screws.
•
Remove the side stand.
CHAS - 346
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CAPONORD 1200
Chassis
Exhaust
EXHAUST
pos.
1
Description
Fixing screw protection
Type
M6x16
Quantity
Torque
3
5 ± 1 Nm (3.68 ± 0.74 lb ft)
Notes
-
Removing the tail pipe
•
Unscrew and remove the two exhaust
valve motor fixing screws.
•
Remove the exhaust valve motor.
CHAS - 347
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CAPONORD 1200
Chassis
•
Unscrew and remove the three exhaust end cover fixing screws.
•
Remove the cover.
•
Unscrew and remove the two fixing
screws.
•
Remove the exhaust end.
Removing the catalytic converter
•
Remove the exhaust end first.
•
Unscrew and remove the catalytic converter fixing screw.
CAUTION
DURING THE ASSEMBLY AND REFITTING, PAY ATTENTION TO THE GASKET.
CHAS - 348
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CAPONORD 1200
•
Chassis
Remove the catalytic converter.
See also
Removing the tail pipe
Removing the exhaust manifold
•
Disengage the spring.
•
Unscrew and remove the three nuts
from the front and rear exhaust manifold
CHAS - 349
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CAPONORD 1200
Chassis
•
Disengage the spring joining the rear
exhaust manifold and the catalytic converter.
•
Disconnect the front and rear lambda
probe.
•
Remove the exhaust manifolds.
Removing the lambda sensor
•
To remove the lambda probe refer to
exhaust end removal.
See also
Removing the tail pipe
CHAS - 350
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CAPONORD 1200
Chassis
Engine oil cooler
•
Remove the fairing lug.
•
Drain the engine oil.
•
Remove both side fairings.
•
Working on the right side, unscrew the
two oil pipes.
•
Disconnect the horn connectors.
See also
Side body panels
•
Working on the left side, unscrew and
remove the screw from the front cylinder.
CHAS - 351
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CAPONORD 1200
Chassis
•
Remove the seeger ring and slide off
the pin.
•
Remove the oil radiator together with
support and horn.
CHAS - 352
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INDEX OF TOPICS
BRAKING SYSTEM
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BRAK SYS
CAPONORD 1200
Braking system
Interventions rules
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
ABS
ABS SYSTEM
pos.
-
Description
ABS ECU fastener screw
ABS ECU fastener nut
BRAK SYS - 354
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Type
M6x25
M6
Quantity
1
2
Torque
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
Notes
Loctite 243
-
CAPONORD 1200
Braking system
Key:
1. ABS ECU control unit
2. Front ABS sensor
3. Rear ABS sensor
4. Battery
5. Main fuse
6. ECU
7. Instrument panel
8. K line (diagnosis)
9. Key
10.ABS control unit fuse
ABS ECU control unit pin configuration
•
PIN 1 - GND - Ground
•
PIN 2 - PCC1 - Vehicle identification ground connection
•
PIN 3 - Speed signal to ECU
•
PIN 4 - IGN - Injection
•
PIN 5 - CAN H line
•
PIN 6 - CAN L line
•
PIN 8 - WL - Alarm warning light
•
PIN 11 - R_SIGN - Rear ABS sensor signal
•
PIN 12 - R_GND - Rear ABS sensor ground connection
BRAK SYS - 355
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Braking system
•
PIN 13 - F_GND - Front ABS sensor ground connection
•
PIN 14 - F_SIG - Front ABS sensor signal
•
PIN 15 - PCC2 - Vehicle identification ground connection
•
PIN 16 - ISO_K - K line (diagnosis)
•
PIN 18 - KL30 - Power supply
Foreword
key:
1. Rear brake calliper
2. Modulator
3. Front bleed valve
4. Front brake reservoir
5. Front brake callipers
6. Rear brake pump
7. Rear brake reservoir
BRAK SYS - 356
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CAPONORD 1200
CAPONORD 1200
Braking system
Operating diagram
ABS functional diagram key
1. Front system circuit
2. Front brake pump
3. Front brake lever
4. Rear system circuit
BRAK SYS - 357
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Braking system
CAPONORD 1200
5. Rear brake pump
6. Rear brake pedal control
7. ABS control unit
8. Rear brake calliper
9. Front calliper (2 callipers)
10.Front brake circuit intake solenoid valve (normally open)
11.Humidifier
12.Rear brake circuit intake solenoid valve (normally open)
13.Rear brake exhaust circuit solenoid valve (normally closed)
14.Rear/front brake circuit low pressure accumulator
15.Front brake exhaust circuit solenoid valve (normally closed)
16.DC electric motor
17.Double circuit hydraulic pump (ABS)
18.Rear brake reservoir
19.Front brake reservoir
ABS OPERATION
General specifications:
The front circuit is similar to the rear circuit.
•
The ABS inlet valve (10 - 12) is normally open and it is closed only when the system intervenes to avoid wheel locking.
•
The outlet valve (13 - 15) is normally closed and it is opened only when the system intervenes
to avoid wheel locking.
•
When the system is in standby, the ABS processor never stops monitoring the speed of the
wheels in order to assess potential wheel slippage.
•
When in standby, the system does not intervene at all when the rider brakes; the braking
system is the same as the one without ABS.
Stages in ABS cycle (the following operations refer to the front circuit but are also applicable to
the rear one):
A - Brake activation: the rider starts braking as he would usually do.
B - Pressure reduction: it coincides with danger recognition (wheel slippage above threshold): the
system closes the inlet valve (10-12) and opens the outlet valve (13-15) temporarily.
At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the
pressure on the callipers partially. The excess fluid temporarily fills the front reservoir (18-19) until the
ABS pump (17) self-activates and delivers the fluid back to the brake pump (2-5).
C - Pressure maintained: the pressure in the callipers (8-9) remains low until total recovery of speed /
wheel grip.
The system restores the fluid taken from the calliper (8-9) in the section of the system between the
brake pump (2-5) and the ABS inlet valve (10-12).
BRAK SYS - 358
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CAPONORD 1200
Braking system
D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers
(8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the
braking back to the rider.
E - If the wheel does not reach complete grip, the system continues operating as before until complete
grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure
reduction phase exceeds the pre-set time limit.
ABS SYSTEM DESCRIPTION
The ABS system is a device to avoid wheels locking in case of emergency braking, increasing vehicle
braking stability when compared to a traditional braking system.
The ABS system enhances control over the vehicle, taking into consideration never to exceed the
physical limits of vehicle grip on the road. The rider is fully responsible for riding at a suitable speed
based on weather and road conditions, always leaving an appropriate safety margin. Under no circumstances can the ABS system compensate for the rider's misjudgement or improper use of brakes.
Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it
difficult to control the vehicle.
A position sensor (3) on the tone wheel (2), forming an integral unit with the vehicle wheel, "reads" the
status of the vehicle wheel spotting any possible lock.
A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly.
CAUTION
WHEN THE ABS STARTS WORKING, A PULSING IS FELT ON THE BRAKE LEVER.
THE WHEEL ANTILOCK SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND. AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLE BAR TURNED, ON UNEVEN OR
SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE. THEREFORE, RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADUALLY.
BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN
ABS CAN ELIMINATE.
When sensors (3) detect a significant speed difference between the rear and the front wheels (for
example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation.
In this case, 2 things may occur:
BRAK SYS - 359
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Braking system
CAPONORD 1200
- the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the
same speed of the other wheel; it is not possible to brake for an instant.
- if the speed difference lasts long, the system may detect an error and deactivates the ABS system.
As a consequence, the system works as any regular braking system.
Riding with an active ABS system
•
During the vehicle start-up, after the instrument panel initial check, the ABS
warning light stops flashing when the
speed is under 5 km/h (3.1 mph).
If the ABS warning light remains on when the
vehicle is running, it means that a fault has
been detected and the ABS system has been
automatically deactivated.
IN CASE OF FAILURE OR WITH ABS DISCONNECTED,
THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS
SYSTEM.
ABS enable/disable
By short pressing the button "B" move the various
functions until the one regarding the ABS appears.
To activate or deactivate the system, briefly press
button "A", which will either activate or deactivate
the system in cycles.
If the system is activated, the ABS warning light
will blink.
If the system is deactivated, the ABS warning light
will stay permanently on.
In both cases, to confirm the selected mode, hold
button "B" pressed for a few seconds.
The function will automatically appear after five
seconds, if the selection is not made promptly, or
when the motorcycle is running.
NOTE
AT KEY ON, IF THE SYSTEM IS FUNCTIONING CORRECTLY, THE ABS INDICATOR LIGHT WILL BLINK (ONCE A
VEHICLE SPEED OF 5 Km/h - 3.1 mph IS EXCEEDED, THE
BRAK SYS - 360
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CAPONORD 1200
Braking system
SYSTEM WILL ONLY BE ACTIVE IF THE WARNING LIGHT
GOES OFF)
NOTE
WHEN THE BIKE'S PANEL IS OFF AND WHEN TURNING IT
ON THE NEXT TIME THE ABS SYSTEM IS STILL ACTIVE,
REGARDLESS OF WHAT WAS SET PREVIOUSLY.
Riding with a deactivated ABS system.
When the ABS system is deactivated, the warning
light on the instrument panel turns on permanently.
Guide to diagnosis
Each time the key is ON, if at least one current or stored* error of the ABS system is not detected:
•
the ABS warning light flashes
When the 5 km/h (3.11 mph) are exceeded:
- if errors are not detected
•
the ABS warning light turns off
- if at least one malfunction is detected
•
the ABS warning light turns on permanently
The ABS system is deactivated!
The system operates perfectly just as any other braking system without ABS.
The detection of malfunctions may require more or less time according to the type of failure.
Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist
within a given time.
If during this given time one of the conditions is missing but then it comes back, the timer is reset and
the system is no longer able to diagnose the error.
The ABS system is still inactive.
Example:
- error code 5D93 requires some minutes before it is diagnosed during the given time:
BRAK SYS - 361
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CAPONORD 1200
Braking system
•
the ABS warning light ABS keeps flashing
ABS FAULTS - GUIDE TO THE DIAGNOSIS
1. ABS WARNING LIGHT ON
2. CONNECT P.A.D.S.
DOES P.A.D.S. COMMUNICATES? (NO, go to 3; YES, go to 4)
3. PERFORM THESE CHECKS:
•
A. Ground connection PIN 1
•
B. +12V at PIN 18
•
C. +12V at PIN 4 with key ON
4. ARE THERE ANY ERRORS? YES, go to point 5; NO, go to 6)
5. CONSULT THE ERRORS DISPLAY TABLE
6. ABS WARNING LIGHT ACTIVATION
ACTIVE?(YES, go to 7; NO, go to 8)
7. CONTACT TECHNICAL SERVICE
8. PERFORM THESE CHECKS:
•
A. Cable continuity between PIN 8 of the ABS control unit connector and PIN 28 of the
instrument panel.
•
B. Check connectors - refer to the operations described in the chapter
If the previous checks are OK, the causes might be:
•
C. ABS control unit malfunction
•
D. Instrument panel malfunction
Use of diagnostics instrument for ABS system
Abs screen pages
ECU INFO screen page
This screen page shows general data regarding
the control unit, for example software type, mapping, control unit programming date
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CAPONORD 1200
Braking system
INFO ECU SCREEN PAGE
Characteristic
Vehicle manufacturing date
Frame number
Software version
Vehicle code
Vehicle identification according to
state of Pins 2 and 15
Value/example
Unit of
measure
ment
Caponord 1200
Norge / Stelvio / Identification provided by
ECU
Notes
The vehicle code stored in the control unit is read.
A different type of vehicle is associated with each
configuration of PIN 2 and PIN 15 connections.
Possible indications are as follows: Norge / Stelvio / ID by ECU.
Configuration with PIN 2 and PIN 15 connected to
ground, as is the case with Caponord 1200, provides the following indication: "Identification provided by ECU";
the ECU also requires a CAN message from the
injection ECU in order to determine vehicle ID.
NOTE: the "X" in the table identifies the connector pin is grounded.
* - CAPONORD 1200 and all motorcycles equipped with ABS control units connected via CAN
line
PARAMETERS screen page
This screen page shows the parameters measured by the several sensors (engine revs, engine
temperature, etc.) or values set by the control unit
(injection time, ignition advance, etc.)
PARAMETERS
Characteristic
Front wheel speed
Rear wheel speed
Value/example
0
0
Unit of
measure
ment
km/h
km/h
Notes
With stopped wheel, 0 Km/h is displayed
With stopped wheel, 0 Km/h is displayed
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CAPONORD 1200
Braking system
Characteristic
Value/example
Battery voltage
11.9
Unit of
measure
ment
V
Notes
ACTIVATION screen page
This screen page is used to delete errors in the
control unit memory and to activate some systems
controlled by the control unit.
ACTIVATION
Characteristic
Front brake bleeding procedure
Rear brake bleeding procedure
ABS warning light
Ambient parameter error reading (1)
Ambient parameter error reading (2)
Ambient parameter error reading (3)
Ambient parameter error reading (4)
Ambient parameter error reading (5)
Error clearing (1)
Error clearing (2)
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Value/example
Unit of
measure
ment
Notes
Useful in case of lever sponginess although the
bleeding has been done as in a regular braking
system
Useful in case of lever sponginess although the
bleeding has been done as in a regular braking
system
The ABS warning light is made to flash.
The ambient parameters are 4: Number of error
detections, Operation cycles from the last detection, Battery voltage, Speed.
Number of error detections: number of times the
error has been detected by the control unit;
for example, if it indicates 2, it means that the error
has been detected (ATT), then it has not been detected for a while (sent to the MEM) and then it
has been detected again.
Operation cycles from the last reading: a cycle is
counted if the following occurs: key ON and speed
over 20 km/h.
If for example 5 is shown, it means that the last
time the error has been measured was 5 cycles
ago.
Press "enter" to transfer errors from the memory
(MEM) to the historical record (STO).
At the next connection between diagnostics instrument and the control unit, the historical errors
(STO) will no longer appear.
CAPONORD 1200
Braking system
ERRORS screen page
This screen page shows potential errors detected
in the vehicle (ATT) or stored in the control unit
(MEM) and it allows to check error clearing (STO).
ERRORS
Characteristic
Front speed sensor: 5D90 electric
malfunction
Front speed sensor: 5D91 the signal
works irregularly
Front speed sensor: 5D92 the signal
decreases periodically
Front speed sensor: no signal or
speed measured too low in relation
to the rear wheel 5D93
Front speed sensor: 5D94 no acceleration after pressure reduction
Front speed sensor: 5D95 excessive
measured speed
Rear speed sensor: 5DA0 electric
malfunction
Rear speed sensor: 5DA1 the signal
works irregularly
Rear speed sensor: 5DA2 the signal
decreases periodically
Rear speed sensor: 5DA3 no signal
or speed measured too low in relation to the front wheel
Rear speed sensor: 5DA4 no acceleration after pressure reduction
Rear speed sensor: excessive measured speed 5DA5
Control unit: missing valve calibration 5DD2
Control unit 5DD3
Recirculation pump 5DF0
Recirculation pump 5DF1
Control unit 5DF2
Low electric voltage - long period
measurement 5DF3
Control unit 5DF5
High electric voltage 5DF7
Vehicle code 5E59
Value/example
Unit of
measure
ment
Notes
Electrical fault in sensor or cable harness
Faulty sensor or signal interference
Possible tone wheel fault due to deformations or
dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel
vibrations
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel or tone wheel with wrong number of teeth
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel
Faulty sensor/tone wheel, or tone wheel with
wrong number of teeth or wrong tyre size
Electrical fault in sensor or cable harness
Faulty sensor or signal interference
Possible tone wheel fault due to deformations or
dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel
vibrations
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel or tone wheel with wrong number of teeth
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel
Faulty sensor or tone wheel with wrong number of
teeth or wrong tyre size
Possible control unit fault
Possible control unit fault
Possible control unit fault
Possible control unit fault
Possible control unit fault
Voltage too low measured for 30 seconds at PIN
18 of the ABS control unit:
Possible control unit fault
Excessive voltage measured at PIN 18 of the ABS
control unit
This error appears if the control unit detects an
inconsistency between its memorised code
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CAPONORD 1200
Braking system
Characteristic
Value/example
Unit of
measure
ment
Notes
(can be read in the ISO page on the Vehicle code
line) and the value detected by the cabling identification PINs
(can be read in the ISO page Vehicle identification
line on the basis of the status of Pins 2 and 15)
and, for Caponord 1200, from the CAN signal received from the injection control unit
Possible control unit fault
Control unit F000
SETTINGS screen page
This screen page is used to adjust some control
unit parameters.
ADJUSTMENTS
Characteristic
Coding (1)
Coding (2)
Coding (3)
Value/example
Unit of
measure
ment
Notes
Used for re-coding the control unit or coding a new
one.
Vehicle identification is done according to the connection of PINS 2 and 15 of the ABS control unit
connector and is stored in the control unit memory.
The identification can be read in the INFO ECU
screen page in the line: Vehicle code.
NOTE: the "X" in the table identifies the connector pin is grounded.
* - CAPONORD 1200 and all motorcycles equipped with ABS control units connected via CAN
line
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CAPONORD 1200
Braking system
Modulator
MODULATOR REMOVAL
•
Remove the fairing lug.
•
Release clamp (1) and disconnect connector (2).
•
By unscrewing the nuts, remove and
plug the brake oil pipes following this
sequence: (3) - (4) - (6) - (5).
•
Slide off the rear system pipes from the hooks (7).
•
Undo and remove the three screws,
collect the washers and remove the
ABS modulator.
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CAPONORD 1200
Braking system
Rear brake calliper
REAR BRAKE
pos.
1
2
3
4
5
6
7
8
-
Description
Rear brake lever pin
Flanged TE screw fastening pump to
footrest mounting
TBEI screw fastening oil pipe to
swingarm
Flanged self-locking nut
Screw + nut fastening pedal to brake
lever
Brake pipe union
Flanged TE screw fastening rear disc
TCEI screw
Flanged TE screw
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Type
M6x16
Quantity
1
2
Torque
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
Notes
Loctite 243
-
M5x12
4
8 Nm (5.90 lbf ft)
-
M6
M6
1
1
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
-
M10x1
M8x18
M6x16
M6x16
2
5
2
1
25 Nm (18.44 lbf ft)
25 Nm (18.44 lbf ft)
12 Nm (8.85 lbf ft)
10 Nm (7.37 lbf ft)
Loctite 243
-
CAPONORD 1200
Braking system
Front brake calliper
FRONT BRAKE
pos.
Description
Union with breather (fixing pipe to
callipers)
TEFL screw (Fixing calliper to fork
stems)
1
2
Type
M10x1
Quantity
2
Torque
25 Nm (18.44 lbf ft)
Notes
-
M10x1.25
4
50 Nm (36.88 lbf ft)
Loctite 270
Front brake pads
Removal
•
Remove the cotter pin.
•
Unscrew and remove the pin.
•
Collect the anti-vibration springs.
•
Extract one pad at a time.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKAGE.
Rear brake pads
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Braking system
CAPONORD 1200
Removal
•
Remove the cotter pin.
•
Remove the pin by sliding it backwards.
•
Extract one pad at a time.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKS.
Bleeding the braking system
VEHICLE PREPARATION
•
It is important to check that there is always enough brake fluid in the reservoir.
•
Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid
replacement" operations are performed.
•
In this case, the bleed process must be accompanied by further pedal strokes and with the
bleed device connected (about 5 for each wheel circuit).
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CAPONORD 1200
Braking system
BLEED SYSTEM AFTER BRAKE PUMP REPLACEMENT
PRELIMINARY OPERATIONS
•
Install the new brake pump.
•
Connect the reservoir to the brake
pump.
•
Connect the brake pipe to the pump
line coupling.
•
Fill the reservoir with new DOT4 brake
fluid.
REGULAR BLEEDING SYSTEM
•
Connect the bleed bottle to the bleed
screw of the front brake calliper.
•
Operate the brake lever.
•
Open the bleed screw until all the pressure has been release and then close
it.
•
Release the brake lever.
•
After releasing the lever, wait two seconds so that the brake fluid flows into
the cylinder.
•
Repeat this procedure until the brake
fluid is clear and has no air bubbles.
(about 10 to 20 times).
NOTE: CHECK BRAKE FLUID LEVEL IN THE
RESERVOIR AND, IF NECESSARY, TOP UP
(CHECKING BRAKE PAD WEAR).
•
Bleed as previously described, also on
the bleed valve installed on the front
brake pump.
•
Then perform the same procedure for
the rear brake calliper, acting only on
the valve installed on that calliper.
•
Fill the reservoir until it reaches the reference "MAX" and refit the cap (check
pad wear).
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Braking system
•
Detach the bleed hoses and close the
bleed screws again to the correct tightening torque.
•
Check the stroke and the sensitivity of
both the lever and the brake pedal.
NOTE: IF AFTER BLEEDING, THE STROKE OF
THE PEDAL OR THE LEVER IS TOO LONG,
CHECK THAT THERE ARE NO LEAKS IN THE
BRAKING SYSTEM AND IF EVERYTHING IS
OK. CONTINUE BLEEDING OPERATIONS USING THE DIAGNOSIS INSTRUMENT.
BRAKE BLEEDING AFTER ABS CONTROL
UNIT REPLACEMENT
VEHICLE PREPARATION
•
Connect the bleed bottle to the bleed
screws of the front and rear callipers
and open it.
•
Fully press down the lever and the
brake pedal and fix them into position
with the respective locking devices.
•
Close the bleed screws of the front and
rear callipers and remove the bleed
bottle.
•
Remove the damaged ABS control
unit.
Note: First of all, detach the brake pipes that
go from the ABS control unit to the brake pump
(1-4) and immediately seal the opened unions
of the ABS control unit with protective caps.
Afterwards, remove pipes (2-3) that go from the
ABS control unit to the brakes and also seal
these unions with protective caps.
•
Install the new ABS control unit, previously filled up.
•
So that the brake fluid remains in the
ABS control unit, first remove the pro-
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CAPONORD 1200
CAPONORD 1200
Braking system
tective caps of the braking circuit unions and connect the respective pipes.
Once all the braking circuits have been connected, remove the protective caps from the
braking pump unions and connect the braking
pump pipes to the ABS control unit.
•
Unlock the lever and the brake pedal.
•
Remove the cap of the reservoir and fill
it with the new DOT 4 brake fluid up to
the reference "MAX".
•
Reinstall the cap.
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS
DESCRIBED AT THE BEGINNING OF THE CHAPTER.
•
Check the stroke and the sensitivity of both the lever and the brake pedal.
•
If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in
the braking system and if everything is OK, continue bleeding operations using the diagnostics instrument as described.
•
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
BRAKE BLEEDING AFTER CALLIPER REPLACEMENT
VEHICLE PREPARATION - The operations are
described for the front system, but they are also valid for both braking systems.
•
Connect the bleed bottles to the bleed
screw of the front calliper and open it.
•
Fully press down the brake lever and
fasten it into position with a locking device so as to avoid fluid flowing out from
the open system.
•
Close the bleed screws of the front calliper and remove the bleed bottle.
•
Replace the damaged calliper with a
new one.
•
Unlock the brake lever.
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Braking system
•
CAPONORD 1200
Remove the cap of the reservoir and fill
it with the new DOT 4 brake fluid up to
the reference "MAX".
•
Reinstall the cap.
BRAKING SYSTEM BLEEDING (only the new
calliper)
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS
DESCRIBED AT THE BEGINNING OF THE CHAPTER.
•
Check the stroke and the sensitivity of both the lever and the brake pedal.
•
If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in
the braking system and if everything is OK, continue bleeding operations using the diagnostics instrument as described.
•
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
BLEEDING SYSTEM WITH DIAGNOSTICS INSTRUMENT
This type of bleeding has to be carried out if after all the checks the brake lever and the pedal
are still spongy.
The operations described here are valid for both systems even though the description refers to
the front system.
FRONT
•
With diagnostics instrument properly connected, select the function "FRONT BRAKE
BLEEDING PROCEDURE".
•
The pump starts rotating.
•
While the pump is performing a rotation cycle, operate and release the front brake lever until
the message diagnostics instrument cycle completion is received.
•
This procedure allows the air to turn and to accumulate.
•
Once the procedure with diagnostics instrument is finished, perform the REGULAR BLEEDING to remove the air from the system completely.
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS DESCRIBED AT THE BEGINNING OF
THE CHAPTER.
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CAPONORD 1200
Braking system
Changing the brake fluid
BRAKE FLUID REPLACEMENT
VEHICLE PREPARATION
•
Connect the bleeding unit to the reservoir of the braking system.
Max. filling pressure to be applied to the system= 3 bar (300 kPa - 43.51 PSI).
PURGING PROCESS TO CHANGE THE BRAKING SYSTEM FLUID
Connect the bleed bottle to the bleed screw of the
front calliper and open it.
•
Operate the bleeding unit and while the
system is being purged, top up the reservoir with the new DOT 4 brake fluid;
keep doing this until clean oil begins to
flow out through the bleed tube.
•
Leave the screw open until the fluid in
the tube is clear and free of air bubbles.
•
Close the bleed screw.
•
Repeat this procedure on the remaining bleed valves of the system and
close them all to the prescribed tightening torque.
•
Remove the bleeding unit.
•
Always fill the reservoir up to the reference "MAX" and refit the cap.
•
Check the stroke and the sensitivity of both the lever and the brake pedal.
•
If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in
the braking system and if everything is OK, continue bleeding operations using the diagnostics instrument as described.
•
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
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CAPONORD 1200
Braking system
Front brake pump
FRONT BRAKE PUMP
pos.
1
Description
Brake pump fixing screws
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Type
M6
Quantity
Torque
2
10 ± 1,5 Nm (7.37 ± 1.10 lb
ft)
Notes
-
CAPONORD 1200
Braking system
Rear brake pump
REAR BRAKE PUMP
pos.
1
Description
Rear brake lever pin
Type
-
2
Microswitch fixing nuts
M6
3
Spring linking pin
M5x7
4
Microclip plate fixing screw
M5X15
5
Brake lever push rod fixing screw
-
Quantity
Torque
1
25 ± 3.75 Nm (18.44 ± 2.76
lb ft)
2
0.4 ± 0.08 Nm (0.29 ± 0.05
lb ft)
1
6 ± 1.2 Nm (4.42 ± 0.88 lb
ft)
1
6 ± 1.2 Nm (4.42 ± 0.88 lb
ft)
1
10 ± 1.5 Nm (7.37 ± 1.10 lb
ft)
Notes
Loctite 243
Loctite 243
Loctite 243
-
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INDEX OF TOPICS
CLUTCH SYSTEM
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CLU SYS
CAPONORD 1200
Clutch system
CLUTCH CONTROL
pos.
1
2
Description
Clutch pump fixing screws
Type
M6
Throttle control fixing screws
M6
Quantity
Torque
2
10 ± 1,5 Nm (7.37 ± 1.10 lb
ft)
3
10 Nm (7.37 lb ft)
Notes
-
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INDEX OF TOPICS
COOLING SYSTEM
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COOL SYS
CAPONORD 1200
Cooling system
Circuit diagram
COOLING SYSTEM
pos.
Description
Electric fan fastener screw
Flanged TE screw fastening left Radiator to trellis
Flanged TE screw fastening expansion tank
1
2
3
Type
M4x45
M6x25
Quantity
6
1
Torque
3 Nm (2.21 lb ft)
10 Nm (7.37 lb ft)
Notes
-
M6x20
3
10 Nm (7.37 lb ft)
-
Electric fan
•
Remove the radiator
•
Tighten the three screws on radiator
front side.
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Cooling system
•
Unscrew and remove the three nuts on
the opposite side, collecting the washers.
•
Remove the electric fan collecting the
spacers.
•
From the front side, collect the screws
and dished washers.
See also
Removing the
radiator
Coolant replacement
•
Remove the right side fairing.
•
Place a container of suitable capacity.
•
Loosen the screw, move the clamp and
slide off the sleeve.
•
Remove the cap.
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CAPONORD 1200
CAPONORD 1200
•
Cooling system
Slide off the sleeve and empty the system completely.
CAUTION
SHOULD GREASE BE NOTED IN THE WATER THIS IS TO
BE CONSIDERED NORMAL BECAUSE DURING THE ASSEMBLY PHASE OF THE WATER PUMP SIGNIFICANT LUBRICATION OF THE SAME IS REQUIRED IN ORDER TO
PREVENT DAMAGE.
Water pump
WATER PUMP
pos.
1
2
3
4
5
6
7
8
Description
Clutch side cover fastener screw
Fastener screw for Pump Cover /
Clutch side cover
Screw fastening Pump Cover /
Clutch Cover / clutch side crankcase
half
Nut fastening water pump drive gear
sprocket
Water pump rotor
Screw fastening chain tensioner slider to water pump
Water pump support fixing screw
Water pump support plug
Type
M6
M6
Quantity
11
3
Torque
13 Nm (9.59 lbf ft)
13 Nm (9.59 lbf ft)
Notes
-
M6
2
13 Nm (9.59 lbf ft)
-
M6
1
12 Nm (8.85 lbf ft)
-
M6
1
1
-
M6
M6x10
3
1
4.50 Nm (3.32 lbf ft)
8-10 Nm (5.90-7.38 lbf
ft)
12 Nm (8.85 lbf ft)
6.5 Nm (4.79 lbf ft)
3M SCOTCH GRIP
2353
COOL SYS - 383
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Cooling system
Removal
COVER REMOVAL
•
Drain off the cooling circuit completely.
•
Unscrew and remove the five water
pump cover fixing screws.
•
Release the clamp.
See also
Coolant replacement
•
Remove the water pump cover.
PUMP ROTOR REMOVAL
•
Remove the water pump cover H20.
•
Unscrew and remove the (anticlockwise) screw
•
Remove the rotor.
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CAPONORD 1200
CAPONORD 1200
Cooling system
COMPLETE H2O PUMP REMOVAL
•
Remove the clutch cover.
•
Unscrew and remove the three H2O
pump fixing screws.
•
Remove the H2O pump and slide off
the drive chain.
NOTE
REPLACE THE O-RINGS ON REASSEMBLY
Removing the radiator
•
Remove the fuel tank.
•
Slide out the connection pin with oil radiator.
•
Drain the fluid from the system.
•
Slacken the clamp on the left side.
•
Slide off the pipe from the thermostatic
valve.
See also
Fuel tank
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Cooling system
Coolant replacement
•
Release the clamp retaining the
breather pipe to radiator.
NOTE
UPON REFITTING, ALWAYS REPLACE WITH A NEW
CLAMP.
•
Operating from the right side, unscrew
and remove the radiator upper screw.
•
Disconnect the left electric fan.
•
Unscrew and remove the three fixing
screws.
•
Remove the expansion tank.
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CAPONORD 1200
CAPONORD 1200
•
Cooling system
Lower radiator and disconnect the right
electric fan.
•
Remove the radiator with the expansion tank.
•
To install the radiator, follow the operations explained above but in reverse order, and replace all the clamps removed.
•
Restore the correct coolant level.
Thermostatic valve
Traditional circuit, three-way thermostatic valve:
1. Hot water inlet from the heads.
2. Outlet towards the short circuit (direct to the
pump).
3. Outlet towards the radiator
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INDEX OF TOPICS
BODYWORK
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BODYW
CAPONORD 1200
Bodywork
TOP FAIRING_WINDSHIELD
Pos.
1
2
Description
Windshield on support fastener
screw
Bracket retainer screw
Type
M6x18
Quantity
4
Torque
10 Nm (7.37 lb ft)
Notes
-
M6x25
4
10 Nm (7.37 lb ft)
-
Quantity
2
Torque
6 Nm (4.42 lb ft)
Notes
-
FRONT FAIRING
Pos.
1
Description
Deflector fixing screw
Type
M5x12
BODYW - 389
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CAPONORD 1200
Bodywork
Pos.
Description
Deflector fixing screw
2
Type
M5x16
Quantity
2
Torque
6 Nm (4.42 lb ft)
Notes
-
Torque
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
2 Nm (1.47 lb ft)
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
10 Nm (7.37 lb ft)
6 Nm (4,42 lb ft)
Tighten by hand
Notes
Loct. 243
MUDGUARD_LUG
Pos.
1
2
3
4
5
6
7
8
9
Description
Lug fixing screw
Control unit support fixing screw
Front with rear lug fixing screw
Front mudguard fixing screw
Control unit support fixing screw
Lug on support fastener screw
Control unit support fixing screw
Lug on support fastener screw
Spacer TCEI screw
BODYW - 390
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Type
M6x20
M6x35
3.9x14
M6x20
M6x12
M6x25
M5
M8
Quantity
2
1
2
4
1
2
2
2
1
CAPONORD 1200
Bodywork
TANK COVER
Pos.
1
Description
Covers fastening screws
Type
M5x9
Quantity
Torque
4
3 ± 0.60 Nm (2.21 ± 0.44 lb
ft)
Notes
-
SIDE FAIRINGS
Pos.
1
Description
Fairing fastener screw
Type
M5x9
Quantity
2
Torque
6 Nm (4.42 lb ft)
Notes
-
BODYW - 391
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CAPONORD 1200
Bodywork
Pos.
2
Description
Fairing fastener screw
Type
M5x16
Quantity
4
Torque
6 Nm (4.42 lb ft)
Notes
-
Quantity
1
Torque
6 Nm (4.42 lb ft)
Notes
-
SADDLE
Pos.
1
Description
Saddle fixing screw
BODYW - 392
Downloaded from www.Manualslib.com manuals search engine
Type
M5x12
CAPONORD 1200
Bodywork
HELMET COMPARTMENT
Pos.
1
2
Description
Covers fastener screw
Compartment fixing screw
Type
M5x20
M5x12
Quantity
8
2
Torque
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
Notes
-
Torque
2 Nm (1.47 lb ft)
25 Nm (18.44 lb ft)
25 Nm (18.44 lb ft)
3 Nm (2.21 lb ft)
Notes
-
LUGGAGE RACK
Pos.
1
2
3
4
Description
Luggage rack screw
Luggage rack cover screw
Luggage rack fastener screw
Luggage rack screw
Type
3.9x14
M8x20
M8x25
5x14
Quantity
2
2
3
5
BODYW - 393
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
REAR BODYWORK
Pos.
1
2
3
Description
Tail fairing fastener screw
Panniers connection fixing screw
License plate holder fastener screw
BODYW - 394
Downloaded from www.Manualslib.com manuals search engine
Type
M5x12
M6
Quantity
6
4
3
Torque
6 Nm (4.42 lb ft)
10 Nm (7.37 lb ft)
Notes
-
CAPONORD 1200
Bodywork
REAR MUDGUARD
Pos.
1
Description
Mudguard fixing screws on wheel adjustment
Type
-
Quantity
1
Torque
10 ± 2 Nm (7.37 ± 1.47 lb
ft)
Notes
Loctite 243
Torque
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
6 Nm (4.42 lb ft)
Notes
-
REAR LIGHTS
Pos.
1
2
3
Description
Turn indicator fixing screw
Taillight screw
License plate light nut
Type
M5x16
M5x16
M5
Quantity
2
2
1
BODYW - 395
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
LOCKS
Pos.
Description
Switch fastener
1
2
TE screw fastening saddle lock / battery compartment to saddle mounting
BODYW - 396
Downloaded from www.Manualslib.com manuals search engine
Type
shear head
screw
M6x25
Quantity
1
Torque
Manual
Notes
-
2
10 Nm (7.37 lb ft)
To reuse: Loctite
243
CAPONORD 1200
Bodywork
FOOTRESTS
Pos.
1
2
3
4
5
Description
Upper screw fastening passenger
footrests to frame side panels
Lower TCEI screw fastening passenger footrests to rider footrest mounting
TCEI screw fastening rider footrest
mounting to frame
Footrest rubber fastener narrow nut
TCEI screw fastening rider footrest
mounting
Type
M8x35
Quantity
2
Torque
25 Nm (18.44 lb ft)
Notes
Loct. 243
M8x35
2
25 Nm (18.44 lb ft)
Loct. 243
M8x35
4
30 Nm (22.12 lb ft)
Loct. 243
M5
M6x16
4
6
6 Nm (4.42 lb ft)
10 Nm (7.37 lb ft)
-
Type
M5x20
Quantity
10
Torque
3 Nm (2.21 lb ft)
Notes
-
M5x20
2
3 Nm (2.21 lb ft)
-
AIR FILTER BOX
Pos.
1
2
Description
Cross head self-tapping screw fastening covers / filter box
Cross head self-tapping screw fastening blow-by tank
BODYW - 397
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
FUEL TANK
Pos.
1
Description
Plastic ring nut
Type
-
2
Level indicator fixing screws
M6x16
3
Saddle fixing
M5
BODYW - 398
Downloaded from www.Manualslib.com manuals search engine
Quantity
Torque
1
20 ± 3 Nm (14.75 ± 2.21 lb
ft)
4
3 ± 0.45 Nm (2.21 ± 0.33 lb
ft)
1
3 ± 0.45 Nm (2.21 ± 0.33 lb
ft)
Notes
-
CAPONORD 1200
Bodywork
TANK COVER
Pos.
1
Description
Covers fastening screws
Type
M5x9
Pos.
1
Description
Instrument panel to trellis fixing screws
Quantity
Torque
4
3 ± 0.60 Nm (2.21 ± 0.44 lb
ft)
Notes
-
INSTRUMENT SUPPORT
Type
M8x25
Quantity
Torque
4
25 ± 5 Nm (18.43 ± 3.68 lb
ft)
Notes
-
Seat
•
Insert the key in the lock located on the
left fairing.
•
Turn the key clockwise.
•
Remove the rear saddle.
BODYW - 399
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Unscrew and remove the front saddle
fixing screw.
•
Remove the front saddle.
Instrument panel
•
Loosen the two fastening screws.
•
Remove the dashboard upper cover.
BODYW - 400
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CAPONORD 1200
•
Bodywork
Remove the two screws fastening the
lower cover of the dashboard.
•
Remove the cover.
•
Disconnect the connector.
•
Remove the instrument panel.
Headlight assy.
•
The following procedure refers to one
single part of the dashboard, but is valid for both.
•
Unscrew and remove the two lower
screws of the left dashboard.
BODYW - 401
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CAPONORD 1200
Bodywork
•
Unscrew and remove the upper screw
of the left dashboard.
•
Remove the dashboard.
•
Unscrew and remove the two fixing
screws of the central dashboard.
•
Unscrew and remove the screw in the
lower part of the light unit.
•
Remove the headlight assembly.
•
Unscrew and remove the light unit upper fixing screw.
BODYW - 402
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
•
Bodywork
Undo and remove the light unit lower
screw.
•
Unscrew and remove the screw in the
lower part of the light unit.
•
Remove the headlight assembly.
Taillight assy.
•
Remove the tail fairing and license
plate holder first.
•
Unscrew and remove the two fixing
screws.
•
Disconnect the connector, then remove the rear light unit.
See also
Tail guard
License plate holder
BODYW - 403
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
Footrest
RIGHT FOOTREST
•
Unscrew and remove the upper screw
(1).
•
Unscrew and remove the two outer
screws (2).
•
Remove the right footrest
•
Unscrew and remove both rear brake
pump internal fixing screws.
LEFT FOOTREST
•
Unscrew and remove the two external
screws.
•
Loosen the gear shift lever rod screw.
•
Slide off the gear shift lever rod.
•
Remove the left footrest.
BODYW - 404
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CAPONORD 1200
Bodywork
Side fairings
•
The following procedure refers to one
single fairing, but is valid for both.
•
Remove the rear expansion cap.
•
Remove the front expansion cap.
•
Release the fairing from its fasteners.
BODYW - 405
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Remove the fairing.
•
For the left side fairing, the cable of the
saddle lock must be removed.
License plate holder
•
Unscrew and remove the two fixing
screws.
•
Remove the access cap, unscrew and
remove the lower mounting screw.
BODYW - 406
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
•
Bodywork
Disconnect the connectors and remove the license plate support.
Air box
•
Remove the air filter box cover.
•
Remove the four screws.
•
Remove the two intake ducts.
See also
Air filter
BODYW - 407
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Cut the ties.
•
Disconnect the air temperature sensor.
•
Remove the two clamps from the blowby system.
•
Remove the air filter box.
BODYW - 408
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
Splash guard
•
Operating from both sides, unscrew
and remove the four fixing screws.
•
Remove the rear splash guard.
Fuel tank
Before accessing the tank (1), the side covers (2),
the central cover (3) and the tank cap (4) must be
removed.
BODYW - 409
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Unscrew and remove the rear fixing
screw.
•
Unscrew and remove the front fixing
screw.
•
Remove the three expansion caps on
the inside of the fairing.
BODYW - 410
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CAPONORD 1200
•
Bodywork
Remove the internal upper expansion
cap.
•
Undo and remove the front screw.
•
Remove the expansion cap placed on
the side part of the fairing, near the turn
indicator.
•
Disconnect the turn indicator connector.
•
Remove the side plastic.
BODYW - 411
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Undo and remove the six fixing screws
of the central cover of the tank.
•
Unscrew and remove the four fixing
screws of the tank cap.
•
Remove the tank cap.
•
Remove the tank central cover.
BODYW - 412
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CAPONORD 1200
•
Bodywork
Undo and remove the two mounting
fixing screws.
•
Disconnect the level sensor.
•
Working from both sides, disconnect
both breather pipes.
BODYW - 413
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Unscrew and remove the two fixing
screws that connect the tank to the underfairing.
•
Disconnect the fuel pump connector.
•
Disconnect the fuel pipe from the
pump.
•
Remove the tank.
•
Remove the lock and turn the key an-
Rear
ticlockwise.
BODYW - 414
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CAPONORD 1200
•
Remove the case.
•
Repeat the operation for the case on
Bodywork
the opposite side.
Rear grab rail
•
Remove the plastic that covers the
handgrip central fixing screw.
•
Unscrew and remove the five rear fixing screws.
BODYW - 415
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CAPONORD 1200
Bodywork
•
Unscrew and remove the two front fixing screws.
•
Unscrew and remove the two central
fixing screws.
•
Disconnect the saddle lock by undoing
the two screws.
•
Remove the handgrip.
BODYW - 416
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CAPONORD 1200
Bodywork
Windscreen
•
Unscrew and remove the four fixing
screws of the top fairing.
•
Remove the windshield.
Instrument cluster support
•
Undo and remove the two instrument
panel support fixing screws.
•
Remove the instrument panel paying
attention to the cable harness.
•
Undo and remove the two shells fixing
screws of the instrument support.
•
Disconnect the connectors.
BODYW - 417
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CAPONORD 1200
Bodywork
Radiator cover
•
Undo and remove the three fixing
screws of the expansion tank.
•
Remove the expansion tank.
•
Unscrew and remove the screw indicated in the figure.
•
Disconnect the connector of the ADD
management control unit
•
Unscrew and remove the two ADD
control unit fixing screws.
•
Remove the control unit.
BODYW - 418
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
•
Disconnect the indicated connector.
•
Unscrew and remove the left fairing lug
Bodywork
fixing screw.
•
Unscrew and remove the left fairing lug
rear fixing screw.
•
Unscrew and remove the front fairing
lug fixing screw.
BODYW - 419
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CAPONORD 1200
Bodywork
•
Remove the left fairing lug.
•
Unscrew and remove the two right fairing lug fixing screws.
•
Remove the right fairing lug.
•
Undo and remove the two upper fixing
screws of the right duct bulkhead.
BODYW - 420
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CAPONORD 1200
•
Bodywork
Unscrew and remove the lower fixing
screw of the right duct bulkhead.
•
Remove the right duct bulkhead.
•
Undo and remove the fairing lug lower
screw.
•
Unscrew and remove the fixing screw
of the left part of the fairing lug.
BODYW - 421
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Undo and remove the fixing screw of
the oil radiator support.
•
Undo and remove the fairing lug lower
screw.
•
Undo the two upper fixing screws of the
fairing lug.
•
Undo the radiator fixing screw.
BODYW - 422
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CAPONORD 1200
•
Undo and remove the stud bolt.
•
Disconnect the radiator pipe.
•
Remove the expansion caps.
•
Separate the two radiators and remove
Bodywork
the radiator protection.
BODYW - 423
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CAPONORD 1200
Bodywork
Battery
•
Undo and remove the four fixing
screws of the battery cover.
•
Remove the battery cover.
•
Disconnect the battery and remove it.
BODYW - 424
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CAPONORD 1200
Bodywork
Tail guard
•
Remove the side panniers support by
unscrewing the two fastening screws.
•
Remove the two expansion caps.
•
Undo and remove the six fixing screws
(1).
BODYW - 425
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Remove the rear handgrip and the license plate support.
•
Remove the tail fairing.
See also
Rear grab rail
License plate holder
Side air deflectors
•
Undo and remove the upper screw.
•
Unscrew and remove the front screw
placed near the radiator.
BODYW - 426
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
•
Unscrew and remove the rear screw.
•
Remove the duct.
Bodywork
INSIDE FAIRING
The following procedure refers to one single fairing, but is valid for both.
•
Cut and remove the clamp.
•
Remove the relay indicated in the figure.
BODYW - 427
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
Bodywork
•
Disconnect the voltage regulator.
•
Cut and remove the clamp.
•
Release the cables.
BODYW - 428
Downloaded from www.Manualslib.com manuals search engine
CAPONORD 1200
•
Remove the relay box.
•
Cut and remove the clamp.
•
Remove the inside fairing.
Bodywork
BODYW - 429
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INDEX OF TOPICS
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PRE-DELIVERY
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PRE DE
Pre-delivery
CAPONORD 1200
Carry out the listed checks before delivering the motorcycle.
WARNING
HANDLE FUEL WITH CARE.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection
- Safety fasteners:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 432
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CAPONORD 1200
Pre-delivery
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
PRE DE - 433
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Pre-delivery
CAPONORD 1200
- Response to throttle control
- Stability when accelerating and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
Static test
Static check after test drive:
- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system
- Stroke of brake and clutch levers (if present)
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Specific operations for the vehicle
HAND GUARDS
PRE DE - 434
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CAPONORD 1200
•
Pre-delivery
Remove the TCEI M6 X 50 screw
which fastens the antivibration weight.
•
Fit the rubber ring in the hand guards.
•
Position and fasten the top screw ensuring to insert the bushing between
the hand guard and the handlebar fastening point.
PRE DE - 435
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CAPONORD 1200
Pre-delivery
•
Place the hand guards fastening them
on the sides using TCEI M6 X 50 screw
being careful when inserting the bushing.
PRE DE - 436
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A
ABS: 187, 354, 362
Air filter: 69, 407
Air temperature sensor: 129
B
Battery: 91, 110, 424
Brake: 171, 368, 369, 375–377
Brake calliper: 368, 369
Brake fluid: 375
Brake pads: 369
Brake pump: 376, 377
Bulbs:
Bushings:
C
CAN line: 188
Catalytic converter: 348
Centre stand: 345
Chain: 14, 261, 342
Chain tensioner: 261
Clutch: 217, 227, 229, 230, 234–237, 240, 246, 275, 288, 293, 379
Coil: 141
Connecting rods:
Connectors: 179
coolant: 382, 384, 386
Coolant: 382, 384, 386
Crankcase: 49, 214, 247, 254, 273, 274, 278, 282
Crankshaft: 49, 273, 277, 280, 281
Cylinder: 49, 264, 266, 267, 269, 272, 276
D
Diagnostics: 362
Drive chain: 14, 342
E
ECU: 182, 362
Electric fan: 161, 381
Electrical system: 14, 76, 432
Engine oil: 67, 197, 351
Engine temperature sensor: 127
Exhaust: 163, 347, 349
Exhaust manifold: 349
F
Fairings: 405
Filter box:
Fork: 301, 303, 304, 314
Front head: 243, 246, 249, 265
Front wheel: 297, 299
Fuel: 66, 139, 197, 295, 385, 409
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Fuel pump: 139, 295
Fuses: 96
G
Gearbox selector: 219
H
Handlebar: 300
Head cover: 71, 242, 243, 250
Headlight: 401
Helmet compartment:
I
Identification: 12
Instrument panel: 400
Intake pressure sensor: 122
L
License plate holder: 403, 406, 426
Luggage rack:
M
Magneto flywheel: 223, 225, 253, 275
Maintenance: 9, 63
Maintenance Table:
Mudguard:
O
Oil filter: 68
Oil pressure sensor: 156
R
Radiator: 197, 382, 385, 418
Rear head: 249, 252, 256, 265
Rear wheel: 329, 331, 342
Recommended products: 54
Run/Stop switch: 162
S
Saddle:
Shock absorbers: 333
Side fairings: 405
Side stand: 158, 346
Side stand sensor: 158
Spark plug: 64
Spark plugs:
Speed sensor: 111
Stand: 158, 344–346
Start-up: 94
Starter motor: 219, 220
T
Tank: 66, 197, 385, 409
Throttle body: 145
Transmission: 13
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Tyres: 15
W
Warning lights:
Water pump: 383
Wiring diagram: 79
Downloaded from www.Manualslib.com manuals search engine
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