APRILIA DORSODURO FACTORY ABS 2011 Leitfaden

SERVICE STATION MANUAL

898998

DORSODURO FACTORY ABS

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

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SERVICE STATION

MANUAL

DORSODURO FACTORY ABS

THE VALUE OF SERVICE

Due to the continuous technical updates and specific mechanic training programs for Aprilia products,

only Aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to

carry out maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its

regular maintenance and using only Original Aprilia Spare Parts are essential!

For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or

search directly from the map on our Official Website:

www.aprilia.com

Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were

developed and tested together with the actual vehicle itself. All Aprilia Original Spare Parts undergo

quality control procedures to guarantee reliability and durability.

The descriptions and illustrations given in this publication are not binding; While the basic characteristics

as described and illustrated in this booklet remain unchanged, Aprilia reserves the right, at any time and

without being required to update this publication beforehand, to make any changes to components, parts

or accessories, which it considers necessary to improve the product or which are required for

manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all Countries. The availability of

individual versions/models should be confirmed with the official Aprilia sales network.

prohibited. Aprilia - After-sales service.

Aprilia trademark is property of Piaggio & C. S.p.A.

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

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SERVICE STATION MANUAL

DORSODURO FACTORY ABS

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, Piaggio & C. S.p.a. commits itself

to continually improve its products and the relative documentation. The main technical modifications and

changes in repair procedures are communicated to all 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 Sectionsmarkedwiththis symbol indicate the correct use of the vehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: [email protected]

INDEX OF TOPICS

CHARACTERISTICS CHAR

SPECIAL TOOLS S-TOOLS

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

POWER SUPPLY P SUPP

SUSPENSIONS SUSP

CHASSIS CHAS

BRAKING SYSTEM BRAK SYS

CLUTCH SYSTEM CLU SYS

COOLING SYSTEM COOL SYS

BODYWORK BODYW

PRE-DELIVERY PRE DE

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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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

EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE

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 VA-

POURS, 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 COMPO-

NENTS; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING

OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN

THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC-

TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES-

SIBLE TO ANIMALS AS THEY MAY DRINK IT.

Characteristics DORSODURO FACTORY ABS

CHAR - 8

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KEEP OUT OF THE REACH OF CHILDREN

DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS

UNDER PRESSURE AND MAY CAUSE BURNS.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.

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 COM-

PONENTS 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 YOUR EYES, RINSE THEM IMMEDI-

ATELY 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

AMOUNTSOFBATTERYACID MAY CAUSEBLINDNESS.IFTHE FLUID GETSINCONTACTWITH

YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE

SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE

QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL

AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES;

KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. EN-

SURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

KEEP OUT OF THE REACH OF CHILDREN

BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC

COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-

TERY TO BE ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

DORSODURO FACTORY ABS Characteristics

CHAR - 9

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When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.

BEFORE DISASSEMBLING COMPONENTS

•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

•Donotloosenand/or tighten screws and nuts using pliers or any other tools than the specific

wrench.

•Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and

identify them with different distinctive symbols.

•Each component needs to be clearly marked to enable identification during reassembly.

•Clean and wash the dismantled components carefully using a low-flammability detergent.

•Keep mated parts together since they have "adjusted" to each other due to normal wear.

•Some components must be used together or replaced altogether.

•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.

•Whentightening nutsandscrews, starteitherfrom thecomponentswith thelargestdiameter

or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-

cessive 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).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure

causes irreparable damage to both the connector and the wiring harness:

Press the relative safety clips, if applicable.

Characteristics DORSODURO FACTORY ABS

CHAR - 10

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: [email protected]

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