Rev. 1.10

11-2009

___________________________________________

BIMOTA DB7
WORKSHOP MANUAL
2008 BIMOTA SPA
All rights reserved
The reproduction, in whole or part, of the topics coveredin this publication, is forbidden: all rights are reserved to
Bimota to which will require (written) authorization
specifying the reasons.
BimotaI

MANUAL PURPOSE – WARNINGSThis manual has been written by Bimota SpA primarily intended for use by dealers Bimota and theirskilled mechanics.
Describes the service procedures for maintenance, repair and replacement of original parts of the
motorcycle in question.
The technicians, that this manual is intended to, must have the adequate experience andcompetence: some information has been deliberately omitted, because they have to be part of theindispensable basics that a technician must have.
The technicians in the use phase of the manual must comply with the original technicalspecifications given by the original manufacturer.
Bimota assumes no responsibility for errors or omissions of technical nature, produced in thewriting of this manual.
All the information provided shall be updated at the time of printing, Bimota pursues a policy ofcontinuous research and development, therefore, reserves the right to make changes of its
products without prior notice and without obligation to make the same changes to products alreadysold.
The modifications or significant changes made to the specifications or procedures will be reported
to all Bimota authorized dealers and, where possible, will be included in subsequent editions of thismanual.

SYMBOLS

All indications right or left refer to the direction of travel of motorcycle.
CAUTIONThe non-compliance with the instructions may create a situation of danger and cause serious
personal injury and even the death of the pilot, persons in the proximity, or person intent to repair
the bike.
IMPORTANT
Indicates the possibility of damage to the vehicle and/or its components if the instructions are not
performed.
NOTES
provides useful information on the current operation.

IIUSE OF THE MANUALThis manual is an easy guide for technicians. All the procedures indicated in the manual areillustrated in a detailed way and regards the operations of disassembly, assembly, inspection andrepair.
1) The manual is divided in chapters. The name and the relative number, placed in a frameon the right upper corner of each page, indicating the current chapter.
2) Each chapter is divided in sections. In the left upper part of each page is reported the title ofthe current section, written in capital letters.
3) Paragraph title, written in small letters respect to the section title.
4) At the beginning of some sections, to make the procedures of disassembly more clear andto help the identification of the bike components, are reported the exploded drawings. It is
possible to identify by number the related piece.
5) The exploded drawing is accompanied by a list with the piece name and relative
characteristics.
6) The instructions for the disassembly/assembly operations are described in sequence.
7) Some operations are accompanied by symbols with the purpose to supply more information
and/or possible danger situation for the pilot or motorcycle.

1
2
4

7

3

________________________ ENGINE 11________________________ ENGINE 11

11.8 - HEAD UNIT: TIMING SYSTEM

Dismantling of timing system countershaft pulleys
Lock with the tool cod. 88713.1805 the rotation of the motive pulleys on the motor carter.
ATTENTION
In the event that the operation is carried out with the engine in frame, lock the rotation of
the motive pulleys using the tool cod. 88713.2011 mounted on the alternator cover.
Loosen the locknut (15) using the bush that came with tool.

5
6
Remove the locknut (15), the spacer (20), and the external pulley (18).

1) External cover vertical belt
2) Air filter
3) External cover horizontal belt
4) Screw5) Filter cover6) Screw
7) Washer8) Lock nut9) Complete mobile turnbuckle10) Oil seal
11) Distribution pulley12) Tightener pivot
13) Complete fixed turnbuckle
14) Distribution toothed belts15) Ring nut16) Tongue17) Spacer18) Distribution pulley19) Pulley washer split20) Spacer21) Ring nut22) Screw23) Washer24) Flange spacer

Remove the first tongue (16) on the trip shaft of timing system.
Remove the washer split (19) and the internal pulley (18).

III

INDEX
GENERAL INFORMATIONS1TECHNICAL SPECIFICATIONS

2USE AND MAINTENANCE

3

BODYWORK

4CONTROLS AND DEVICES

5WHEELS-BRAKES-SUSPENSIONS

6

FRAME

7

EXHAUST - INTAKE

8IVINJECTION - IGNITION

9ELECTRICAL SYSTEM

10V

Table of contents
MANUAL PURPOSE – WARNINGSSYMBOLS
USE OF THE MANUAL
INDEX

II
II
III
IV

CHAPTER 1
GENERAL INFORMATIONS
1.1 - IDENTIFICATION OF THE MOTORCYCLE
Sub 1-2
Punching of the frame (European version) ..................................................................Sub 1-2
Punching of the frame (United States version)..............................................................Sub 1-2
Punching of the engine (European / united states version)..........................................Sub 1-3
Frame tag.....................................................................................................................Sub 1-3
1.2 - PRODUCTS SPECIFICATIONS
Sub 1-4
1.3 - HAZARDOUS PRODUCTS / WARNINGS
Sub 1-5

CHAPTER 2
TECHNICAL SPECIFICATIONS
2.1 -TECHNICAL DATA
Sub 2-2
Colors............................................................................................................................Sub 2-2
Particulars.....................................................................................................................Sub 2-2
Engine.......................................................................................................................... Sub 2-2
Drive………...................................................................................................................Sub 2-3
Drive system ................................................................................................................Sub 2-3
Timing system / valves..................................................................................................Sub 2-3
Tension belts adjustment at cold…...............................................................................Sub 2-4
Engine shaft..................................................................................................................Sub 2-4
Cylinder / piston............................................................................................................Sub 2-5
Gearbox........................................................................................................................Sub 2-5
Cooling system.............................................................................................................Sub 2-6
Front wheel...................................................................................................................Sub 2-6
Front suspension..........................................................................................................Sub 2-6
Rear wheel................................................................................................................... Sub 2-7
Final drive.....................................................................................................................Sub 2-7
Rear suspension...........................................................................................................Sub 2-7
Hydraulic brakes...........................................................................................................Sub 2-8
Charging system / alternator.........................................................................................Sub 2-8
Injection system / ignition............................................................................................. Sub 2-9
Intake............................................................................................................................Sub 2-9
Feeding system............................................................................................................Sub 2-9
Lights / dash.................................................................................................................Sub 2-9VI

2.2 - SIZE
Sub 2-10
2.3 - LUBRICANTS AND REFUELINGSub 2-11
2.4 - TORQUE WRENCH SETTINGS
Sub 2-12
Frame torque wrench settings......................................................................................Sub 2-12
Engine torque wrench settings.....................................................................................Sub 2-18
2.5 - SERVICE TOOLSSub 2-21
Specific equipment for engine......................................................................................Sub 2-21
Specific equipment for frame........................................................................................Sub 2-25

CHAPTER 3
USE AND MAINTENANCE
3.1 - PRELIMINARY CHECKS
Sub 3-3
Running-in period........................................................................................................ Sub 3-3
Check-up before run.....................................................................................................Sub 3-4
3.2 - STARTING - ENGINE WARM UP
Sub 3-5
3.3 - TABLE OF PERIODIC MAINTENANCE
Sub 3-6
Dealer operations.........................................................................................................Sub 3-6
Customer operations....................................................................................................Sub 3-7
3.4 - MAINTENANCE OPERATIONS
Sub 3-8
Motor oil level control....................................................................................................Sub 3-8
Motor oil and filter cartridge replacement.....................................................................Sub 3-9
Valves clearance check-up.........................................................................................Sub 3-12
Valves clearance adjustment......................................................................................Sub 3-13
Liquid cooling level control.........................................................................................Sub 3-14
Liquid cooling replacement........................................................................................Sub 3-15
Air filters replacement and cleaning...........................................................................Sub 3-16
Front brake fluid replacement.....................................................................................Sub 3-19
Rear brake fluid replacement.....................................................................................Sub 3-20
Brake circuit bleeding ................................................................................................Sub 3-22
Brake circuit filling......................................................................................................Sub 3-24
Clutch liquid replacement...........................................................................................Sub 3-27
Clutch liquid draining..................................................................................................Sub 3-28
Clutch liquid filling.......................................................................................................Sub 3-30
Steering stem bearings clearance adjustment............................................................Sub 3-32
Chain tension adjustment...........................................................................................Sub 3-34
Brake pads wear check-up and replacement.............................................................Sub 3-36
Front brake pads check-up.........................................................................................Sub 3-36
Filling up brake fluid....................................................................................................Sub 3-37
Rear brake pads check-up..........................................................................................Sub 3-37
Throttle cable regulation..............................................................................................Sub 3-39
Clutch lever and front brake lever adjustment............................................................Sub 3-40
Rear brake pedal and shift lever position adjustment.................................................Sub 3-41
Fork adjustment..........................................................................................................Sub 3-42
Rear shock adjustment...............................................................................................Sub 3-44
Steering damper..........................................................................................................Sub 3-46
Rear height regulation / bike trim................................................................................Sub 3-47

VII

3.5 - DIAGNOSTIC INSTRUMENTS
Sub 3-48
3.5.1 - Walbro diagnosis.............................................................................................. Sub 3-48
3.6 - Software installation.............................................................................................Sub 3-49
3.6.1 - Installation of diagnosis software Service OEM 564.........................................Sub 3-49
3.6.2 - USB drivers installation.....................................................................................Sub 3-49
3.7 - Vehicle connection for diagnostic.........................................................................Sub 3-49
3.7.1 - Diagnostic software...........................................................................................Sub 3-52
3.7.2 - Real time parameter view..................................................................................Sub 3-55
3.7.3 - Diagnosis...........................................................................................................Sub 3-56
3.7.4 - End of line..........................................................................................................Sub 3-57
3.7.5 - Hour meter.........................................................................................................Sub 3-58
3.8 - Installation of Windownloader OEM 2000 program (use for ECUC).....................Sub 3-58
3.8.1 - Calibration update program...............................................................................Sub 3-59
3.9 - Installation of EcugLoader-1000 program (use for ECUG)...................................Sub 3-61
3.9.1 - Calibration update program...............................................................................Sub 3-61

CHAPTER 4
BODYWORK
4.1 - WINDSHIELD AND REARVIEW MIRRORS
Sub 4-2
Rearview mirrors dismantling……………….………………………………………………Sub 4-2
4.2 - FAIRING
Sub 4-4
Disassembly of side fairing and lower fairing……..………………………………….….Sub 4-4
4.3 - FRONT FENDER
Sub 4-6
Front fender dismantling…………………………………………………………………….Sub 4-6
4.4 - TAIL - SEATSub 4-7
Tail dismantling……………………………………………………………………………….Sub 4-7
Seat dismantling….……….………………………………………………………………….Sub 4-8
4.5 - LICENSE PLATE HOLDER – REAR FENDER
Sub 4-9
Dismantling of license plate holder……………....…………………………………….….Sub 4-9
Rear fender dismantling…………………………………..……………………………….Sub 4-10
4.6 - REAR FENDER – CHAIN GUARD
Sub 4-11

CHAPTER 5
CONTROLS AND DEVICES
5.1 - THROTTLE CONTROL
Sub 5-2
Twist throttle dismantling…….......………….………………………………………………Sub 5-3
5.2 - FRONT BRAKE CONTROL
Sub 5-4
Disassembly of front brake master cylinder……………..…..……..………………….….Sub 5-5
5.2 - REAR BRAKE CONTROL
Sub 5-6
Rear brake dismantling…………..………………………………………………………….Sub 5-7
5.4 - HYDRAULIC CLUTCH CONTROL
Sub 5-9
Disassembly of hydraulic clutch pump…………….……..…..……..………………….….Sub 5-5
5-5 – SHIFT CONTROL
Sub 5-11
Complete shift lever dismantling..........………....…………………………………….….Sub 5-12

VIII

CHAPTER 6WHEELS – BRAKES – SUSPENSIONS
6.1 - FRONT WHEEL
Sub 6-2
Front wheel dismantling.............................................................................................. Sub 6-3
6.2 – FRONT FORKS
Sub 6-5
Forks disassembly.......................................................................................................Sub 6-6
6.3 – FRONT BRAKE
Sub 6-8
Front brake disassembly..............................................................................................Sub 6-9
Dual discs dismantling..............................................................................................Sub 6-11
6.4 – REAR WHEEL AND SECONDARY DRIVE
Sub 6-12
Rear wheel dismantling.............................................................................................Sub 6-13
Secondary drive check-up.........................................................................................Sub 6-14
Chain washing...........................................................................................................Sub 6-14
Chain lubrication........................................................................................................Sub 6-14
Front sprocket dismantling........................................................................................Sub 6-15
Rear sprocket dismantling.........................................................................................Sub 6-16
Rear wheel check-up.................................................................................................Sub 6-16
6.5 - SWING ARM
Sub 6-18
Swing arm disassembly.............................................................................................Sub 6-19
6.6 - REAR BRAKE
Sub 6-22
Disassembly of rear brake caliper..............................................................................Sub 6-23
Speed sensor dismantling..........................................................................................Sub 6-24
Rear disc dismantling ...............................................................................................Sub 6-24
6.7 - REAR SHOCK
Sub 6-25
Rear shock dismantling.............................................................................................Sub 6-26
Rocker arm dismantling.............................................................................................Sub 6-27

CHAPTER 7
FRAME
7.1 - HANDLEBAR
Sub 7-2
Handlebar dismantling................................................................................................ Sub 7-3
7.2 - STEERING
Sub 7-5
Steering stem bearings clearance adjustment.............................................................Sub 7-6
Disassembly of steering components..........................................................................Sub 7-6
7.3 - STEERING DAMPER
Sub 7-8
Steering damper dismantling.......................................................................................Sub 7-9
7.4 - FOOT PEGS
Sub 7-10
Foot pegs support dismantling..................................................................................Sub 7-11
7.5 - KICKSTAND
Sub 7-13
Kickstand dismantling............................................................................................... Sub 7-14
Kickstand disassembling.......................................................................................... Sub 7-14
7.1- FRAME AND CHASSIS PLATES
Sub 7-16
Frame and structural parts dismantling.................................................................... Sub 7-17
Upper fairing support dismantling............................................................................ Sub 7-17
Frame dismantling................................................................................................... Sub 7-18
IX

7.7 - TAIL
7.8 - LICENSE PLATE HOLDER

Sub 7-19
Sub 7-20

CHAPTER 8
EXHAUST – INTAKE
8.1 - EXHAUST
Sub 8-2
Exhaust dismantling................................................................................................... Sub 8-3
8.2 - FUEL TANK
Sub 8-7
Fuel tank dismantling..................................................................................................Sub 8-8
Fuel tank reassembling..............................................................................................Sub 8-8
Fuel pump dismantling...............................................................................................Sub 8-9
Gas cap dismantling...................................................................................................Sub 8-9
8.3 - THROTTLE BODY
Sub 8-10
Airbox and throttle body dismantling.........................................................................Sub 8-11
Injectors dismantling.................................................................................................Sub 8-13
Stepper motor dismantling........................................................................................Sub 8-15
Airbox disassembling - throttle body.........................................................................Sub 8-16
8,4 - INTAKE - AIRBOX
Sub 8-17

CHAPTER 9
INJECTION – IGNITION
9.1 – SYSTEM COMPONENTS
Sub 9-2
Electronic control system........................................................................................... Sub 9-2
Battery support.......................................................................................................... Sub 9-3
Battery support dismantling....................................................................................... Sub 9-4
Electro-injector........................................................................................................... Sub 9-6
Stepper motor.............................................................................................................Sub 9-7
Air pressure sensor....................................................................................................Sub 9-8
Coolant temperature sensor.......................................................................................Sub 9-8
Coolant temperature dash..........................................................................................Sub 9-9
Air temperature dash..................................................................................................Sub 9-9
Air temperature engine sensor.................................................................................Sub 9-10
Ignition coils.............................................................................................................Sub 9-10
Coils check-up.........................................................................................................Sub 9-11
Spark plugs..............................................................................................................Sub 9-11
Throttle valve position potentiometer.......................................................................Sub 9-12
R.p.m. Sensor / stroke.............................................................................................Sub 9-12
Injection relay..........................................................................................................Sub 9-13

X

CHAPTER 10
ELECTRICAL SYSTEM
10.1 - WIRING DIAGRAM
Sub 10-2
Utilities wiring diagram.............................................................................................. Sub 10-2
Injection wiring diagram............................................................................................ Sub 10-3
10.2 - FUSE BOX
Sub 10-4
10.3 - WIRING ARRANGEMENT ON MOTORCYCLE
Sub 10-5
10.4 - LIGHTING DEVICES
Sub 10-21
Dipped light bulb replacement................................................................................Sub 10-21
High-beam light bulb replacement..........................................................................Sub 10-22
Low-beam light bulb replacement..........................................................................Sub 10-22
License plate holder light bulb replacement...........................................................Sub 10-23
Lights relay.............................................................................................................Sub 10-23
Headlight directing.................................................................................................Sub 10-24
10.5 - SIGNALLING DEVICES
Sub 10-25
Left handlebar controls..........................................................................................Sub 10-25
Stop switches........................................................................................................Sub 10-26
Neutral indicator light............................................................................................Sub 10-27
Oil pressure sensor...............................................................................................Sub 10-28
Coolant temperature sensor..................................................................................Sub 10-29
Turn signal bulb replacement................................................................................Sub 10-30
Rear stop light replacement..................................................................................Sub 10-31
Rear view mirror regulation..................................................................................Sub 10-32
10.6 - SAFETY DEVICES AND PROTECTIONS
Sub 10-33
Main switch...........................................................................................................Sub 10-33
Kickstand switch...................................................................................................Sub 10-34
10.7 - DASHBOARD
Sub 10-35
Dash dismantling..................................................................................................Sub 10-35
Dash system.........................................................................................................Sub 10-36
Multifunction digital display...................................................................................Sub 10-37
10.8 - DIAGNOSIS INSTRUMENT
Sub 10-40
Multimeter.............................................................................................................Sub 10-33

XIV

GENERALINFORMATIONS

1CHAPTER 1
GENERAL INFORMATIONS
1.1 - IDENTIFICATION OF THE MOTORCYCLE
Sub 1-2
Punching of the frame (European version) ..................................................................Sub 1-2
Punching of the frame (United States version)..............................................................Sub 1-2
Punching of the engine (European / united states version)..........................................Sub 1-3
Frame tag.....................................................................................................................Sub 1-3
1.2 - PRODUCTS SPECIFICATIONS
Sub 1-4
1. - HAZARDOUS PRODUCTS / WARNINGS
Sub 1-5

Sub 1-1

GENERALINFORMATIONS

1

1.1 - IDENTIFICATION OF THE MOTORCYCLEThe Bimota DB7 is marked by two identification numbers, respectively for the frame and for theengine and by a plate with the data of the model.
The numbers which identify the model must be mentioned when asking for spare parts.

Punching of the frame (European version)
1. Manufacturer
2. Model3. Variant/version
4. Model year
5. Production site
6. Identification number

1

2

3

4

5

6

ZES DB07 00 8 R 000000

Punching of the frame (USA version)
1. Manufacturer
2. Model3. Check digit
4. Model year
5. Production site
6. Identification number

1

2

3

4

5

6

ZES D711S * 9 R 000001

The vehicle identification number is stamped on the right side of the steering head tube.

Sub 1-2

GENERALINFORMATIONS

1

Punching of the engine (Europe / USA version)
The vehicle matriculation number is stamped on the right side of the steering tube.

1
1. Engine type
2. Model Year
3. Production sequence number

2

3

XBE X 000001

Frame tag
The label with the data regarding the model is positioned on the left side of DB7.
In the Europe version (1) is placed on the left aluminium plate of the frame.
In the USA version (2) is placed on the left side of the frame near the steering head tube (2).
The information reported on this plate are absolutely necessary to order the spare parts.

Sub 1-3

GENERALINFORMATIONS

1

1.2 - PRODUCTS SPECIFICATIONS
The table shows the characteristics relating to the various products used for lock, lubrication andseal.
Recommended
product

Specifications

Loctite 222

Low strength threadlocker.

Loctite 243

Medium strength threadlocker, tolerates slight oily contaminations.

Loctite 270

Stud lock high strength threadlocker.

Loctite 510

Flange sealant for sealing rigid metal joints. High strength, solvent proof, 200°C
resistant, 350 BAR, fill 0,4mm clearance.

Loctite 128455

Permanent structural adhesive for cylinder coupling or threads. High strength,
solvent resistant. -55°C ÷ +175°C.

Loctite 577

Medium strength pipe sealant for metal threads, for water and every gas (except
for oxygen). 0,4mm clearance filler.

Loctite 480

Rubber-toughened instant adhesive, for bonding metal to metal and metal torubber.

Loctite 601

High strength low viscosity retaining compound (for thread, bush, grooved, key).
-55°C ÷ +150°C.

Loctite 401

Medium strength threadlocker.

Loctite 128443

Product suitable to lock metallic cylinder coupling or threads. High strength, hightemperature proof, solvent proof.

Loctite 128443

Instantaneous jelly adhesive, traction and cut resistant.

942470014

DUCATI liquid gasket.

Sub 1-4

GENERALINFORMATIONS

1

1.3 - HAZARDOUS PRODUCTS / WARNINGS
FUEL
Always work in well-ventilated areas. Keep cigarettes, sparks and flames away from the working area, orplace where the fuel is stored.
The fuel is extremely flammable and, under certain conditions, can explode. Keep out of reach of children.
USED MOTOR OIL
The used motor oil, if repeatedly left in contact with the skin for long periods of time, may be the origin ofepithelial cancers. If the used motor oil is handled daily, we recommend to wash as soon as possible yourhands thoroughly with soap and water after handling. Keep away the reach of children.
BRAKE FLUID
The reversal of the fluid on plastic, rubber or painted parts of the motorcycle may cause damage to the parts
themselves. Before proceeding to the maintenance of the system, place a clean workshop cloth on theseparts each time you proceed to the performance of service. Keep out of reach of children.
BRAKE POWDER
Do not ever use of jets of compressed air or dry brush to clean all the brakes.
Inhalation of asbestos fibres has proven to cause respiratory diseases and cancer.
LIQUID COOLANT
Under certain conditions, the ethylene glycol present in the engine coolant is combustible and its flame is not
visible. If the ethylene glycol takes fire, its flame is not visible but it can cause serious burns.
Do not spill engine coolant liquid on the exhaust system or engine parts.
These parts may be hot enough to light the liquid which then burns without flames visible.
The coolant (ethylene glycol) may cause irritation of the skin and is poisonous if swallowed. Keep out ofreach of children.
Do not remove the radiator cap when the engine is still warm. The coolant is under pressure and can causeburns.
Keep hands and clothing away from the cooling fan as it is started automatically.
BATTERY
The battery frees explosive gas, keep away sparks, flames and cigarettes. Verify that, during battery
charging, ventilation of the area is adequate.
EXHAUST / CARBON MONOXIDEWhere it is necessary to keep the engine running to perform certain maintenance operations, verify that thework area is well ventilated. Do not ever keep the engine running in a closed space.
Exhaust gases contain carbon monoxide, a poisonous gas that can cause loss of consciousness, and lead todeath.
Operate the engine in an open space or with the help of a system for evacuation of exhaust gases, whereclosed space.
HOT PARTS
The engine and parts of the exhaust system become very hot with the use of motorcycle and remain hot still
for a long time after you run the engine. To manipulate these parts to use gloves insulation, or wait until parts
are well cooled.
The exhaust can be hot, even after turning off the engine, be very careful to not touch with any part of theexhaust and not park the vehicle near flammable materials (including wood, leaves, etc..).

Sub 1-5

TECHNICALSPECIFICATIONS

2CHAPTER 2
TECHNICAL SPECIFICATIONS
2.1 -TECHNICAL DATA
Sub 2-2
Colors............................................................................................................................Sub 2-2
Particulars.....................................................................................................................Sub 2-2
Engine.......................................................................................................................... Sub 2-2
Drive………...................................................................................................................Sub 2-3
Drive system ................................................................................................................Sub 2-3
Timing system / valves..................................................................................................Sub 2-3
Tension belts adjustment at cold…...............................................................................Sub 2-4
Engine shaft..................................................................................................................Sub 2-4
Cylinder / piston............................................................................................................Sub 2-5
Gearbox........................................................................................................................Sub 2-5
Cooling system.............................................................................................................Sub 2-6
Front wheel...................................................................................................................Sub 2-6
Front suspension..........................................................................................................Sub 2-6
Rear wheel................................................................................................................... Sub 2-7
Drive chain....................................................................................................................Sub 2-7
Rear suspension...........................................................................................................Sub 2-7
Hydraulic brakes...........................................................................................................Sub 2-8
Charging system / alternator.........................................................................................Sub 2-8
Injection system / ignition............................................................................................. Sub 2-9
Intake............................................................................................................................Sub 2-9
Feeding system............................................................................................................Sub 2-9
Lights / dash.................................................................................................................Sub 2-9
2.2 - DIMENSIONS
Sub 2-10
2.3 - LUBRICANTS AND REFUELINGSub 2-11
2.4 - TORQUE WRENCH SETTINGS
Sub 2-12
Frame torque wrench settings...................................................................................Sub 2-12
Engine torque wrench settings..................................................................................Sub 2-18
2.5 - SERVICE TOOLSSub 2-21
Specific equipment for engine...................................................................................Sub 2-21
Specific equipment for frame.....................................................................................Sub 2-25

Sub 2-1

TECHNICALSPECIFICATIONS

2

2.1 - TECHNICAL SPECIFICATIONSColorsCode

Description

Additional description

X 14451

Bimota red

Lechler

X 14446

Pearl white

Lechler

Particulars
Reference
Dimensions

Frame

Technical specs

Total length

2040 mm

Total width

730 mmTotal height1105 mm

Wheel base1430 mm

Handlebar height (from the edge of grip
to the ground)

810 mmSeat height

810 mmDry weight without liquids and battery

172 KgCurb weight with full load

300kg

Type

Composite structure: steel CrMo4
tubes framework and aluminium
6082 plates

Rake

25°

Steering angle

22°

Trail

100 mmFront wheel

Forged aluminium alloy

Front wheel size

MT3.50x17”

Front tyre size

120/70-ZR17

Rear wheel

Forged aluminium alloy

Rear wheel size

MT6.00x17”

Rear tyre size

190/55-ZR17

Front brakeSemi-floating holed dual discs

Rear brakeSemi-floating holed discSub 2-2

TECHNICALSPECIFICATIONS

2EngineReference

Technical specs

Type

4 stroke, 90° L twin

Bore

104 mmStroke64,7 mm

Displacement

1099 cm³

Compression ratio

12,5 ± 0,5 :1

Shaft horsepower (95/1/CE)

113 kW (154 CV) / 9750 min-1

Shaft torque (95/1/CE)

118 Nm (Kgm) / 8000 min-1

Min rpm

1300 ± 50 min-1

Max rpm

10700 rpm

Timing system

Toothed belt with double over head camshaft, 4 valves
per cylinder and 8 rocker arms

Lubrication system

Forced lubrication by, with oil cooler

Oil pump type

GearedCooling system

Liquid cooling system

Air filter

Two filter units

Crankshaft type

One-piece

Drive
Reference

Technical specs

ClutchDry multi-plate clutch

Clutch control

Hydraulic control

Gearbox

6 speed gear

Primary drive

32/59

Secondary drive

15/38

Gearbox type

With constant mesh spur gears, operated by alever on the left side of the motorcycle

Drive system
GEAR RATIO
1°

15/37

2°

17/30

3°

20/28

4°

22/26

5°

23/24

6°

24/23
Sub 2-3

TECHNICALSPECIFICATIONS

2Timing system/valves
Reference

Assembly value

Check value

With valves clearance 1 mm
Opening 15° BTDC
IntakeClosing 58° ABDC

Timing system
diagram

Opening 60° BBDC
ExhaustClosing 20° ATDC
Intake valve diameter

42 mm

Exhaust valve diameter

34 mm
Intake 11.8 mm

With valves clearance 0 mm
Exhaust 10.6 mm
Valves lift

Rocker arm opening-intake

0,13 ÷ 0,18 mm

0,10 ÷ 0,25 mm

Rocker arm opening-exhaust

0,13 ÷ 0,18 mm

0,10 ÷ 0,25 mm

Rocker arm closing-intake

0,05 ÷ 0,10 mm

0,05 ÷ 0,25 mm

Rocker arm closing-exhaust

0,05 ÷ 0,10 mm

0,05 ÷ 0,25 mm

Tension belt adjustment at cold
Reference

Assembly value (new belt)

Restore value (used belt)

DDS

110 ± 5 Hz (horizontal)
110 ± 5 Hz (vertical)

80 ± 5 Hz (horizontal)
80 ± 5 Hz (vertical)

Edge min value at cold

70 Hz

70 Hz

Engine shaft
Reference

Normal value

Limit value

Out-of-round wear

0,005 mm

Conical shape

0,005 mm

Crankshaft pivots alignment

0,01 mm on diameterSub 2-4

TECHNICALSPECIFICATIONS

2Cylinder/piston
Reference

CylinderNormal value

Limit value

Max. out-of-round wear

0.03 mmMax. conical shape

0.03 mm

Section A diameter

104.000 mm ÷ 104.010 mm

Section B diameter

104.010 mm ÷ 104.020 mm

Section C diameter

104.020 mm ÷ 104.030 mm

Piston – cylinder couplingcleareance0.085 ÷ 0.105
Piston external diameter 100 mm
measured at 6.0 mm fromthe piston base

Piston0 ÷ 0.01 mm

Section A diameter

103.905 mm ÷ 103.915 mm

Section B diameter

103.915 mm ÷ 103.925 mm

Section C diameter

103.925 mm ÷ 103.935 mm

Connecting rod head
diameter

45 mm

Shaftt class

Connecting rod classSemi-bearings class

A

A

Blue+Yellow

B

A

Yellow+Yellow

A

B

Blue+Blue

B

B

Blue+Yellow

Piston – gudgeon pin
clearance

0.010 ÷ 0.018 mm

0.035 mm

Connecting rod –gudgeon pin clearance

0.035 ÷ 0.048 mm

0.065 mm

Connecting rod

Coupling of connecting
rod semi-bearings

Compression of engine
cylinders

13 ÷ 15 bar

11 bar (MIN.),difference between the twocylinders: 2 bar (MAX.)

Gearbox
Reference

Normal value

Limit value

Gearbox shafts

Axial clearance

0.05 ÷ 0.25 mm

Gearbox drum

Axial clearance

0.10 ÷ 0.40 mm

Speed selection fork

Fork sliding shoe thickness

3,90 ÷ 4,00 mm

Fork – gear clearance

0,070 ÷ 0.285 mm

0,4 mmSub 2-5

TECHNICALSPECIFICATIONS

2

Cooling system
Reference
TypeTechnical spec

Liquid cooled, closed circuit type, with double
fan curved radiator and mixing thermostat

Coolant capacity

2.7 ± 0.5 lt

Front wheel
Reference

Normal value

Limit value

Tire tread min. thickness

Max wear point

2 mmTyre pressure

At cold

Wheel pivot imperfection

In 100 mm

Wheel rim imperfection

radial0.8 mm

2 mm

axial

0.5 mm2 mm

2.3 bar
0.2 mmFront suspensions
Reference

Technical spec

Model

Marzocchi

Spring preload andrebound/compression adjustable
upside-down fork

Fork

Stem diameter

43 mm

Stem stroke

120 mmHydraulic brakeStandard position: unscrew the regulatorsfrom all close position (counter clockwise)

Compression: 1 turn

Spring preload
Standard position: unscrew the regulatorsfrom all close position (counter clockwise)

7,5 turns

Rebound: 1,5 turns

Stem oil capacity

Sub 2-6

TECHNICALSPECIFICATIONS

2

Rear wheel

Reference

Normal value

Limit value

Tire tread min. thickness

Max wear point

2 mmTyre pressure

At cold

Wheel pivot imperfection

In 100 mm

Wheel rim imperfection

radial0.8 mm

2 mm

axial

0.5 mm2 mm

2.3 bar
0.2 mmFinal drive
Type

Reference

REGINA 135ZRDK-100MG

Technical spec

size
Links number

5/8” x 5/16”
99+1 open link

Rear suspension

Model

Mono-shock

StrokeReference

Technical spec

Extreme tech

Progressive dumping, use an rocker
arm between the frame and the shock
low pivot. The mono-shock is reboundand compression adjustable (low andhigh speed) and it’s also spring preload
adjustable.
60 mm

Hydraulic brakes standard position: unscrew High and low speed compression: 10
the regulators from all close position
clicks(counter clockwise)High and low speed rebound: 10 clicks
Spring preload

15 mm

Wheel stroke

130 mmSub 2-7

TECHNICAL
SPECIFICATIONS

2

Hydraulic brakes
Reference

Normal value

Limit value

FRONT
Brake disc

Brake caliper

Master cylinder

Type

Dual semi-floating holed
discs

Thickness

5 ± 0.1

Slide material

SteelDiameter

320 mmBraking surface

39,6 cm²

Model

BREMBOType

34-4 pot

Pot diameter

34 mm

Pads material

TT2910Type

Radial master cylinder

Master cylinder bore

Ø 18 mm

4.5 mm (min)REAR
Brake disc

Brake caliper

Master cylinderType

Semi-floating holed disc

Thickness

5 ± 0.1

Slide material

SteelDiameter

220 mmBraking surface

31.2 cm²

Model

BREMBOType

32-2 pot

Pot diameter

32 mm

Pads material

FERODO I/D 450

type

Hydraulic pump

Master cylinder boreØ 11 mm

4.5 mm (min)Charging system / alternator
Reference
Battery

Alternator

Technical spec

Voltage

12 V

Capacity

10 Ah

Type

Airtight, maintenance free

Capacity

12 V – 480 W

Sub 2-8

TECHNICALSPECIFICATIONS

2

Injection system – ignition
Reference

Technical spec

Ignition

Type

Electronic inductive spark

Spark plugs

Model

NGK (MAR10A-J)

Starting

Type

Starter motor

Fuel system
Reference

Technical spec

Lead-free fuel95 - 98 RON

Throttle bodyØ 60 mm

Injectors per cylinder

1

Holes per injector

12

Feeding system
Model
Control unit

WALBROTypeECUG - 1

Lights - Instruments
Reference
Bulbs

Fuses

Technical spec

Headlamps: high-beam, low-beam H7 (12V – 55W)
License plate light

12V – 5W

Low-beam / stop

LED
Bulb 12V – 5W/21W (USA market)

Rear turn signals

LED
Bulbs 12V-10W (USA market)

Front turn signals

LED
Bulbs 12V-10W (USA market)

Main

30A

Lights

15A

General services

15A

Dashboard

5A

Injection

15A

General services

10A

Fans

15A

Sub 2-9

TECHNICALSPECIFICATIONS

2

2.2 - SIZE

Sub 2-10

TECHNICALSPECIFICATIONS

2

2.3 - LUBRICANTS AND REFUELING
RefuelingType

Quantity

Fuel tank, reserve included

Lead-free fuel ,with octane number 18,0 dm³ (litres) – reserve included
to the origin of at least 95

Lubricant circuit

Lubricant circuit

Brakes (front-rear) and clutch
circuitBrake DOT 4

Front fork

EBH 16 oil

380cc

Cooling system

Coolant 40÷50% + water

2,2 dm³ (litres)

3,7 dm³ (litres)

IMPORTANT
It's not permitted the use of additives in the fuel or in the lubricants.

Motor oil
A good oil has some specific features. Use only extremely detergent oil, certify on the bottle tobe equivalent, or higher, to the service necessity SE, SF or SG.

Viscosity: SAE 10W-40
If the motorcycle is used in an area where the temperatures are to the limit of range, select theright oil viscosity using the chart.

Sub 2-11

TECHNICALSPECIFICATIONS

2

2.2 - TORQUE SETTINGS
Frame torque settings
Description

Size (mm)Torque (Nm)

Notes

GENERAL
Screw M4

4

3

Screw M55

5-6

Screw M66

10-12

Screw M88

22-25

Screw M10

10

50

Screw M12

12

85-90

SIDE STAND
Side stand rotation screw

M8

20

Loctite 243

M10x25x1,540

Loctite 128455

Locking screw of the small plate side stand switch holder

M5x10

6

Loctite 243

Locking screw of the limit switch plate

M5x10

5

Loctite 243

Locking screw of the side stand sensor holder

M5x8

5

Loctite 243

Side stand base locking screw

M4x8

3

Loctite 243

Side stand spring locking screw

M8x12

20

Loctite 243

GreaseSide stand plate to carter locking screw

FRONT / REAR SPROCKET - CHAIN
Front sprocket locking nut

M25x1

186

Locking screw of the front sprocket coverM6x12x1

8

Nut + shock-absorber pivot to fixing the rear sprocket tothe sprocket-holder flange

10x1,25

40

Grease under head
Loctite 222

M5x12

5

243

Locking screw of head light to holder

self-tapping

manualScrew + rear turn light locking nut

M6x20

8

LIGHTING DEVICES
Locking screw of head-light holder to upper fairing

Rear light locking nut

M6

8

Locking screw of rear light to tail

M5x14

5

Locking screw of rear light to small plate (USA)

M4x10

3

Screw + locking nut of rear light plate to license plate
holder (USA)

M5x12

5

Screw + locking nut of license plate holder to tail

M5x16

5

M5

4

Locking nut of license plate light

NOTES
The tightening torque must be applied slowly and gradually using a calibrated torque wrench tool.
In case of screwing with automatic impact wrench, the reference torque must be reduced of 10%.

Sub 2-12

TECHNICALSPECIFICATIONS

Description

Size (mm)2Torque (Nm)

Notes
Loctite 243

ELECTRICAL SYSTEM
Control Unit locking screw

M4x20

3

Screw + locking nut of the fuse box to the frame

M5x10

5

Screw + horn locking nut

M6x16

8

Voltage regulator locking screw

M6x20

10

Lambda sensor

M18x1,545

Battery box locking screw

M6

10

Battery box fastener locking nut

M6

8

Speed sensor locking screw

M4x5

3

Loctite 222

FRONT FORK – STEERING HEAD TUBE
Locking screw of the fork small foots

M8x40

22

GreaseLocking screw of the fork stems to the steering base

M6x25

12

GreaseLocking screw of the fork stems to the steering head

M8x22

25

GreaseLocking screw of the steering ledge spacer

M6x10

10

Loctite 243

Locking screw of the steering head to the steering pivot

M8x22

25

GreaseM30x1x1330

Grease (under head)

M35x1

30??

GreaseSpecial locking screw of the steering head
Locking ring nut of steering bearings

STEERING DAMPER
Locking screw of the steering damper eye to the clamp

M6x25

10

Loctite 222

Locking screw of the steering damper clamp to the fork

M5x22

5

Loctite 222

Locking screw of the steering damper to the frame

M6x25

10

Loctite 243

Locking screw of the nylon collar

M4x8

3

Screw + locking nut of the shock to the eccentric cam

M12x1,25x98

60

GreaseScrew + locking nut of the shock to the rocking arm

M12x1,25

60

GreaseScrew + locking nut of the small connecting rod to swing arm

M10

35

Screw + locking nut of the small connecting rod to rocking arm

M10

35

M12x1,25x25

60

Rocking arm pivot / engine plates ring nut

M24x1

50/100?????

Locking nut of the engine plates to the rear engine pivot joint

M10x1,25

35

GreaseLocking screw of the engine plate to the engine

M10x3240

Grease (under head)
Loctite 243

M16x1,5x20

55

Grease (under head)

REAR SHOCK

Rocking arm pivot / engine plates locking screw

Swing arm pivot special locking screw

Grease (under head)

NOTES
The tightening torque must be applied slowly and gradually using a calibrated torque wrench tool.
In case of screwing with automatic impact wrench, the reference torque must be reduced of 10%.

Sub 2-13

TECHNICALSPECIFICATIONS

Description

Size (mm)2Torque (Nm)

Notes

SWING ARM
Eccentric clamp fixing screw

M8x22

25

Loctite 243

Swing arm plates fixing screw

M10x1,25

50

Loctite 243(grease under head)

Fixing screw of the upper and lower chain slider

M4x8

3

Loctite 243

Fixing screw of the side chain slider

M4x12

3

Loctite 243

M16x1,5x20

55

grease under headM10x1,25x65

45

GreaseBrake bleeding screw

M10x1

20/manJunction screw of brake hoses to calliper and master cylinder

M10x1

20

Fixing screw of the master cylinder to handlebar

M6x1,25

11

Fixing screw of the brake oil tank to master cylinder

M6x10

10

Loctite 243

Swing arm pivot fixing screw

FRONT BRAKE SYSTEM
Brake calliper fixing screw

REAR BRAKE SYSTEM
Fixing screw of the rear brake calliper

M8x20

25

GreaseFixing screw of the rear master cylinder

M6x16

10

Loctite 243

Fixing screw of the rear brake oil tank

M5x30

5

Loctite 243

Bleeding screw

M10x1

20/manM10x1

20Junction screw of brake hoses to calliper and master cylinder

FRONT WHEEL
Fixing screw of the front wheel pivot

M20x1x13????

GreaseM8x18

22

Loctite 243

Fixing screw of the front brake disc to rim

M8x20

22

Loctite 243

Fixing screw of the shock absorber flange to rim

M8x25

22

Loctite 243

Shock absorber small pivot + rear sprocket fixing nut tosprocket holder flange

M10x1,25

40

Loctite 243(grease under head)

Rear wheel pivot

M26x2

100

GreaseFixing screw of the front brake disc to rim
REAR WHEELHANDLEBAR – CLUTCH CONTROL – THROTTLE CONTROL
Fixing screw of semi-handlebar to fork clamp and fork stem

M8x30

25

GreaseRotation screw semi-handlebar to clamp

M4x8

3

Loctite 243

Fixing screw of the clutch pump clamp to semi-handlebar

M6x25

11

NOTES
The tightening torque must be applied slowly and gradually using a calibrated torque wrench tool.
In case of screwing with automatic impact wrench, the reference torque must be reduced of 10%.

Sub 2-14

TECHNICALSPECIFICATIONS

2

Description

Size (mm)Torque (Nm)

Notes

Fixing screw of the master cylinder clamp to semi-handlebar

M&x1x25

11

Throttle control covers fixing screw

M6x1x20

10

Fixing screw of the oil tank plate holder to clutch pump

M6x10

10

Clutch small piston fixing screw

M6x16

10

Fixing screw of aluminium plates to frame

M10x1,25

50

Engine/frame pivot fixing nut

M12x1,25

55

Fixing screw of the load-bearing tail to frame plates

M8x20/25

22

M8

20

Loctite 243

Fixing screw of upper fairing small frame to the frame

M6x16

11

Loctite 243

Fixing screw of upper fairing small frame to the main switch

M5x10

5

Loctite 243

FRAME

Screw + fixing nut of main switch to frame

GreaseFOOTPEGS AND LEVERS
Fixing screw of foot peg to frame

M8x16

22

Loctite 243

Fixing screw of the foot protection to the foot peg

M4x8

3

Loctite 243

Fixing screw of the foot peg to the left holder

M8x20

22

Loctite 243

M5

6

Fixing screw of the gear counter lever clamp

M6x20

10

Screw + fixing nut of gear control bar uniballM5

5

Fixing screw of gear lever to foot peg holder

M8x1,25

22

Loctite 243

Gear lever clamp fixing screw

M5x14

5

Loctite 222

Fixing screw of the foot peg to the right holder

M8x22

22

Loctite 243

Fixing screw of rear brake lever to small plateM10x1,25

50

Loctite 243

Fixing screw of brake lever small plate to engine

M10x1,25

50

Loctite 243

Brake lever clamp fixing screw

M5x14

5

Loctite 222

Screw+ fixing screw of master cylinder rod uniball

M6x30

10

M6

10

Fixing screw of the radiator to the frame

M6x22

10

Water drain plug on pump cover

M10x1

18

Screw+ fixing nut of radiator to support stirrup

M6x25

10

Radiator bulkhead fixing screw

M6x10

10

Coolant expansion tank fixing screw

M5x10

5

Lock nut of gear counter bar

Master cylinder bar lock nut

Loctite 222

LIQUID COOLINGNOTESThe tightening torque must be applied slowly and gradually using a calibrated torque wrench tool.
In case of screwing with automatic impact wrench, the reference torque must be reduced of 10%.

Sub 2-15

TECHNICALSPECIFICATIONS

Description

Size (mm)Torque (Nm)

2

Notes

OIL RADIATOR
Oil radiator nipple on carterM14x1,525

Loctite 243

Oil radiator hose union on carter nipple

M16x1,525

Lub with motor oil

Oil radiator hose union on radiator nipple

M16x1,518

Lub with motor oil

Fixing screw of the radiator stirrup to head

M6x12

10

Screw + fixing nut of the radiator to stirrup

M6x25

10

Fixing screw of fuel cap to tank

M5x12

5

Fixing screw of fuel pump to tank

M5x16

5

Loctite 243

Fixing screw of tank rear support plate to tank

M6x25

10

Loctite 243

Fixing screw of tank rear support plate to rear frame bar

M6x12

12

M7

man

FUEL TANK

Vent hoses union and tank drain

FEEDING - INTAKE - CANISTER
Fixing screw of intake cones to throttle body

M5x16

5

Loctite 243

Fixing collar of throttle body to intake manifold

--

2,5

Fixing screw of intake cones to airbox bottom

M6x12

10

Fixing screw of injection support to airbox

M5x30

5

Fixing screw of intake air hoses manifold to airbox

M5x12

5

Screw + fixing nut of canister support small plate to tail

M6x14

10

Screw + fixing nut of canister small plate to support plate

M6x20

10

M6x1

10

CO capM10x1,25

25

Fixing screw of silencer stirrup to tail

M6x16

10

Screw + fixing nut of silencer plate to stirrup

M6x30

10

Fixing screw of plate to silencer

M6x16

10

Loctite 510

Screw + fixing nut of mid-pipe to frame/mid-pipe fixing stirrup

M6x30

10

Loctite 128455

Mid-pipe protection fixing screw

M5x10/16

6

Loctite 128455

EXHAUST
Fixing nut of exhaust manifold to head

Loctite 243

NOTES
The tightening torque must be applied slowly and gradually using a calibrated torque wrench tool.
In case of screwing with automatic impact wrench, the reference torque must be reduced of 10%.

Sub 2-16

TECHNICALSPECIFICATIONS

Description

Size (mm)Torque (Nm)Rider's seat fixing screw

M5x12/16

6

Rear small seat fixing screw

M5x12

6

2

Notes

SEAT

FRONT FENDER
Fixing screw of front fender to holder

M5x10

5

Fixing screw of fender holder small plate

M5x16

6

M4x16

3/man

M6

10

Fixing screw of upper fairing closing bulkhead

M4x16

3/man

Fixing screw of upper side fairings to upper fairing

M6x16

8/man

Fixing screw of side fairings to the frame

M6x20/25

10

Fixing screw of lower fairing to small plate

M6x25

10

Fixing screw of lower fairing plate to frame

M6x35

12

Fixing screw of front lower fairing to lower fairing

M6x16

8/man

Fixing screw of front lower fairing to side fairings

M6x16

8/man

Fixing screw of tail to the frame

M8x20/35

22

Fixing screw of under tail closure

M4x20

3/man

BODYWORK
Fixing screw of plexiglass to upper fairing
Fixing nut of upper fairing and rear view mirrors to holder

NOTES
The tightening torque must be applied slowly and gradually using a calibrated torque wrench tool.
In case of screwing with automatic impact wrench, the reference torque must be reduced of 10%.

Sub 2-17

TECHNICALSPECIFICATIONS

2Engine torque settings
Description

Size (mm) Torque (Nm)NotesIdler and tensioner pulley mounting studs

M20x1

50

LOCK 2 or TB1324

Camshaft pulley retaining nut

M17x1

71

GREASE A

Rocker arm shaft covers

M12x1,25

15

LOCK 2 or TB1324

Coolant temperature sensor on coolant outlet union

M12x1,523

LOCK 4 – Restrain the insert
when tightening

Cylinder head nut:
Stage 1
Stage 2
Stage 3

M10x1,5

Cam cap bolt:
Stage 1
Stage 2

M8x1,25

Coil retaining screw

M6x1

10

Pulleys flange retaining bolts

M6x1

10

Rocker cover bolt

M6x1

10

Exhaust manifold stud

M6x1

10

LOCK 2 or TB1324

Vacuum gauge connection screw on cylinder head

M6x1

5

LOCK 2 or TB1324

Evaporative emissions canister fitting on cylinder head

M6x1

5

LOCK 2 or TB1324

Air breather fitting on horizontal cylinder head

M6x1

5

LOCK 2Air breather blanking screw on vertical cylinder head

M6x1

10

LOCK 6

Intake manifold bolt

M6x1

10

Bolts securing coolant unions to cylinder head

M5x1

8

Pre-applied Tecnologic 150
threadlocker

20
40
60
10
22,5

Apply GREASE C to theunderside of the nut and thethread of the studEngine oil

Oil cartridge

M16x1,511

Engine oil on gasket

Oil cartridge nipple

M16x1,542

LOCK 2 or TB1324

Oil pick-up pipe plug

M14x1,524

LOCK 5 or TB1375B

Oil drain plug

M12x1,520

Clutch cover oilway blanking plug

M10x1,515

Neutral sensor

M10x1,25

10

Oil pump adapter bolt

M10x1

Clutch cover inner oilway screw

M10x1,515

LOCK 5

Cylinder head/barrel stud

M10x1,525

LOCK 2 or TB1324

Hor. cylinder cover + swingarm attachment bolt:
Stage 1
Stage 2

M8x1,25

Vertical cylinder cover bolt:
Stage 1
Stage 2

M8x1,25

LOCK 5LOCK 5 or TB1375B

19
25
19
25

Sub 2-18

TECHNICALSPECIFICATIONS

Description

Size (mm) Torque (Nm)

2

Notes

Gear stop lever bolt

M8x1,25

18

LOCK 2 or TB1324

Blow-by valve bolt

M6x1

10

Chain side secondary bearing retaining bolt

M6x1

10

LOCK 2

Clutch side primary bearing retaining bolt

M6x1

10

LOCK 2 or TB1324

Crankcase screw – idler area

M6x1

10

Outer crankcase screw

M6x1

9

Oil pick-up gauze filter bolt

M6x1

14

Left-hand side crankcase cover screw

M6x1

10

Bosch sensor bolt

M6x1

10

Right-hand side crankcase cover screw

M6x1

9

Chain cover oil circuit blanking screw

M6x1

5

Right-hand side crankcase cover screw

M6x1

9

Under-piston oil jet retaining screw

M5x0,88LOCK 2 or TB1324

Oil cooler nipple

M14x1,527

LOCK 5 or TB 1375B

Vertical cylinder cover bolt:
Stage 1
Stage 2

M8x1,25

Crankcase hollow screw

M8x1,25

20

Left-hand side crankcase cover screw

M6x1

10

Drylock left-hand side crankcase cover screw

M6x1

10

Pre-applied Loctite 516

Starter motor mounting bolt

M6x1

10

LOCK 2 or TB1324

Starter motor rear bolt

M6x1

10

LOCK 2 or TB1324

Idler gear shaft retaining bolt

M6x1

10

LOCK 2 or TB1324

Front sprocket retaining nut

M24x1

190

GREASE B

Flywheel retaining nut

M24x1

330

LOCK 5Connecting rod cap bolts:
Stage 1
Pause for 2 sec., then back off through 360°
Stage 1
Stage 2Tighten down to 65°±1°
Torque check

M10x1

Crankshaft grub screw

M8x1,25

13

TB1375B

Drilled crankshaft grub screw

M8x1,25

13

TB1375B

Selector drum locating screw

M16x1,530

Gear stop lever screw

M8x1,25

18

Selector claw bolt

M8x1,25

25

Selector claw locator nut

M6x1

10

LOCK 5

19
25

35
20
35

Apply
GREASE B
to thread

70±103

LOCK 2 or TB1324

Sub 2-19

TECHNICALSPECIFICATIONS

Description

Size (mm) Torque (Nm)

2

Notes

Selector claw bolt

M6x1

9

LOCK 2 or TB1324

Idler and tensioner pulley bolts

M20x1

50

LOCK 2 or TB1324

Camshaft pulley retaining nut

M15x1

71

GREASE A

Timing belt driveshaft gear nut

M14x1

55

GREASE A

Idler and tensioner pulley nut

M8x1,25

25

GREASE A

Timing belt cover screw

M6x1

10

LOCK 2 or TB1324

Self-tapping screw for timing belt cover filter

M3,5

Dry clutch centre nut

M25x1

250

LOCK 5

Oil filler plug

M22x1,55

Wet clutch centre nut

M20x1

120

GREASE B

Oil temperature sensor

M12x1,518

LOCK 4

Oilway blanking plug

M10x1

20

LOCK 5

Dry clutch drum bolts

M8x1,25

35

LOCK 4Right-hand side crankcase cover screw

M6x1

9

Clutch spring bolt

M5x0,8

5

Coolant inlet union

M30x1,525

LOCK 5

Coolant outlet union

M22x1,525

LOCK 5Pick-up sensor inspection screw

M12x1

15

LOCK 2 or TB1324

Water pump cover plug

M10x1

20

Spark plug

M10x1

12

Coolant pump bearing stop screw

M6x1

10

LOCK 2 or TB1324

Stator wiring clamp bracket bolt

M6x1

10

LOCK 2 or TB1324

Water pump cover plug

M6x1

10

Left-hand crankcase cover screw

M6x1

10

Inspection cover screw

M6x1

4,5

Alternator rotor/flywheel bolt

M6x1

13

LOCK 2 or TB1324

By-pass pump cap

M15x1

25

LOCK 2 or TB1324

Oil pump retaining bolt

M6x1

10

Oil pump retaining bolt

M8x1,25

26

Oil pump retaining bolt

M6x1

10

Coolant outlet union

M22x1,525

Coolant circuit hose clamps

LOCK 52,5Sub 2-20

TECHNICALSPECIFICATIONS

2

2.5 – SERVICE TOOLSSpecific equipment for engine
Part no.

Description

88713.2011

Tool to lock crankshaft at Top Dead Centre

88713.2676

Wrench for tightening cylinder head nuts

88713.2103

Stand for cylinder head assembly

88765.1523

Timing check tool

88713.1821

Wrench for tightening timing belt tensioner pulley shafts

88713.2861

Camshaft oil seal installer

88713.2060

Gearbox output shaft oil seal installer

88713.1806

Tool for tightening Z=20 camshaft pulley

Sub 2-21

TECHNICALSPECIFICATIONSPart no.

Description

88713.2069

Rocker spring tensioning kit

88765.1524

Timing belt pulley timing tools

88765.1518

Valve lift gauge

88713.2878

Fork-type feeler gauge 0.1 mm, 0.2 mm, 0.3 mm

88713.2874

Alternator holding tool for tightening nut

88713.1920

88713.2827

2

Tool for installing O-rings on crankcase studs

Plate for gear selector fork positioning

88713.2442

Tool for installing valve guide seals

88713.1749

Puller for drive pulley and coverSub 2-22

TECHNICALSPECIFICATIONSPart no.

Description

88713.2133

Clutch centre wrench

88700.5665

88713.1010

88713.1805

Clutch cover assembly tool

Exhaust gases pick-up connector

Tool for tightening timing belt driveshaft pulley88765.1188

Top Dead Centre test gauge

88713.2102

Wrench for tightening primary sprocket ringnut

88713.0869

2

Water pump front seal installer

88713.0870

Installation tool for counter plate for water pump front seal

88700.5749

Crankcase assembly cap

Sub 2-23

TECHNICALSPECIFICATIONSPart no.

88713.2877

2

Description
Sparkplug wrench

88713.2842

Inlet/exhaust valve guide installer

88713.2846

Exhaust valve seat installer

88713.2847

Inlet valve seat installer

88713.2870

Connecting rod guide tool

88713.2834

Punch and sleeve for installing camshaft circlip

88713.2832

Timing belt tensioner pulley wrench

Sub 2-24

TECHNICALSPECIFICATIONS

2Specific equipment for frame

Part no.

Description

507097010

Special tool for swingarm eccentric adjustement507097100

Special tool for steering head nut tightening

Sub 2-25

USE
MAINTENANCE

3

CHAPTER 3
USE AND MAINTENANCE
3.1 - PRELIMINARY CHECKS
Sub 3-3
Running-in period........................................................................................................ Sub 3-3
Check-up before run.....................................................................................................Sub 3-4
3.2 - STARTING - ENGINE WARM UP
Sub 3-5
3.3 - TABLE OF PERIODIC MAINTENANCE
Sub 3-6
Dealer operations.........................................................................................................Sub 3-6
Customer operations....................................................................................................Sub 3-7
3.4 - MAINTENANCE OPERATIONS
Sub 3-8
Motor oil level control....................................................................................................Sub 3-8
Motor oil and filter cartridge replacement.....................................................................Sub 3-9
Valves clearance check-up.........................................................................................Sub 3-12
Valves clearance adjustment......................................................................................Sub 3-13
Liquid cooling level control.........................................................................................Sub 3-14
Liquid cooling replacement........................................................................................Sub 3-15
Air filters replacement and cleaning...........................................................................Sub 3-16
Front brake fluid replacement.....................................................................................Sub 3-19
Rear brake fluid replacement.....................................................................................Sub 3-20
Brake circuit bleeding ................................................................................................Sub 3-22
Brake circuit filling......................................................................................................Sub 3-24
Clutch liquid replacement...........................................................................................Sub 3-27
Clutch liquid draining..................................................................................................Sub 3-28
Clutch liquid filling.......................................................................................................Sub 3-30
Steering stem bearings clearance adjustment............................................................Sub 3-32
Chain tension adjustment...........................................................................................Sub 3-34
Brake pads wear check-up and replacement.............................................................Sub 3-36
Front brake pads check-up.........................................................................................Sub 3-36
Filling up brake fluid....................................................................................................Sub 3-37
Rear brake pads check-up..........................................................................................Sub 3-37
Throttle cable regulation..............................................................................................Sub 3-39
Clutch lever and front brake lever adjustment............................................................Sub 3-40
Rear brake pedal and shift lever position adjustment.................................................Sub 3-41
Fork adjustment..........................................................................................................Sub 3-42
Rear shock adjustment...............................................................................................Sub 3-44
Steering damper..........................................................................................................Sub 3-46
Rear height regulation / bike trim................................................................................Sub 3-47
3.5 - DIAGNOSTIC INSTRUMENTS
Sub 3-48
3.5.1 - Walbro diagnosis............................................................................................. Sub 3-48
3.6 - Software installation............................................................................................Sub 3-49
3.6.1 - Installation of diagnosis software Service OEM 564........................................Sub 3-49
3.6.2 - USB drivers installation....................................................................................Sub 3-49

Sub 3-1

USE
MAINTENANCE

3

3.7 - Vehicle connection for diagnostic.........................................................................Sub 3-49
3.7.1 - Diagnostic software...........................................................................................Sub 3-52
3.7.2 - Real time parameter view..................................................................................Sub 3-55
3.7.3 - Diagnosis...........................................................................................................Sub 3-56
3.7.4 - End of line..........................................................................................................Sub 3-57
3.7.5 - Hour meter.........................................................................................................Sub 3-58
3.8 - Installation of Windownloader OEM 2000 program (use for ECUC).....................Sub 3-58
3.8.1 - Calibration update program...............................................................................Sub 3-59
3.9 - Installation of EcugLoader-1000 program (use for ECUG)...................................Sub 3-61
3.9.1 - Calibration update program...............................................................................Sub 3-61

Sub 3-2

USE
MAINTENANCE

3

3.1 - PRELIMINARY CONTROLS
Running in period
During the running in period carefully follow the maintenance program as recommended in the
manufacturer's warranty manual. The non compliance of these rules relieve Bimota from any
liability for any damage to the engine and its duration.

Maximum rotation speed up to 1000 km (621 mi)
During the first 1000 km (621 mi) be careful that the tachometer do not exceed 5500÷6000 rpm.
In the first hours ride it is advisable to continuously vary the load and the running of rpm, evenremaining within the indicated speed limit.
For this purpose roads full of turns and also hilly roads are very suitable, where engine, brakes andsuspensions are subject to effective running in. For the first 100 km be careful on brakes avoiding
abrupt and long braking, this to allow the correct settlement of the friction material on the brakediscs. To allow a reciprocal adaptation of all the moving mechanical parts and in particular to notaffect the long term functionality of the main part of the engine it is advisable not to make too
abrupt accelerations and not to keep engine for a long time at high rpm, especially up hill. Besides
it is advisable to often check the chain, taking care to grease it if necessary.

Maximum rotation speed from 1000 to 2500 km (from 621 to 1553 mi)Higher performance can be demanded to engine, but 7000 rpm must never overcome and you
have to run in the engine in this conditions up to 2500 km (1553 mi) of ride. As much as theserecommendations will be followed the longer will be the engine duration and lower the revisions
and adjustments.

Sub 3-3

USE
MAINTENANCE

3

Check-up before run
Failure of the inspections before leaving can cause damage to the vehicle and result in serious
injury to the rider.
Before traveling check the following points:- control the level of fuel in the tank.
- control the tension and lubrication of the drive chain.
- check the right functioning of all the service lights.

Engine oil level
Control the level in the sump through inspection window. Fill up with recommended oil.

Brake and clutch fluid
Check on their reservoirs the liquid level.

Coolant
Control the level of liquid in the expansion reservoir; fill up if needed.

Tire condition
Control the pressure and the wear of the tires

Command functionality
Move the brake lever and brake pedal, clutch lever, twist throttle, shift lever and check thefunctionality.

Lights and signals
Verify the integrity of the bulbs for lighting, for turn signal and the horn functionality. In the case ofburned bulbs replace them with other similar as shown.

Locking
Check the locking of the fuel tank cap and of the saddle.

Side stand
Check the functionality and the right positioning of the side stand.

Sub 3-4

USE
MAINTENANCE

3

3.2 – STARTING - ENGINE WARM UP
This vehicle is equipped with automatic choke (stepper motor).
These function allows you to automate the process of engine warm up.
Move the starting switch (1) to the ON position (2).
Verify that a green light N (gear in neutral) and red (oil pressure) on the dashboard are on.
Allow the engine to start spontaneously without operating the twist throttle.
IMPORTANT
Led that indicates the oil pressure has to go off a few seconds after starting the engine.
If the light is on, stop the engine and check the oil level. Do not start the engine if the oil pressure isinsufficient.
Press the starter button to start the engine
In case of the engine doesn’t start it’s necessary to wait at least 2 seconds before pressing the
button (3) again.
IMPORTANTDo not operate the engine at high rpm.
When it is cold, wait for oil heating and for its movement at all points that need lubrication.
CAUTION
You can start the motorcycle with the side stand opened and the gearbox in neutral position, orwith the gear engaged, taking pulled the clutch lever (in this case the side stand must be closed).

Sub 3-5

USE
MAINTENANCE

3

3.3 - TABLE OF PERIODIC MAINTENANCE
Operations to be performed by the dealer
Operations list with kind of work (kilometers, miles or expiration time)
Km x1000

1

12

24

36

48

60

Mi x1000

0,6

7,5

15

22,5

30

37,5

Months

6

12

24

36

48

60

Engine oil replacement
Engine oil filter replacement
Engine oil suction filter cleaning
Engine oil pressure check-up
Valve clearance check-up and/or adjustment (1)Tension check-up of timing system belts (1)Timing system belts replacement
Spark plug check-up and cleaning. Replace if necessary
Air filter check-up and cleaning (1)Air filter replacement
Throttle body synchronization and idling speed check-up (1)Brake and clutch fluid level check
Brake and clutch fluid replacement
Brake and clutch controls check-up and adjustment
Throttle twist / starter check up and lubrication
Tyre pressure and wear check-up
Brake pads check-up. Replace if necessary
Steering bearings check-up
Tension check, alignment and chain lubrication
Clutch disks check-up. Replace if necessary (1)Coolant level check
Coolant replacement
Fan functioning check and cooling circuit retain
Rear wheel elastic coupling check-up
Wheel hub bearings check-up
Lights and turn signals devices check
Tightening check of frame/engine fixing screw nuts
Side stand check-up
Tightening check front wheel nut
Tightening check rear wheel nut
External fuel hoses check

Sub 3-6

USE
MAINTENANCE

3

Km x1000

1

12

24

36

48

60

Mi x1000

0,6

7,5

15

22,5

30

37,5

Months

6

12

24

36

48

60

Front fork oil replacement
Leak check of fork oil and rear shock
Sprocket fixing check
General lubrication and greasing
Battery charging and check-up
Motorcycle street test
General cleaning* Perform the maintenance at the first expiration (km, mi , or months)(1) Work to carry out only at the km/Mi expiration reaching.

Operations to be performed by the customer
Operations list with kind of work (kilometers, miles or expiration time)
Km x10001

Mi x1000

0,6Months6

Engine oil level check
Brake and clutch fluid level check
Tyre pressure and wear check-up
Chain tension check and lubrication
Brake pads check-up. If it's necessary the replacement, go to the dealer* Effect the maintenance work at the first expiration (km, mi , or months)

Sub 3-7

USE
MAINTENANCE

3

3.4 - MAINTENANCE OPERATIONSEngine oil level control
The engine oil level visible by the inspection window (1) positioned on the right side of the oilsump. Wait a few minutes after having switched off the engine in order to stabilize the level.
Check the level with the vehicle in upright position and with warm engine (but switched off).
The level has to remain between the MIN and MAX marks. If the level is low it is necessary toproceed to top up.
Take off the loading cap (2) and add the appropriate oil, up to the fixed level.
Screw the cap in and mount the removed parts.

Sub 3-8

USE
MAINTENANCE

3

Engine oil and filter cartridge replacement
NOTES
This operation must be performed at warm engine (engine off) because the oil in these conditions
is more fluid and its drainage is faster and complete.
Remove fairings.
Remove the drain cap (3) with seal (A) of the engine oil sump and drain the exhausted oil.

CAUTION
Not waste exhausted oil and / or filter cartridges in the environment.
Check that there are no metal particles attached to the magnetic drain cap (3), so re-screw the cup
with its gasket (A)Tightening to the required torque.
Remove the filter cartridge (4) using an oil filters standard tool.
IMPORTANTThe removed filter can not be reused.
Mount a new cartridge (4) taking care to lubricate the seal with oil engine.
Screw into place and lock with the required torque
NOTES
It is also possible to fill the filter cartridge (4) with engine oil before mounting it.

Sub 3-9

USE
MAINTENANCE

3

Every two oil changes is advisable to clean the suction oil filter net.
Unscrew the four screws (5) of the outer cap (6) and remove the cap.
Be careful to the gasket (7).

Remove the filter element (8), check the OR seals (9) and replace them if needed.

Sub 3-10

USE
MAINTENANCE

3

Proceed to its cleaning with compressed air and fuel being careful not to tear the net. Replace thefilter net (8), the seal (7) and OR seal (9) on the cap (6).
Remove the load cap (2) and fill with the prescribed oil to up to the mark which identify the MAX
level on the inspection window.
Close the cap and run the engine, idling for a few minutes.

Verify that there are not oil leaks and that the oil pressure indicator light on the dashboard goes off
after a few seconds from engine switch. Otherwise, stop the engine and perform the necessary
checks.
After a few minutes check that the oil level corresponds to the prescribed and if necessary restore
the MAX level.
Reassembly the removed structures.

Sub 3-11

USE
MAINTENANCE

3

Valves clearance check-up
Operate as described under "valves clearance check-up and adjustment" subchapter.
With the valve in the resting position and using a thickness gauge inserted between the skid of therocker arm (A) and the lower side of the cam (B), verify that the clearance is like the one
prescribed.
The clearance must be within the values prescribed:
Opening rocker arm
Intakeworking
check
Exhaustworking
check

0,13 ÷ 0,18 mm
0,10 ÷ 0,25 mm
0,13 ÷ 0,18 mm
0,10 ÷ 0,25 mm

Sub 3-12

USE
MAINTENANCE

3

With the valve in the resting position and using a thickness gauge inserted between the skid of theclosing rocker arm (C) and the upper side of the cam (D), verify that the clearance is like the one
prescribed.
Closening rocker arm
Intakeworking
check
Exhaustworking
check

0,05 ÷ 0,10 mm
0,05 ÷ 0,25 mm
0,05 ÷ 0,10 mm
0,05 ÷ 0,25 mm

If the values are out of prescribed limits calculate, however, the value and proceed with registrationof the valves clearance.

Valves clearance adjustment
Refer to sub-chapter "valves clearance check-up and adjustment" in the “engine” chapter.

Sub 3-13

USE
MAINTENANCE

3

Liquid cooling level control
Check coolant level in the expansion reservoir on the right side of the vehicle, at the intervals
indicated in the "periodic service tab" .
The proper level should be between the MAX and MIN marks on the reservoir itself.
If the level is low it is necessary to provide for the topping;
Remove the right side fairing.
Unscrew the cap (1) and add a mixture of water and antifreeze liquid up to the markMAX.
Screw the cap (1) and reassembly the removed structures.

The liquid cooling prescribed must be mixed with water in the following percentages :ANTIFREEZE: 35 ÷ 40% of the volume
WATER: 65 ÷ 60% of the volume
IMPORTANTA particularly hard water with high percentage of mineral salts can damage the engine.
In the presence of particularly cold climates the percentage of antifreeze can be increased up to
55% of the volume.
IMPORTANT
A solution with a percentage of antifreeze less than 30% does not provide adequate protection
against corrosion.

Sub 3-14

USE
MAINTENANCE

3

Liquid cooling replacement
CAUTION
This operation must be done to engine cold. If the operation is performed with the engine warm, it
can cause losses of coolant or hot steam which may cause severe burns.
Remove the right fairing and unscrew the cap (1) of the expansion tanks.

Place a container under the engine and put the vehicle on the side stand.
Unscrew the cap from the liquid drain hole (2) on the pump cover.
Let drain completely all the liquid.
Screw in the liquid drain hole (2) the plug with a new gasket.

Proceed to the loading of the circuit by pouring the new liquid in the expansion tank, after removing
the cap (1). Wait a few minutes to allow the liquid to fill all the internal canalizations. Fill completely
the expansion tank and close the cap (1).
Start the engine and wait a temperature of the liquid of 110 °C ; run the engine for about 10
minutes. Cool the engine to allow the escape of air in the circuit.
CAUTION
Don’t approach hands, tools, clothing to the radiator fan because it start automatically without
notice and may result dangerous.
IMPORTANT
Verify that there aren’t circuit leaks.
Complete filling by the expansion tank filler, raising the liquid level to top mark MAX. Tighten thecap (1) of the expansion tank and reassembly all removed structures.

Sub 3-15

USE
MAINTENANCE

3

Air filter replacement and cleaning
Intake air filter
The air filter must be replaced at the intervals described on the "periodic service tab" .

1)Filter box2)Air Filter3)Rubber gasket filter support4)Support sleeve air box5)Screw
6)Sleeve7)Air intake pipe

to access to the air filter:
remove the left side fairing (8) as described in the “fairings” sub-chapter.

Sub 3-16

USE
MAINTENANCE

3

Unscrew and remove the 3 fixing screws (5), and release the sleeve holder (4) and sleeve (6) fromthe filter box (1) being careful to damage not the rubber gasket.
The intake manifold (7) must not be removed from the sleeve (6).
Remove the air filter (2) from the filter box (1).
Clean the filter (2) using a jet of air compressed, or replace it.

Reinstall the cartridge in the filter box and reassembly all the parts and the removed
structures.
IMPORTANT

An air filter obstructed reduce the air entry, increasing the fuel consumption, reducing theengine power, encrusting the spark plugs.
Don’t use the motorcycle without the air filter, because the dust may enter into the engine,
damaging it.
In case of use on dusted or wet roads, replace the filter often.

Sub 3-17

USE
MAINTENANCE

3

Air filter of the timing system cover
Check the air filter (5) in the horizontal belt timing system cover (6): to remove it, remove the coverand unscrew the screws (7).
When you‘ve checked, you can reassembly the filter (5) by tightening the screws (7) andreassembly the horizontal belt timing system cover (6).

Sub 3-18

USE
MAINTENANCE

3

Front brake fluid replacement
Remove the cover (1) with membrane from the brake fluid reservoir unscrewing the screws (2).
To suck the fluid out from the reservoir.
Enter the new oil inside the reservoir up to the mark MAX.

Operate the lever two or three times so as to allow the circuit to go under pressure.
Keep pulled the lever to the grip.

Connect a transparent hose to the draining valve (3) then dip the other end in a container placed in
the floor .
Unscrew the draining valve (3) to allow the oil to come out.

Sub 3-19

USE
MAINTENANCE

3

CAUTION
During the filling operation keep the oil level above the MIN mark to prevent the formation of air
bubbles inside the circuit.
Drain the oil from the draining valve (3) until the leakage of liquid of different colour.
Screw the draining valve (3) and restore the proper level of oil tank .
NOTES
Repeat the process on both caliper.
Put the cover (1) carrying out operations in reverse order of disassembly operations.

Rear brake fluid replacement
Unscrew the cover (4) of the rear brake fluid reservoir.
To suck the fluid into the reservoir.
Enter the new oil inside the reservoir up to the mark MAX.

Sub 3-20

USE
MAINTENANCE

3

Press the pedal two or three times so as to allow the circuit to go under pressure.
Keep the pedal pressed.

Connect a transparent hose to the draining valve (5) then dip the other end in a container placed in
the floor .

CAUTION
During the filling operation keep the oil level above the MIN mark to prevent the formation of air
bubbles inside the circuit.
Drain the oil from the draining valve (5) until the leakage of liquid of different colour.
Re-screw the draining valve (5) and restore the proper level of oil tank.
Put the cap (4) screwing it on the reservoir.

Sub 3-21

USE
MAINTENANCE

3

Brake circuit bleeding
CAUTION
The fluid used in the brake circuit, apart damaging the paint, is very damaging in contact of eyesand skin; wash thoroughly with running water the interested parts in the event of accidental
contact.
Remove the cover (1) with membrane from the brake fluid reservoir (2) unscrewing the screws (3).

Unscrew the cover (4) of the rear brake fluid reservoir (5).

Sub 3-22

USE
MAINTENANCE

3

Connect to draining valve (3) or (5) of the caliper a bleeding device, commonly available in trade.
Loosen the draining valve (3) or (5) and pump with the bleeding device until no more fluid exit fromthe circuit.
NOTES
When using a brake bleeding device, follow the manufacturer’s instructions.
In case of a draining device is not available, connect a transparent plastic hose to the draining
valve 3 or 5 of the caliper, then dip the other end into a container on the floor, with used brake fluid
inside.

Unscrew of ¼ of turn the draining valve.
Move the lever or the brake pedal till the total leakage of the liquid.
Perform the operation for each brake caliper.

Sub 3-23

USE
MAINTENANCE

3

Brake circuit filling
CAUTION
The fluid used in the brake circuit, apart damaging the paint, is very damaging in contact of eyesand skin; wash thoroughly with running water, the interested parts in the event of accidental
contact.
Fill the reservoirs (1) and (2) with prescribed oil taken from an intact container.

IMPORTANTKeep always at level the oil of the circuit during the whole operation and leave the end of thetransparent hose always dipped in the drained liquid.

Sub 3-24

USE
MAINTENANCE

3

Move several times the lever or the brake pedal to fill the circuit and bleed the air.

Connect to the bleeding valve (3) or (5) the brake bleeding device.
NOTES
When using a brake bleeding device, follow the manufacturer’s instructions.
Pump with the bleeding device and loosen the bleed valve (3) or (5) checking always that the level
does not fall below the MIN.
Repeat this step until any more air bubbles does not appear in the transparent hose connected tothe bleeding valve.
Block the draining valve (3) or (5) to the torque wrench recommended.
In case of a bleeding device is not available, connect a transparent plastic hose to the drain valve(3) or (5) as described for the brake circuit bleeding.

Sub 3-25

USE
MAINTENANCE

3Open the draining valve (3) or (5) of ¼ of turn and operate the lever or the brake pedal until fluid
begins to exit from the valve then close the draining valve. Pull completely the lever or pedal thenloosen the bleeding valve at least of ¼ of turn.
Wait a few seconds; close the draining valve (3) or (5) then slowly release the lever or the pedal.
IMPORTANT
Don't release the lever or the brake pedal if the valve is not very tight.
Repeat this operation until the plastic hose will come out liquid free of bubbles.
Make the bleeding operation acting on a valve at a time.
Lock to the torque required the bleeding valve (3) or (5) and install the protective cap.
To completely remove the air that may remain in the highest point of the front brake pump, act thesame way on the bleeding valve (6). Level the brake fluid in the reservoir.

Sub 3-26

USE
MAINTENANCE

3

Clutch liquid replacement
CAUTION
The fluid used in the clutch system, apart damaging the paint, is very damaging in contact of eyesand skin; wash thoroughly with running water, the interested parts in the event of accidental
contact.
Unscrew the cover (1) with membrane from the system clutch reservoir.
Suck the oil inside the reservoir.
Fill new oil in the reservoir to reach the MAX.

Operate the lever two or three times so as to allow the circuit to go under pressure.
Keep pulled the lever to the grip

Connect a transparent hose to the draining valve (2) then dip the other end in a container on thefloor.
Loosen the drain junction (2) to allow the oil to come out.

Sub 3-27

USE
MAINTENANCE

3

CAUTION
During the filling operation always maintain the oil liquid above the MIN to prevent formation air
bubbles in the circuit.
Drain the oil from bleeding valve (2) until the leakage of liquid of different colour. Re-screw the
bleeding valve (2) and tighten to the recommended torque wrench and restore the proper oil level
into the reservoir.

Clutch liquid draining
CAUTION
The fluid used in the clutch system, apart damaging the paint, is very damaging in contact of eyesand skin; wash thoroughly with running water, the interested parts in the event of accidental
contact.
Remove the protective cap place above the draining valve (2).
Connect to the draining valve (2) a bleeding device.
Loosen the draining valve and pump with the bleeding device until no more fluid leaks from thecircuit.
In case of a bleeding device is not available, connect a transparent plastic hose to drain valve (2)then dip the other end in a container placed on the floor and containing clutch exhausted fluid.

Screw (¼ of turn) the bleeding valve.
Remove the cap (1) with membrane from the fluid reservoir.

Sub 3-28

USE
MAINTENANCE

3

Move the clutch lever up to the complete leakage of the fluid.
To empty completely the circuit it is advisable to remove the clutch piston assembly (4) unscrewing
the three fixing screws (3).

Take off the clutch piston assembly (4) being careful to the OR gasket (5) positioned inside.

Sub 3-29

USE
MAINTENANCE

3

Push on the small internal piston to make leak all the fluid content inside the cap.

Proceed the reassembly of the piston assembly tightening the screws (3) to the prescribed torque.
Tighten the bleeding valve to the prescribed torque.

Clutch liquid filling
CAUTION
The fluid used in the clutch system, apart damaging the paint, is very damaging in contact of eyesand skin; wash thoroughly with running water, the interested parts in the event of accidental
contact.
Fill the reservoir with prescribed oil from an intact container.
IMPORTANTKeep always the oil of the circuit at level during the whole operation and leave the end of thetransparent hose always dipped in the drained liquid.

Sub 3-30

USE
MAINTENANCE

3

Move several times the clutch lever to fill the circuit and bleeding the air.

Connect the bleeding device to the bleeding valve (2).
NOTES
When using a bleeding device, follow the manufacturer’s instructions.
Pump with the bleeding device and loosen the drain valve (2) checking always that the level does
not fall below the MIN.
Repeat this step until any more air bubbles does not appear in the transparent hose connected tothe bleeding valve.
In case a bleeding device is not available connect a transparent plastic hose to the drain valve (2)as described for the circuit bleeding.

Open the bleeding valve of ¼ of turn and operate the clutch lever until the fluid start to come out
from the valve (2) then close the draining valve. Pull completely the clutch lever then loosen the
bleeding valve at least of ¼ of turn.
Wait a few seconds; close the draining valve (2) then slowly release the lever.
IMPORTANTDo not release the clutch lever if the valve is not well tighten.

Sub 3-31

USE
MAINTENANCE

3

Repeat this last action until fluid free of air bubbles will come out from the transparent hose.
Tight the bleeding valve (2) to the prescribed torque and install the protection cap.
Bring the fluid at about 3 mm above the MIN reference level of the reservoir.
Re-screw the cap (1) with the membrane.

Steering bearings clearance adjustment
If there is an excessive handlebar movement or shaking of fork respect to axis
it is necessary to proceed to adjust the steering bearings clearance in the following way:
Loosen the screws (1) and (2) on the steering head triple clamps.

Sub 3-32

USE
MAINTENANCE

3

Unscrew and remove the screw (3) from the steering head.
Now pull up the steering head (4).

Tighten with the appropriate special tool Bimota (cod 507097100) the ring nut of the pivot steering(5) to get the correct bearings clearance.

Reassemble by pushing the steering head (4) on the ring nut (5) and tighten the screws (1) and (2)to the prescribed torque.

Sub 3-33

USE
MAINTENANCE

3

Tighten the screw (3), which fix the steering head to the steering pivot, to prescribed torque.

.

Chain tension adjustment
Move the motorcycle to find the position where the upper part of the chain is more tight. Place themotorcycle on its side stand with the gearbox in neutral (best if you have a central stand).
Place the ruler in the position indicated by the arrow (see the sticker on the swing arm).
Push the chain downwards and tension up until the distance between the swing arm and the chain
pin centre is 58÷60mm.
CAUTION
If the slack is more than 60 mm, the chain may damage the swing arm.

Sub 3-34

USE
MAINTENANCE

3

To adjust tension proceed in the following way:
Loosen the wheel axle (1).
Turn both the right and left adjustment screws (2) of an equal number of turns to obtain the properslack for the chain.
Turn the adjustment screws counter clockwise to tighten the chain.
Turn the adjustment screws clockwise and push the rear wheel forward to get more slack.
Move the motorcycle forward, stop it and put it on the side stand.
Check the chain slack again.

Align the end part of the swing arm plate (3) with reference marks (4) punched on the chain
regulator on both sides of the swing arm.
The two left and right swing arm terminals must be in correspondence to the same referencemarks. If the alignment is not correct, turn the left or right adjusting screw until the terminals are tocorrespond on the graduated scale of the swing arm and then check again the chain clearance.

Tighten the rear wheel axle (1) to the tightening torque of 100Nm.
IMPORTANTA chain not correctly taut causes a quick wear of the drive system.
CAUTION
The proper tightening of the wheel axle is essential for the rider and passenger safety.

Sub 3-35

USE
MAINTENANCE

3

Brake pads wear check-up and replacement
CAUTION
The fluid used in the brake circuit, apart damaging the paint, is very damaging in contact of eyesand skin; wash thoroughly with running water, the interested parts in the event of accidental
contact.
IMPORTANTAt the motorcycle delivery, after having replaced the pads, inform the Customer that for at least
100 km (60 mi) he must use the front brake carefully to allow a correct and complete settlement offriction materials.

Front brake pads check-up
Check through the aperture of the caliper if the drill on the friction surface of the pads (1) is visible.
IMPORTANT
If just one of the pads is worn-out it is necessary to replace both.
Follow this way to replace the pads:
Remove the calipers.
Remove the safety split pins (2), push the small pistons of the caliper completely inside, opening
the used pads.
Slip off the wear pads (1).
NOTES

Replace the pads with a shiny and “glassy” aspect.
Insert the new pads with the relative safety split pins (2).
Reassemble the brake calipers.
Move several times the brake lever to allow the settlement of the pads.
Check that the brake fluid level in the pump oil reservoir is not below the mark MIN.

Sub 3-36

USE
MAINTENANCE

3

Filling up brake fluid
Turn the half handlebars to level the reservoir.
Remove the tank cap by unscrewing the two screws (1)Remove the inner membrane from the reservoir and top up with the prescribed fluid to the
maximum level.

Reassemble the removed components.

Rear brake pads check-up
Check through the aperture of the caliper that at least 1 mm of friction surface is visible on thepads.
IMPORTANT
If just one of the pads is worn-out it is necessary to replace both.

Sub 3-37

USE
MAINTENANCE

3

Proceed to pads replacement in the following way:
Remove the safety split pins (1) (on the caliper inner side) from pads pin (2).
Push the small pistons of the caliper completely inside their own seat, opening the used pads.
Slip off the pads pin (2).
Remove the pads holder spring (3) placed between the semi-calipers.
Slip off the wear pads (1)NOTES
Replace the pads with a shiny and “glassy” aspect.

Insert the new pads and relative spring (3). Insert the pin (2) and lock it with the safety split pin.
Move the brake pedal several times to allow the settlement of the pads under the action of brakefluid force.
Verify that the oil level in the reservoir is between the MIN and MAX mark. Otherwise provide totopping after having unscrewed the reservoir cap (4).

NOTES
Remove the calipers if the replacement operation is difficult.
CAUTION
Being the brake calipers a security part of the bike, be careful when reassembly to the tightening
torque of calipers fixing screws

Sub 3-38

USE
MAINTENANCE

3

Throttle cable regulation
The throttle grip in all steering positions must have a play that measured on the end of the grip
should be of 2÷4mm.

If adjustment is necessary, act on the regulator (1) and (2) placed in correspondence to the rightside of the steering tube. The regulator (1) acts on opening of the throttle control, while regulator(2) on the closing.

Remove the protection cases from the regulators and loosen the lock nuts (3).
Adjust acting proportionally on both registers: by turning it clockwise increase the play, counterclockwise decreases it. When adjustments are completed tighten the lock nuts and wear theprotection cases on regulators.
Periodically it is necessary to check the condition of the outer sheath of the opening cable (1) andthe closing cable (2). There must not be any crush or cracks in outer covering.
To maintain the control smoothness lubricates periodically the cables ends with the required
grease.
After having adjusted the gas control play, check the smooth operation of internal cable: if there arefrictions substitute it.

Sub 3-39

USE
MAINTENANCE

3

Clutch lever and front brake lever adjustment
The clutch lever and the front brake lever have a knob (2) for the adjustment of the distance
between the lever itself and the half-handlebar grip.
The levers distance is regulated by 10 knob clicks (2).
Rotating clockwise the lever moves away from the handle grip.
Whereas, rotating the knob anticlockwise, gets near.

CAUTION
The adjustment of the clutch and brake levers must be carried out at stopped motorcycle

Sub 3-40

USE
MAINTENANCE

3

Rear brake pedal and shift lever position adjustment
In accordance to any pilot drive requirement it is possible to adjust the position of the shift pedal
and rear brake pedal respect to the footpegs.
To modify the position of the shift control pedal proceed as follows:
Lock the shaft (1) and loosen the lock nuts (2) and (3).
NOTES
The nut (2) has a left hand thread.
Rotate the rod (1), operating with a spanner on the hexagonal part, till the shift lever pedal has
reached the required position.
Tighten both the lock nuts (2) and (3).

To modify the position of the rear brake pedal proceed as follows:
Loosen the screw (2) that blocks the eccentric cam (3), therefore loosen the lock nut (4) of theregulator rod (5).
Rotate the adjuster rod (5) clockwise to lower the brake lever (1), and counter clockwise to raise it.
Once the correct position is found tighten the lock nut (4) and check, moving manually on thepedal, that there is play before starting the braking action.
Rotate the cam (3) until it touch the pedal and, keeping it in this position, tighten the screw (2).
Make sure the rear wheel turns freely with the brake pedal released.

Sub 3-41

USE
MAINTENANCE

3

Fork adjustment
The motorcycle fork is adjustable in preload, rebound and compression.
The adjustment is done by external screw adjusters:
1) to modify the internal springs preload;2) to modify the hydraulic brake in rebound;3) to modify the hydraulic brake in compression.
Place motorcycle upright, in stable way.
Screwing completely clockwise the adjustment screws (2) and (3) and the preload regulator (1) up
to block them, you get “0” position, corresponding to maximum braking and preload.
Starting from this position, rotating counter clockwise, you can count the various turns
corresponding to position “1/2 turn”, “1 turn” etc.
The standard adjustment are the following:
Spring preload: 7,5 turns
Compression: 1 turnRebound:1,5 turn.

Spring preload:
To modify the preload of the internal spring of each stem, rotate the preload adjuster (1) with a
22 mm hexagonal wrench.
SOFT: rotate the adjuster counter clockwise to SOFT position, in case of light weights, and driving
on normal and plain roads.
HARD: rotate the adjuster clockwise to HARD for a more severe driving.

Sub 3-42

USE
MAINTENANCE

3

Rebound hydraulic brake:
Rotate with a screwdriver the adjuster (2), placed on the top of each fork stem, to adjust therebound hydraulic brake.
SOFT: rotate the adjuster counter clockwise, towards to SOFT position, in case of light weights,
and driving on normal and plain roads.
HARD: rotate the adjuster clockwise, towards to HARD, for a more severe driving.

Compression hydraulic brake:
Rotate with a screwdriver the adjuster (3), placed on the fork foot, to adjust the compression
hydraulic brake.
SOFT: rotate the adjuster counter clockwise, towards to SOFT position, in case of light weights,
and driving on normal and plain roads.
HARD: rotate the adjuster clockwise, towards to HARD, for a more severe driving.

Sub 3-43

USE
MAINTENANCE

3

Rear shock adjustment
The rear shock absorber has external adjusters which enable to adequate the bike set up inaccordance to load and driving requirements.
It is adjustable in compression (high and low speed), in the spring preload and in rebound (highand low speed).
The adjustment is carried out by external registers:
1) to modify the spring preload;2) to modify the rebound hydraulic brake (high and low speed);3) to modify the compression hydraulic brake (high and low speed).
Place motorcycle upright, in stable way.
Screwing completely clockwise the adjustment screws (2) and (3) and the preload adjuster (1) up
to lock them, you get “0” position, corresponding to maximum braking and preload.
Starting from this position, rotating counter clockwise, you can count the various turns/clicks
corresponding to position “1/2 turn”, “1 turn” etc.
Standard settings:
Spring preload:
Compression:
Rebound:

15 mm
9 clicks
9 clicks.

Preload spring:
Use an appropriate tool to adjust the preload of the rear shock absorber.
SOFT: rotate the preload ring nut register counter clockwise for a more soft driving position, in caseof light loads.
HARD: rotate the preload ring nut register clockwise for a more rigid driving position, in case ofheavy loads.

IMPORTANT
When using with passenger and baggage, preload to maximum the rear shock absorber spring to
improve the dynamic performance of vehicle and avoid possible interference with ground. Thismight require to adjust the rebound hydraulic brake.

Sub 3-44

USE
MAINTENANCE

3

Rebound hydraulic brake:
The rebound adjuster (2) is placed in the upper part of the shock absorber and is adjustable bothfor low and high speeds. To adjust the rebound to high speed use a 15mm wrench while for low
speed a 4mm hexagonal key.
Rotating the adjuster you will notice clicks, count the number of clicks from all closed position(clockwise) for high speed, while for low speed refer the adjuster mark to the numbered scale.
SOFT: rotate the adjuster counter clockwise, in case of light loads and driving on standard andplain road.
HARD: rotate the adjuster clockwise, for a more severe drive and rough roads.

Compression hydraulic brake:
The compression adjuster (3) is placed on the upper part of the shock absorber and is adjustable
both for low and high speed. To adjust the compression to high speed use a 15mm wrench while
for low speed a 4mm hexagonal key.
Rotating the adjuster you will notice clicks, count the number of clicks from all closed position(clockwise) for high speed, while for low speed refer the adjuster mark to the numbered scale.
SOFT: rotate the adjuster counter clockwise in case of light loads and driving on standard and plain
road.
HARD: rotate the adjuster clockwise for a more severe drive and rough roads.

CAUTION
The shock absorber contains high pressure gas and could cause serious damages if dismantled byinexperienced personnel.

Sub 3-45

USE
MAINTENANCE

3

Steering damper
The steering damper (1) is under the dashboard support and it is fixed to the frame and to theforks.
Its action contributes to make steering more precise and more stable, improving the driveability of
motorbike specially in extreme conditions.
Rotating clockwise the damper control (2) the steering will be harder and rotating it counterclockwise it will be softer.
Every regulation position is identified by “click”.
To set up the steering damper in the standard position, rotate completely the regulator (1) counterclockwise.

CAUTION
Never try to modify the steering damper control (1) while driving to avoid loosing the motorbike
control.

Sub 3-46

USE
MAINTENANCE

3

Rear height regulation / bike trim
The bike trim can be modified in accordance to the rider requirements by rotating the eccentric
cams (1) that fixes the suspension upper part.
Before modifying the standard setting, take note of the reference position to restore the original
setting.
To determinate the setting acts as follow:
Place motorcycle upright on a plain surface.
Loosen the screws (2) that tighten the clamps on cams.
Rotate the cams (1) using the Bimota special tool cod. 507097010.
Tighten the screws (2) (tightening torque: 22Nm).
CAUTIONThe bike setup modification is a very delicate operation and can be dangerous if carried out withincompetence.
Drive carefully after having changed the bike trim to take confidence with the new setup.

Sub 3-47

USE
MAINTENANCE

3

3.5 - DIAGNOSTIC ISTRUMENTS
3.5.1 - Walbro diagnosis

Installation of Service Walbro OEM56, Windownloader OEM 2000 and ECUGLoader
softwares for the diagnostic of Walbro ECUG/ECUG equipped Bimota models.

Comments, critics or suggestions must be envoy at:
BIMOTA S.p.A.
Via Giaccaglia, 38
47900 Rimini
Italiae-mail: assistenza.tecnica@bimota.it
Copy for: Dealers and Distributors
All rights reserved. This manual is reserved and can't be reproduced, distributed or make known without thewriting authorization of Bimota S.p.A.

Sub 3-48

USE
MAINTENANCE

3

Introduction
This document defines the operations to be performed to install the software needed for diagnostic
check and updating of calibrations on models equipped with Walbro ECUC/ECUG unit.
Prerequisites
To use the software is necessary to have a PC (better if notebook, if it should be a desktop PC you
must consider that the bike should be to a distance of about 1 m), provided of:- USB port
- CD player- Window Xp operative system- Bimota Diagnosis cable supplied with Bimota Diagnosis kit cod. 506290140

3.6. - Software installation
3.6.1 - Installation diagnosis program Service OEM 564
To install from CD:
1) Insert CD into the player
2) Copy the content of Service OEM564 file on own PC where you consider more opportune.

3.6.2. - USB drivers installation
The USB drivers are in the “drvUsb” directory.
When connecting the interface cable (cod. Bimota 506290140) Window will automatically provide
to the installation of the new hardware: on this occasion indicate the position of drivers USB
contained in the above mentioned CD.

3.7 - Vehicle connection for diagnostics
To connect the vehicle at the PC for diagnostic, connect the interface cable to the USB port on the
PC and to the diagnosis plug on the vehicle:

Sub 3-49

USE
MAINTENANCE

3

Bimota DB5 : the diagnosis connector (1) is placed on the left side of the upper fairing, near to
the mirror holder arm.

Bimota DB6 : the diagnosis connector (2) is placed behind the right triangular cover.

Sub 3-50

USE
MAINTENANCE

3

Bimota Tesi 3D: the diagnosis connector (3) is placed on the left side of the headlight.

BIMOTA DB7: the diagnosis connector (4) is placed behind the right fairing.

Sub 3-51

USE
MAINTENANCE

3

3.7.1 - Diagnostic software
NOTES
To carry out the diagnosis of the parameter of the control unit it is necessary to:- Make sure that the main switch key is on OFF position.
- Connect the diagnosis cable cod 506290140 to the diagnosis connector.
Launch the diagnostic program named “Service OEM 564”.

It will appear the following screen:

Sub 3-52

USE
MAINTENANCE

3

Click OK
It will appear the following screen:

Select the English.WCL file.
It will appear the following screen:

Sub 3-53

USE
MAINTENANCE

3Enter the menu Open in top left and select device.
Once selected device, it will appear the following screen, select file
“CNS_G1BIM_03$US_NEW.dcn” for the control unit ECUG, or file
CNS_C9B_04$US_NEW_SERVICE.dcn for ECUC control unit.

It will appear the standard working screen called “console”:

At this point it is necessary to select the COM port to use for the connection between the PC andthe control unit (set as default on COM1).
This is the program operative screen enabling to carry out the following operations:
1) Display of engine parameters in real time2) Display and possible reset of errors on injection system
3) Setting of “end line” parameters
4) Display of hour-counter

Sub 3-54

USE
MAINTENANCE

3

3.7.2 - Real time parameters view
To display the parameters on real time it is necessary to “start the console” by clicking directly on
the “hammer” icon or selecting start from the console menu.
This operation must be carried out with key ON and diagnosis cable connected to PC.
From the console menu it is always possible to know the type of control unit connected.
This operation must be carried out with key ON and diagnosis cable connected to PC.

Here after explanation of each single item:- ERCOUNTER:- RPM:- MAP:- TPS:- AIR_T:- ENGINE_T:- BATT_V:- START_SWITCH:- SIDESTAND:- NEUTRAL:

Crank shaft r.p.m.
r.p.m.
atmosphere pressure
throttle position sensor
air temperatureengine temperaturebattery voltage
start switch
side stand switch
neutralThe communication with the control unit can be interrupted by clicking on “prohibition” icon, or
selecting stop on console menu.

Sub 3-55

USE
MAINTENANCE

3

3.7.3 - Diagnosis
To enter to the diagnosis it is sufficient to select menu ”Diagnostic”.
This operation must be carried with key ON and diagnosis cable connected to PC.
You can read the errors stored by the control unit pushing the button READ and cancel them withbutton RESET.
This operation must be carried out with key ON and diagnosis cable connected to PC.

Sub 3-56

USE
MAINTENANCE

3

3.7.4 - End of line
The menu End of Line is dedicated to the following operations:- reset TPS- setting of idle CO value of vertical and horizontal cylinder- offset the injection quoted plans.
This operation must be carried out with key ON and diagnosis cable connected to PC.
1. To reset the TPS you have to read the values in the field “TPS value” positioning the throttle toits minimum and maximum opening then writing the read values respectively in the fields“TPS_MIN” and “TPS _MAX”.
2. For the idle CO modification it is sufficient to insert the desired multiplicative value in the field
CO_MIN_1 (horizontal cylinder) CO_MIN_2 (vertical cylinder).
In the example below 1,047 means to increase of about 5% the idle injection time.

3. To offset the injection quoted plans of both cylinders use the same procedure for idle CO, writing
the desired value in the field INJ_OFFSET_0. The field INJ_OFFSET_1 is not active.
The field MAP_ID displays the identifying number of calibration.
To upload the setting on the control unit is necessary to click on button “set line end parameters”.

Sub 3-57

USE
MAINTENANCE

3

3.7.5 - Hour counter
Entering in the menu Hours counter is possible to know how many working hours has the control
unit. This operation must be carried out with key ON and diagnosis cable connected to PC.

NOTES
To switch from a function to another (for example from hour counter to diagnostic) is necessary toclose the application and then open the subsequent.

3.8 - Installation of Windownloader OEM 2000 program (use for ECUC)
For CD installation:
1. Insert the CD in the player
2. Copy the content of the file WinDownLoader-OEM2000 on your PC where is more suitable foryou.

Sub 3-58

USE
MAINTENANCE

3

3.8.1 - Calibration update program
NOTES
To carry out the control unit programming is necessary:
1. Make sure that ignition key is on OFF position.
2. Connect diagnosis cable cod. 506290140 to diagnosis connector
3. Insert the two-way “bridge connector” on the corresponding diagnosis cable
cod.506290140.
4. Place ignition key on the ON position.
5. Start the update calibration procedure described below.
Launch the updating calibration program of the control unit called “Windownloader-OEN 2000”.

It will appear the following screen:

Sub 3-59

USE
MAINTENANCE

3

The first operation is to select the communication port to use for the connection between the PC
and the control unit (set by default on COM1).
From menu file or from button ”sheet” is possible to select the version of the calibration to”download” inside the control unit.

Once selected the file, the download of the calibration can be launched by pressing the button “redarrow” or by selecting the download option from menu file.
Wait about 3 minutes for download completion after which will appear the message “download
successfully completed”
Take the ignition key on OFF position and disconnect the diagnosis cable.

NOTES
The file MAP.txt contains the references map/calibration model.

Sub 3-60

USE
MAINTENANCE

3

3.9. - Installation of EcugLoader-1000 program (use for ECUG)
For the installation from CD:
1. Insert the CD in the player
2. Copy the content of file ECUGLOADER-1000 on your PC where is more suitable for you.

3.9.1 - Calibration update program
NOTES
To carry out the control unit programming is necessary:− Make sure that ignition key on OFF position− Connect diagnosis cable cod. 506290140 to diagnosis connector− Insert the two-way “bridge connector” on corresponding diagnosis cable cod.506290140.
− Place ignition key on the ON position.
− Start the update calibration procedure described below
Launch the updating calibration program (ECUGLOADER-1000) of the control unit

Sub 3-61

USE
MAINTENANCE

3

It will appear the following screen:

The first operation is to select the communication port to use for the connection between the PC
and the control unit (set default on COM1).
From menu file or from button ”sheet” is possible to select the version of the calibration to”download” inside the control unit.

Sub 3-62

USE
MAINTENANCE

3

After having selected the file you can start the download of the calibration pressing the button “redarrow” or selecting the download option from menu file.
Wait about 3 minutes for download completion after which will appear the message “download
successfully completed”
Take the ignition key on the OFF position and disconnect the diagnosis cable.

Sub 3-63

4

BODYWORK

CHAPTER 4
BODYWORK
4.1 - FRONT FAIRING AND REARVIEW MIRRORS
Sub 4-2
Rearview mirrors removal…..……………….………………………………………………Sub 4-2
4.2 - FAIRING
Sub 4-4
Removal of side firings and lower fairing………….………..………………………….….Sub 4-4
4.3 - FRONT MUDGUARD
Sub 4-6
Front mudguard removal...………………………………………………………………….Sub 4-6
4.4 - TAIL - SEATSub 4-7
Tail removal…..……………………………………………………………………………….Sub 4-7
Seat removal..…….……….………………………………………………………………….Sub 4-8
4.5 - LICENSE PLATE HOLDER – REAR MUDGUARD
Sub 4-9Removal of license plate holder……..…………....…………………………………….….Sub 4-9
Removal of rear mudguard………………………………..……………………………..….Sub 4-10
4.6 – PINION COVER – CHAIN GUARD
Sub 4-11

Sub 4-1

BODYWORK

4

4.1 - WINDSHIELD AND REARVIEW MIRRORS
Rearview mirrors removal

1)
2)
3)
4)
5)
6)
7)
8)

dashboard
front fairing support
fairing coverfront fairingwindshieldrear view mirrors rubber
rear view mirrorsnut

Sub 4-2

4

BODYWORK

Unscrew and remove the four screws (9) then remove the fairing cover (3).

Unscrew the two nuts (8) which fix the rearview mirrors (7) and the upper fairing (4) to the support(2). Repeat the same operations on the opposite side of the bike (refer to the drawing).

Front fairing removal
Unscrew the three fixing screws (10) of both side fairings (11) and widen with care or remove
completely to remove the front fairing.
Slip the front fairing (4) off.

Sub 4-3

BODYWORK

4

4.2 - FAIRING
Disassembly of side fairings and lower fairing

1) frontal lower fairing2) lower fairing
3) side fairing

Sub 4-4

BODYWORK

4

Unscrew the two screws (4) which fix the frontal lower fairing (1) to the side fairings (3).
Unscrew the fixing screw (5) under the lower fairing (2).
Slip off the frontal fairing by pulling upward as indicated by the arrow.

Unscrew and slip off the fixing screws (6) to remove the side fairings (3).

Unscrew and slip off the fixing screws (7) to remove the lower fairings (2).

Sub 4-5

BODYWORK

4

4.3 - FRONT MUDGUARD
Front mudguard removal
Unscrew and slip off the fixing screws (1) on both side of the front mudguard.
Remove the front mudguard (2).

To reassemble perform the removal operation in reverse order.

Sub 4-6

BODYWORK

4

4.4 - TAIL – SEAT
Tail removal
Unscrew the screw (1) of the exhaust silencer holder.

On both side of the bike unscrew the screws (2) which tie up the tail (3) to the frame plates.

Slip off the tail (3) towards the direction indicated by the arrow paying attention to disconnect therear turn signals cable and the rear lights cable (4).

Sub 4-7

BODYWORK

4

Seat removal
To remove the rider seat is not necessary to removal the tail.
Unscrew the six screws (1) under the tail and slip off the lower cover (2).

Unscrew the three screws (3) inside the tail.

Remove the seat (4) upwards, as indicated by the arrow.

Sub 4-8

BODYWORK

4

4.5 - LICENSE PLATE HOLDER – REAR MUDGUARD
Removal of license plate holder
Remove the lower cover under the tail then disconnect the six connectors (4) of turn signals / taillights which are inside.

Unscrew the four screws (1) which fix the license plate holder (2) to the tail (3).
Remove the license plate holder (2).

Sub 4-9

BODYWORK

4

Unscrew the two screws (5) to remove the license plate holder (6).

Rear mudguard removal
Unscrew the three fixing screws (1) and remove the rear mudguard (2).

Sub 4-10

BODYWORK

4

4.6 – PINION COVER – CHAIN GUARD
Unscrew the three fixing screws (1) to remove the pinion cover (2).

Unscrew the three fixing screws (3) to remove the chain guard (4).

Unscrew the two fixing screws (5) to remove the lower chain protection (6).

Sub 4-11

CONTROLS AND
DEVICES

5

CHAPTER 5
CONTROLS AND DEVICES
5.1 - THROTTLE CONTROL
Sub 5-2
Throttle twistgrip removal…..…….......….….………………………………………………Sub 5-3
5.2 - FRONT BRAKE CONTROL
Sub 5-4
Disassembly of front brake master cylinder……………..…..……..………………….….Sub 5-5
5.2 - REAR BRAKE CONTROL
Sub 5-6
Rear brake removal…..…………..………………………………………………………….Sub 5-7
5.4 - HYDRAULIC CLUTCH CONTROL
Sub 5-9
Disassembly of hydraulic clutch pump…………….……..…..……..………………….….Sub 5-5
5-5 – SHIFT CONTROL
Sub 5-11
Complete shift lever removal…............………....…………………………………….….Sub 5-12

Sub 5-1

CONTROLS AND
DEVICES5

5.1 - THROTTLE CONTROL

1) grip2) throttle3) right switch
4) throttle cables

Sub 5-2

CONTROLS AND
DEVICES

5

Throttle twistgrip removal
Slip off slightly the protection cap (1) of the throttle cable.
Unscrew the screws (2) of the throttle (3) and open the throttle control.

Disconnect the throttle opening and closing cables (4) by unhooking the cable ends (5) from theirseats.
Remove the twistgrip (3) from the right hand handlebar.

Sub 5-3

CONTROLS AND
DEVICES5

5.2 - FRONT BRAKE CONTROL

1) complete master cylinder
2) aluminium brake lever3) brake lever pawl4) microswitch lever pivot5) brake lever regulator pivot6) radial master cylinder
7) screw8) microswitch9) rubber hose
10) screw11) brake fluid tank plate holder12) small rubber
13) Special screw
14) nut
15) brake fluid tank16) cable tie

Sub 5-4

CONTROLS AND
DEVICES

5

Disassembly of front brake master cylinder
CAUTION
The manufacturer of the brake pump, considering the importance of this part in terms of safety,
suggests not working in any way inside the pump.
An overhaul not correctly done, can seriously endanger the rider safety.
The replacement operation must be limited to the control lever, the oil reservoir with relative holder
components and pump holder.
Empty the brake circuit.
Disconnect the brake control hose from the master cylinder group.
Unscrew the fixing screws (1) of the mounting clamp (2) and remove the front brake mastercylinder (3) from handlebar. For the removal of the pump unit components (3) refer to the exploded
drawing.

When you reassemble the hoses is necessary to put the junction (4) with gaskets (5) and tighten
the junction to the correct tightening torque.

Reconnect the brake pump hose to the master cylinder unit.
After having reassembled the clutch control fill the brake circuit using the proper oil.

Sub 5-5

CONTROLS AND
DEVICES5

5.2 - REAR BRAKE CONTROL

1) screw2) washer D53) oil reservoir4) rear brake reservoir spacer5) rubber hose
6) cable ties7) screw8) rear master cylinder
9) rear master cylinder rod10) nut
11) nut
12) uniball13) eccentric cam14) screw15) brake lever fixing plate16) brake lever spacer17) screw18) flanged bush19) bush20) rear brake pedal21) screw22) brake pedal
23) brake pedal rubber24) screw25) special screw
26) screw

Sub 5-6

CONTROLS AND
DEVICES

5

Rear brake removal
Empty the brake circuit.
Remove right fairing.
CAUTION
The manufacturer of the brake pump, considering the importance in terms of safety of this part,suggests not working in any way inside the pump.
An overhaul not correctly done can seriously endanger the rider safety.
Unscrew the special screw and hydro-stop switch (27) from the pump (8) and slip off the brakehose keeping the gaskets (28).

Unscrew the special screw (25) and remove the rear brake lever (20) as shown on picture A.

Sub 5-7

CONTROLS AND
DEVICES5

To remove the rear master cylinder (8) is necessary to remove the right engine plate (28).
Unscrew the screws and the nut (29) and remove the right engine plate (28).

Unscrew the fixing screws (7) of the rear brake pump (8) to the right plate engine (28).

Remove the oil reservoir (3) together with its hose (5) from the frame unscrewing the screw (1).
Remove the complete rear brake control.

Sub 5-8

CONTROLS AND
DEVICES5

5.4 - HYDRAULIC CLUTCH CONTROL

1) complete clutch pump2) screw3) clutch pump4) adjustment pin5) aluminium clutch lever6) pawl7) special screw8) oil reservoir bush9) oil reservoir holder plate10) screw11) bleeding cap12) oil reservoir13) nut M514) cable tie15) rubber hose16) holed junction bolt17) washer18) clutch hose19) holed junction bolt20) cap21) rubber22) microswitch

Sub 5-9

CONTROLS AND
DEVICES

5

Disassembly of hydraulic clutch pump
Empty the clutch pump circuit:
Unscrew the special screw (16), keeping the gaskets (17) to disconnect the clutch control hosefrom the master cylinder group.

Unscrew the fixing screws (2) of the mounting clamp and remove the clutch pump (3) from thehandlebar.

For disassembly and replacement of clutch pump components follow the instructions
exploded draw.
After having reassembled the clutch control fill the clutch circuit using the proper oil.

of theSub 5-10

CONTROLS AND
DEVICES5

5-5 – GEARCAHNGE CONTROL

1) screw2) screw3) gearchange lever4) nut5) uniball6) nut7) nut8) uniball9) screw
10) L.H. footpeg holder
11) TSPEI screw
12) TBEI screw
13) L.H. foot guard14) gearchange pedal
15) eccentric cam pawl16) rubber17) TBEI large head screw18) screw19) special screw20) pin21) holder22) left footpeg
23) screw24) flanged bush25) footpeg spring26) radial seeger27) gearshift bar28) O-ringSub 5-11

CONTROLS AND
DEVICES

5

Complete gearshift pedal removal
Unscrew and remove the fixing screw (19) of the gearshift lever (14) with care to the OR ring (28)and to the flanged bush (24).

Unscrew the lever fixing screw (2) from the gearshift shaft.
Slip off the lever (3) and the complete gearshift pedal assembly from the motorcycle.

NOTES
Before slipping off, mark the position of the lever (3) on to the gearshift shaft.
To remove the lever (3) from gearbox control, unscrew the screw (1).
CAUTION
After having carried out some works on the gearbox control is necessary to check the gearshiftpedal position.
For the reassembly perform in reverse order the operations carried out for the removal of the unit.
In particular use grease on the OR (28), apply threadlocker on the screws (1) and (2), then tighten
to the prescribed torque.

Sub 5-12

WHEELS-BRAKESSUSPENSIONS

6

6.1 - FRONT WHEEL
Sub 6-2
Front wheel removal…................................................................................................ Sub 6-3
6.2 – FRONT FORKSub 6-5
Fork removal…..….......................................................................................................Sub 6-6
6.3 – FRONT BRAKE
Sub 6-8
Front brake removal……..............................................................................................Sub 6-9
Brake discs removal..…..............................................................................................Sub 6-11
6.4 – REAR WHEEL AND FINAL DRIVE
Sub 6-12
Rear wheel removal……............................................................................................Sub 6-13
Final drive check-up………........................................................................................Sub 6-14
Chain washing...........................................................................................................Sub 6-14
Chain lubrication........................................................................................................Sub 6-14
Drive sprocket removal…..........................................................................................Sub 6-15
Rear sprocket removal…...........................................................................................Sub 6-16
Rear wheel check-up.................................................................................................Sub 6-16
6.5 - SWING ARM
Sub 6-18
Swing arm disassembly.............................................................................................Sub 6-19
6.6 - REAR BRAKE
Sub 6-22
Rear brake caliper removal…....................................................................................Sub 6-23
Speed sensor removal…............................................................................................Sub 6-24
Rear brake disc removal….........................................................................................Sub 6-24
6.7 - REAR SHOCK
Sub 6-25
Rear shock removal…...............................................................................................Sub 6-26
Rocker arm removal…...............................................................................................Sub 6-27

Sub 6-1

WHEELS-BRAKESSUSPENSIONS

6

6.1 - FRONT WHEEL

1) front rim 3.50”x17”2) spacer3) wheel bearings
4) front wheel pivot spacer5) front brake disks
6) screw M8x187) L.H. fork leg assembly8) R.H. fork leg assembly9) brake calipers spacers10) R.H. brake caliper11) L.H. brake caliper12) screw M10x1,25x65
13) special screw M20x1x1314) screw M8x4015) front wheel axle

Sub 6-2

WHEELS-BRAKESSUSPENSIONS

6

Front wheel removal
Remove the front brake calipers together with their hoses by unscrewing the screws (12).
Recover the spacers (9).

CAUTION
Not operate the brake lever when the calipers are dismantled. This might cause the expulsion of
the pushing pistons of the brake pads.
Not to damage the brake hose, the pliers unit should not remain attached to cable. Besides be
careful not to twist the brake hose.
Support adequately the motorbike so that the front wheel is raised from the ground.
Loosen the screws (14) of the L.H. leg lower end.
Unscrew the special screw (13) from the front wheel axle.

Sub 6-3

WHEELS-BRAKESSUSPENSIONS

6

Loosen the screws (14) of the R.H. leg lower end .
Pull the front wheel axle (15).
Remove the wheel and recover the L.H. spacer (4).

IMPORTANTTo reassembly the front wheel perform the operations in reverse order taking care to properly
replace the L.H. spacer of the wheel axis.
If there isn’t enough clearance between brake disk and caliper body, the brake disks can bedamaged and the braking efficiency reduced.
If you have not used a torque wrench for the installation, make check as soon as possible from a
Bimota dealer that the installation is correctly performed.

Sub 6-4

WHEELS-BRAKESSUSPENSIONS

6

6.2 – FRONT FORK

1) L.H. fork leg2) right fork stem3) front wheel pivot
4) screw5) washer6) front fender right holder
7) screw8) front wheel pivot spacer
9) screw10) front fender left holder11) front fender13) screw14) nylon washer

Sub 6-5

WHEELS-BRAKESSUSPENSIONS

6

Fork disassembly
Remove the upper fairing, the front brake calipers, the front fender, the front wheel.
NOTES
Before slipping the forks off measure with a calliper or take note of the marks visible on the fork
from above the steering head. They indicate the unthreading of the fork of the steering head
recommended by Bimota.
Loosen the clamp bolts (16).

Loosen the bolts (17) securing the handlebar clamps to the fork legs.

Sub 6-6

WHEELS-BRAKESSUSPENSIONS

6

Loosen the clamp bolts (18) securing the fork legs to the bottom steering clamp.

Withdraw the fork legs (1) and (2) downwards in order to carry out to all the necessary
maintenance operations.

NOTES
Reassembling the fork or changing the front height of the bike, do not slip the fork off more than
three marks visible above the steering head and inside between the two fork legs as indicated in
the picture above.

Sub 6-7

WHEELS-BRAKESSUSPENSIONS

6

6.3 – FRONT BRAKE

1) holed bolt2) AI washer
3) front brake hose
4) pads
5) bleeding valve6) bleeding valve cap
7) R.H. front caliper8) L.H. front caliper9) screw10) front tire11) spacer12) front brake disk13) screw14) front rim15) 90° valve

Sub 6-8

WHEELS-BRAKESSUSPENSIONS

6

Removal of the front brake system
CAUTION
Brake fluid is corrosive and will damage paintwork. Avoid contact with eyes and skin. In case of
accidental contact, wash the affected area with abundant running water and consult a doctor if
necessary.
Empty the brake circuit.
Unscrew the special screws (1) securing the brake hose to the master cylinder and recover thesealing washers (2).
Remove the master cylinder.

Slip the screw (16) off and release the brake hose (3) from the clip on the steering plate.

Sub 6-9

WHEELS-BRAKESSUSPENSIONS

6

Unscrew the four retaining bolts (9) securing the front calipers to the fork legs.
Recover the spacers (11).

Unscrew the special screws (1) from both calipers and recover sealing washers (2).
Detach the front brake calipers from the brake hose (3).

IMPORTANTThe brake caliper manufacturer advises against any servicing of the internal components ofcalipers. Incorrect overhaul of this safety-critical component can endanger rider safety.
An overhaul not correctly done can seriously endanger the pilot safety.
Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly.
For the substitution of the components mentioned above refer to exploded draw at the beginning ofchapter.

Sub 6-10

WHEELS-BRAKESSUSPENSIONS

6

Dual disks dismantling
NOTES
The front brake discs consist of an inner carrier, which is mounted to the wheel, and an outer rotor.
Both parts must be changed together as a pair.
Remove the front wheel.
Unscrew the six fixing screws of the disk to the wheel (13).
Remove the disks (12) on both side of the wheel.

IMPORTANTThe brake disks must be perfectly clean, without rust, oil, grease, dirt and must not show deep
scratches.

Sub 6-11

WHEELS-BRAKESSUSPENSIONS

6

6.4 – REAR WHEEL AND SECONDARY DRIVE

1) nut2) rear sprocket3) chain4) spacer5) seeger ring6) sprocket holder flange7) pin8) spacer9) rear rim10) tug absorber rubber
11) bush
12) bearing
13) screw14) flange15) spacer16) sealed bearing17) 90° valve18) rear brake disk19) screw20) right spacer bush21) rear tire22) front sprocket cover23) screw24) front sprocket25) lock washer
26) nut

Sub 6-12

WHEELS-BRAKESSUSPENSIONS

6

Removal of the rear wheel
Lift the rear wheel from the ground using a bike stand that hold the swing arm side supports (1).
Loosen the rear wheel pivot (2).
Remove the rear axis pivot.
Bring forward the wheel and remove the drive chain from the rear sprocket.
Remove the rear wheel.

Installation notes:
To install the rear wheel, reverse the removal procedures.
Adjust the drive chain.
Tighten the rear wheel pivot to the specified torque: 100 Nm.
NOTES
Pay attention to do not damage the brake pads installing the wheels.
After having installed the wheel, operating the brake several times then check that the wheel spins
free.
Check the wheel again if the brake makes contact and if the wheel doesn't spin free.
If you have not used a torque wrench for the installation, contact soon a Bimota dealer to check if
the installation has been correctly done. If the installation is not correct you might have reduction in
the braking performance of the bike.

Sub 6-13

WHEELS-BRAKESSUSPENSIONS

6

Secondary drive check up
To check the wear of the secondary drive is necessary to proceed to the visual inspection of thefront sprocket (24) and of the rear sprocket (2). If the teeth profile is shown as in figure (dottedline) the sprocket must be renewed.

Chain washing
Chains with O-rings must be washed in oil, diesel fuel or paraffin (kerosene).
Do not use petrol, trichloroethylene or other solvents, which could damage the rubber O-rings. For
the same reason use only sprays specifically formulated for use with O-ring chains.
.
Chain lubrication
Chains with O-rings are lubricated and sealed to protect the O-rings themselves against wear in
the pin/bushing area. However, these chains need lubricating at regular intervals to protect metalparts of the chain and the O rings.
Lubrication also serves to keep the O-rings soft and pliable to ensure the maximum sealing
efficiency.
Using a brush, apply a thin protective film of high-density gearbox oil along the entire length of thechain both inside and outside.

IMPORTANTThe substitution of the rear sprocket (2) must be done together with the front sprocket (24) and thechain (3).

Sub 6-14

WHEELS-BRAKESSUSPENSIONS

6

Front sprocket removal
Remove the front sprocket cover (22) unscrewing the screws (23).
Loosen the chain and perform the disassembly of the chain using the appropriate tool.

Remove the chain.
Engage a low gear and unscrew the nut (26).
Remove the nut (26) and the safety washer (25) on the sprocket.
Remove the front sprocket (24) with the chain (3) from the gearbox output shaft.

Sub 6-15

WHEELS-BRAKESSUSPENSIONS

6

Rear sprocket removal
Remove the rear wheel.
Remove the sprocket holder flange (6) from the rear wheel (14).

Unscrew the six nuts (1) then remove the six pins (7).
Remove the rear sprocket (2) from the sprocket holder flange (6).

Sub 6-16

WHEELS-BRAKESSUSPENSIONS

6

Rear wheel check up
Visually inspect the wheel for cracks, scoring and deformation; change the wheel if
damaged.Mount the rim on a balancing device.
Using a dial gauge, measure rim run-out and out-of-round relative to the wheel shaft axis.
If values are not within the limits is necessary to replace the wheel.

Sub 6-17

WHEELS-BRAKESSUSPENSIONS

6

6.5 - SWING ARM

1) swingarm pivot2) right front swingarm spacer3) watertight bearing
4) inner right swingarm spacer5) swingarm
6) lower chain slider7) screw8) inner left swingarm spacer9) oil seal10) bearing
11) upper chain slider12) nut
13) swingarm eccentric cam14) screw15) lower chain guard16) screw17) left swingarm plate18) nut
19) clip nut20) rear fender21) nylon washer22) screw23) right swingarm plate24) rear bikestand bush25) screw
26) screw

Sub 6-18

WHEELS-BRAKESSUSPENSIONS

6

Swing arm removal
Lift the bike from the ground with a proper central stand.
Before proceeding to remove the swing arm it is necessary to remove the following particulars:- rear fender and chain guard- real wheel- rear brake- exhaust manifold of vertical cylinder- mono shock absorber- release the swing arm from the connecting rods of the rear suspension arm
Unscrew and remove the special screws (27) from both engine plates (28).
If necessary loosen the three lower screws of the engine plates to make easier the removing of theswing arm.

Slip the swing arm pivot (1) off and remove the swing arm (5).

Sub 6-19

WHEELS-BRAKESSUSPENSIONS

6

Unscrew the three screws (29) then remove the upper chain slider (30).

Unscrew the three screws (31) then remove the lower chain slider (32).

Unscrew the two screws (14) of the swing arm caps that lock the two eccentric cams (13).

Sub 6-20

WHEELS-BRAKESSUSPENSIONS

6

Remove the two eccentrics (13) from the swing arm.

Unscrew the four screws (26) and remove the swing arm plate (23). Repeat the same operation on
the opposite side.

Sub 6-21

WHEELS-BRAKESSUSPENSIONS

6

6.6 - REAR BRAKE

1) holed nut2) washer3) rear brake hose4) rear caliper5) R.H. chain-tighten slider6) screw7) screw8) speed sensor
9) rear wheel pivot
10) L.H chain-tighten slider11) screw12) rubber cap13) bleeding valve14) rear pads15) hydro-stop

Sub 6-22

WHEELS-BRAKESSUSPENSIONS

6

Removal of the rear brake caliper
IMPORTANTThe brake caliper manufacturer advises against any servicing of the internal components ofcalipers. Incorrect overhaul of this safety-critical component can endanger rider safety.
An overhaul not correctly done can seriously endanger the pilot safety.
Operations should be limited to renewal of the pads, fasteners and the bleed valve assembly.
For the substitution of the components mentioned above refer to exploded draw at the beginning ofchapter.
Empty the rear brake circuit.
Unscrew and remove the screw (1) that fixes the brake hose (3) to the rear brake caliper and therelative gaskets (2).

Unscrew the two screws (6) then remove the rear brake caliper (4).

NOTES
For the brake pads replacement operations follow what mentioned in Chapter “USE AND
MAINTENANCE – brake pads wear check-up and replacement.”

Sub 6-23

WHEELS-BRAKESSUSPENSIONS

6

Speed sensor removal
To remove the speed sensor (8) loosen the fixing screw (11).

To replace the components mentioned above refer to what shown in the exploded draw at the
beginning of chapter.

Rear brake disc removal
Unscrew and remove the five screws (16) that fix the brake disk to the rear wheel then remove therear brake disk (17).
CAUTIONThe brake disk must be perfectly clean, without rust, oil, grease, dirt and must not show deep
scratches

Sub 6-24

WHEELS-BRAKESSUSPENSIONS

6

6.7 - REAR SHOCK

1) nut2) rocker arm fixing screw
3) screw4) swingarm pivot fixing screw
5) L.H. engine plate6) rocker arm pivot7) shim adjuster8) oil seal9) bearing10) rocker arm11) bush
12) shock absorber13) R.H. engine plate14) ring nut15) screw16) screw17) uniball18) nut
19) rear shock to swingarm fixing screw20) connecting rod21) nut22) pivot of rear upper engine joint23) lower chain slider24) screw

Sub 6-25

WHEELS-BRAKESSUSPENSIONS

6

Rear shock
The rear suspension uses a fully adjustable progressive hydraulic monoshock with an interposedrocker arm between the frame and the shock bottom fulcrum. The shock is adjustable in reboundand compression (both at high and low speeds) and preload spring. The swing arm pivots on theengine and the engine plates.

Rear shock removal
Remove the rear wheel.
To remove the rear shock (12) from the swing arm and rocker arm (10) it is necessary to unscrew
and slip the upper screw (25) off then slip the lower screw (18) off and the respective lock-nuts.

Check visually the shock and identify any oil leak or other problems. Replace the shock, if
necessary.
IMPORTANTFor any problem related to shock functioning, contact Bimota authorized dealer.

Sub 6-26

WHEELS-BRAKESSUSPENSIONS

6

Rocker arm removal
Unscrew and remove the two screws (15) and the relative fixing nuts (18) of the connecting rods(20) to the swing arm.

Unscrew and remove the screw (16) then remove the fixing nuts (18).

Sub 6-27

WHEELS-BRAKESSUSPENSIONS

6

Remove the special screw (2) from the L.H. engine plate (5).

Remove the special screw (2) from R.H. engine plate (13)Remove with an Allen wrench the ring nut (14) from the R.H. engine plate (13).

Sub 6-28

WHEELS-BRAKESSUSPENSIONS

6

Remove the rocker arm pivot (6) from the R.H. engine plate (13) then remove the rocker arm (10)paying attention to the nylon spacers (7).

Sub 6-29

FRAME

7

CHAPTER 7
FRAME
7.1 - HANDLEBAR
Sub 7-2
Handlebar removal….................................................................................................. Sub 7-3
7.2 - STEERING
Sub 7-5
Steering head bearings adjustment..............................................................................Sub 7-6
Disassembly of steering components..........................................................................Sub 7-6
7.3 - STEERING DAMPER
Sub 7-8
Steering damper removal….........................................................................................Sub 7-9
7.4 - FOOT PEGS
Sub 7-10
Foot pegs support removal…….................................................................................Sub 7-11
7.5 - SIDETAND
Sub 7-13
Sidestand removal…................................................................................................. Sub 7-14
Sidestand disassembling.......................................................................................... Sub 7-14
7.1- FRAME AND CHASSIS PLATES
Sub 7-16
Frame and structural parts removal…...................................................................... Sub 7-17
Front fairing support removal……............................................................................ Sub 7-17
Frame removal…..................................................................................................... Sub 7-18
7.7 - TAIL
Sub 7-19
7.8 - LICENSE PLATE HOLDER
Sub 7-20

Sub 7-1

FRAME

7

7.1 – HANDLEBAR

1) half-handlebar L.H./R.H.
2) screw3) dowel4) screw5) shim6) half-handlebar holder L7) half-handlebar holder R
8) OR
9) dowel10) throttle grip

Sub 7-2

7

FRAME

Handlebar removal
To remove the R.H. handlebar it is necessary to remove the following particulars:- throttle grip
- R.H. switch- front brake control
To remove the left handlebar, is necessary to remove the following particulars:- L.H. switch- handle grip
- clutch hydraulic control
To remove the steering head (upper steering clamp):
Loosen the clamp screws (4) from each half-handlebar support.
Open the supports (6) and (7) paying attention to do not lose the shims (5) then remove eachsupport.

Unscrew the screw (2) then extract the half-handlebar (1) from its support (6).
Repeat the operation for the other half-handlebar.

Sub 7-3

FRAME

7

IMPORTANT
When reassembling the handlebars on the fork legs pay attention to insert the dowel bolt (3),screwed on the bottom of the steering head, in the relative housings of each handlebar supports(11).
Apply the prescribed grease on the thread of fixing screws (4).

Sub 7-4

FRAME7

7.2 - STEERING

1) screw2) screw3) washer4) steering head base assembly5) dust seal
6) steering bearing
7) steering bearing bush8) ring nut of steering pivot
9) screw10) special screw
11) steering head12) flanged M8 nut13) screw14) main switch spacer15) main switch fixing screw16) lock17) cable tie18) OR

Sub 7-5

FRAME

7

Steering head bearings adjustment
Disassembly of steering components
To disassembly the steering head parts first remove:- side fairings- upper fairing- fork legs- steering damper support- release brake hose behind steering
NOTES
All components which are fixed on the triple clamps assembly, including electric cables and flexible
cables, may remain mounted so long as they not interfere with the operations to be performed.
Remove the steering head (11).

Loosen the ring nut (8) and unscrew it from steering stem with the Bimota special tool
cod.50709710.

Sub 7-6

FRAME

7

from the bottom of the steering tube remove the steering clamp base (4) assembly together with Oring (18), dust seal (5) and crown of lower ball bearing (6).

Loosen the fixing screws (13) of the steering tube.
Remove the upper steering bearing bush together with o-ring, dust seal and bearing.
Remove the lower steering bearing bush.

Sub 7-7

FRAME7

7.3 - STEERING DAMPER

1) screw M6x25x TCEI CZ
2) bush3) steering damper4) bush 10x6,3x75) bush 6,5x10x5,56) screw M4x8 TBEI
7) screw M5x22 TCEI CZ
8) steering damper holder
9) screw M6x25 TEF
10) OR11) nylon collar

Sub 7-8

FRAME

7

Steering damper removal
Remove the upper fairing.
Unscrew and remove the screw (1) which fixes the steering damper (3) to its holder (8), recovering
the two bushes (2) and (4) and the o-ring (10).

Unscrew the screw (3) which fixes the steering damper (3) to the frame, recovering the two bushes(5) and (2) and the o-ring (10).

Remove the support clamp (12) by unscrewing the screw (13).

Sub 7-9

FRAME7

7.4 - FOOT PEGS

1) screw2) R.H. footpeg holder
3) screw4) R.H. foot guard5) screw6) pin7) footpeg fork8) R.H. footpeg
9) spring10) seeger11) screw
12) L.H. footpeg holder13) screw
14) L.H. foot guard15) screw16) pin17) holder18) seeger19) spring20) L.H. footpeg
21) special screw22) OR23) flanged bush

Sub 7-10

7

FRAME

Footpegs support removal
In order to remove the L.H. footpeg assembly first remove the gearchange pedal unit (24) from theleft footpeg support (2).
Unscrew the two screws (11) which fix the support to the engine plate then remove the footpeg
assembly (12).

It is also possible to remove the L.H. footpeg assembly together with the gearchange pedal groupas showed by the picture below.

Remove the two screws (3) which fix the support to the engine plate then remove the footpeg
assembly (2).

Sub 7-11

FRAME

7

Foot pegs removal
In order to remove the footpeg and the footpeg fork from the support (2) (12), unscrew and remove
the screws (1) (13).

In order to remove the footpeg (8) from the footpeg fork (7), remove the seeger (10) then slip thepin (6) off releasing the footpeg and the spring (9). Operate in the same way for the L.H. foot peg.

Sub 7-12

FRAME

7

7.5 – SIDESTAND

1) screw M10x25 TCEI CZ
2) sidestand plate3) complete sidestand4) spring fixing screw
5) screw M4x8 TSPEI
6) sidestand foot7) sidestand leg8) screw M5x8 TBEI
9) screw10) sensor plate11) sidestand stopping plate12) screw M5x10 TBEI
13) sensor support plate14) sidestand switch15) inner spring15) outer spring

Sub 7-13

7

FRAME

Sidestand removal
Disconnect the connector of the sidestand switch (14) from the main cable.
Unscrew the screws (1) which fix the sidestand support plate (2) to the engine then remove thesidestand assembly.

Sidestand disassembly
In order to remove the springs (15) and (16) release them from the sidestand support plate (2) andfrom the screw (4) on the back side of the leg (7).

Sub 7-14

FRAME

7

Unscrew the screw (9) which fixes the sidestand to the support plate then remove it.

Unscrew the fixing screw (8) then remove the small plate (10).
Unscrew the two screws (12) then remove the small plate (13).

.
Unscrew the screw (12) then remove the small plate (11).

IMPORTANTMounting the sidestand in the support plate, check that there is not excessive clearance and thatthe two ends of the sidestand are not bent in respect to the stem.
If breaking signs are noted replace the sidestand.
Sub 7-15

FRAME

77.1- FRAME AND CHASSIS PLATES

1) frame
2) L.H. frame plate3) R.H. frame plate4) screw TCEI M10x1,255) nut M12x1,25 Gally
6) screw M6x12 TBEI
7) velnut M68) L.H.fairing fixing plate9) screw M8x20 TSPEI10) spacer11) engine pin12) frame support13) rubber pad14) R.H. fairing fixing plate15) spacer16) screw M6x10 TBEI

Sub 7-16

FRAME

7

Frame and structural parts removal
In order to remove the frame it needs to remove all the parts mounted on it, making reference to all
the removal procedures reported in the specific sections.
The structural parts of the frame are the front fairing support and the tail.
Both have the function to support some of the motorcycle structures and for this reason they must
be in perfect conditions.

Front fairing support removal
Remove the front fairing.
Remove the dashboard.
Disconnect the electric connections and remove any cable clamp from the fairing support.
Remove the front fairing support unscrewing the side screws (17) and the two screws(18) which fix
the main switch.

Sub 7-17

FRAME

7

Frame removal
Remove the rear frame support, unscrewing the screws (9) from both the frame plates.

Unscrew and remove the four screws (4) then remove the L.H. chassis plate (2).
Repeat the same operation for the R.H. chassis plate (3).

Sub 7-18

7

FRAME

7.7 – TAIL

1) screw M4x20 TBEI
2) nylon washer
3) velnut M44) tail lower cover5) screw M8x35 TSPEI
6) screw M8x20 TSPEI
7) license plate holder
8) screw M5x12 TBEI
9) D5 washer
10) screw M6x20 TCEI CZ
11) left turn indicator12) right turn indicator13) M6 nut
14) M5 nut
15) M5 nut
16) screw M5x16 TCEI CZ
17) M6 nut18) washer

19) tail light fixing plate20) cable ring21) bush
22) tail light23) license plate light24) license holder25) screw M5x16 TBEI
26) reflex reflector
27) D4 washer28) M4 nut29) washer30) screw M5x14 TBEI
31) rear seat32) rider seat33) tail34) sticker “millenovantotto” + flag35) rear light wiring

Sub 7-19

FRAME7

7.8 - LICENSE PLATE HOLDER

1) tail light plate2) screw M5x12 TBEI
3) M5 nut4) tail light5) spacer6) screw M4x10 TCEI CZ
7) screw M4x25 TCEI8) reflex reflector9) reflex reflector plate holder10) screw M4x1011) washer
12) M5 nut
13) D5 washer
14) M4 nut
15) washer
16) tail light wiring17) rear mudguard18) screw M5x20 TBEI19) spacer20) M5 nut21) rear reflex reflector22) side reflex reflector (amber)

Sub 7-20

EXHAUST - INTAKE

8

CHAPTER 8
EXHAUST – INTAKE
8.1 - EXHAUST
Sub 8-2
Exhaust removal…..................................................................................................... Sub 8-3
8.2 - FUEL TANK
Sub 8-7
Fuel tank removal…....................................................................................................Sub 8-8
Fuel tank refitting..…...................................................................................................Sub 8-8
Fuel pump removal…..................................................................................................Sub 8-9
Filler cap removal........................................................................................................Sub 8-9
8.3 - THROTTLE BODY
Sub 8-10
Airbox and throttle body removal…...........................................................................Sub 8-11
Injectors removal…...................................................................................................Sub 8-13
Stepper motor removal…...........................................................................................Sub 8-15
Airbox disassembling - throttle body.........................................................................Sub 8-16
8.4 - INTAKE - AIRBOX
Sub 8-17

Sub 8-1

EXHAUST - INTAKE

88.1 - EXHAUST1) Silencer2) exhaust expansion3) vertical cylinder head exhaust pipe4) horizontal cylinder head exhaust pipe5) R.H. expansion cover6) L.H. expansion cover7) expansion holder
8) gasket
9) lambda sensor
10) washer11) spring12) spring13) screw M6x30 TCEI CZ
14) M6 screw cap15) fixing plate16) rubber17) silencer holder18) rubber

19) bush20) M6 nut21) washer
22) D6 washer23) screw M6x16 TCEI CZ24) holder mounting support25) rubber pad26) M6 nut27) washer28) washer29) screw M5x16 TBEI30) CO cap
31) T bush32) washer M5x16 TBEI33) D5 grover washer34) screw M5x10 TBEI35) washer D5

Sub 8-2

EXHAUST - INTAKE

8

Exhaust removal
Remove the fairings.
Unscrew the screw (13) which fix the silencer (1) to the support arm (17) and recover the bushes
and gaskets.

Remove the springs (12) and slip the silencer (1) off from the exhaust pipe.

Sub 8-3

8

EXHAUST - INTAKE

Unscrew the three nuts (20) that fix the vertical exhaust manifold (3) to the cylinder head.

Remove the spring (12), slip the vertical exhaust manifold (3) off and recover the gasket (8).

Sub 8-4

EXHAUST - INTAKE

8

Remove the screw (36) which fixes the exhaust expansion (2) to the L.H. engine plate.
Remove the spring (12).

Unscrew the screw (13) which fix the exhaust expansion (2) to the R.H. engine plate and recover
the bushes, washers and gaskets.
Remove the exhaust expansion (2).

Sub 8-5

8

EXHAUST - INTAKE

Remove the lambda sensor (9) from the horizontal exhaust manifold (4).

Unscrew the three nuts (20) which fix the horizontal exhaust manifold (3) to the cylinder head.
Remove the horizontal exhaust manifold (4) and recover the gasket (8).

Unscrewing the three screws (34) to remove the exhaust expansion cover (5) then recover thewashers and bushes.

Sub 8-6

EXHAUST - INTAKE

88.2 - FUEL TANK

1) fuel tank2) sticker “bimota”
3) filler cap
4) screw M5x12 TCEI CZ
5) D5 washer
6) screw M6x30 TCEI CZ
7) T bush8) washer9) washer10) vibration damper11) union12) screw M6x12 TCEI CZ

13) fuel pump14) washer 6x18x1.615) screw M5x16 TCEI CZ16) hose guide17) bush18) plate19) vibrations damper20) screw M6x25 TCEI CZ21) clamp22) 4x9 pipe23) Y union

Sub 8-7

8

EXHAUST - INTAKE

Fuel tank removal
Remove the tail.
Remove the screw (6) which fixes the front of the tank.

Remove the screws (20) on the back of the tank.

If necessary, before removing the tank remove the drain hoses, the electric connector and thegasoline hose paying attention to gasoline leakages.
Remove the tank.

Fuel tank refitting
To refit the fuel tank repeat in reverse order the operations described above paying attention toproperly replace the gasoline hose, the electric connector and the drain hoses in the original
position.
IMPORTANT
Check the condition of fuel hose sheath on the vertical cylinder head; replace it if necessary.
Sub 8-8

EXHAUST - INTAKE

8

Fuel pump removal
Unscrew the six screws (15) which fix the fuel pump to the tank.
Slip the fuel pump (13) off from tank and recover the o-rings (24).

Filler cap removal
Open the filler cap, unscrew the four screws (4) and recover the washers.
Remove the filler cap (3).

Sub 8-9

8

EXHAUST - INTAKE

8.3 - THROTTLE BODY

1) intake manifold
2) screw3) clamp
4) screw M5x16 TCEI CZ
5) throttle body6) stepper motor7) intake duct8) screw M6x12 TCEI CZ
9) washer10) gasket11) rubber hose
12) T union13) plugs holder

14) injector mounting support15) screw M5x30 TCEI CZ16) injector17) horizontal injector joint18) vertical injector joint19) screw M5x14 TCEI CZ20) screw M5x10 TSPEI21) clamp22) quick coupling union23) screw M4x8 TBEI
24) hose fixing plate25) washer 6x10x1.526) injector spring

Sub 8-10

EXHAUST - INTAKE

8

Airbox and throttle body removal
Remove the fuel tank.
Remove the air intake manifolds.
Release the throttle cable.
Disconnect the wiring (27) from the injectors (13). If needed disconnect the wiring (27) from themain electric wiring.

Loosen the clamps (3) on the intake manifold (1).

Sub 8-11

EXHAUST - INTAKE

8

Disconnect the connector (28) of the injectors wiring to stepper motor.

Loosen the connector (29) of injectors wiring to the throttle body potentiometer.

Loosen the clamp (30) which fix the oil vent hose (31) to the oil expansion tank (32).

Sub 8-12

EXHAUST - INTAKE

8

Slip the air box (33) off from the throttle body (5) and the injectors (16).

Injectors removal
Unscrew the screw (19) to remove the injectors (16) complete of hoses (11) from the air box (33).

Sub 8-13

EXHAUST - INTAKE

8

Remove the injector hoses (11) from the air box.

Remove the injectors wiring (27) from the air filter box.

Sub 8-14

EXHAUST - INTAKE

8

Stepper motor removal
In the middle of the throttle body is mounted the stepper motor (6).
Disconnect the hoses (34) and (35) from the throttle body and the air filter box.
Unscrew the two screws (36) and remove the motor.

Sub 8-15

EXHAUST - INTAKE

8

Air box - throttle body disassembly
Unscrew the six screws (4) and remove the throttle body (5) from the air box (33).

Sub 8-16

EXHAUST - INTAKE

88.4 - INTAKE – AIRBOX

1) manifold
2) screw M5x10 TBEI
3) fixing plate of oil expansion tank4) oil expansion tank5) screw M5x8 TBEI
6) air box – expansion tank union
7) air box8) rubber gasket9) airbox manifold holder10) screw
11) air filter12) oil vent hose13) cable guide14) air intake hose15) clamp16) airbox electric wiring

Look also the “ Use and maintenance” chapter.

Sub 8-17

INJECTION - IGNITION

9CHAPTER 9
INJECTION – IGNITION
9.1 – SYSTEM COMPONENTS
Sub 9-2
Electronic control system............................................................................................. Sub 9-2
Battery support............................................................................................................ Sub 9-3
Battery support removal….......................................................................................... Sub 9-4
Fuel injector…............................................................................................................. Sub 9-6
Stepper motor...............................................................................................................Sub 9-7
Air pressure sensor......................................................................................................Sub 9-8
Coolant temperature sensor (engine)..........................................................................Sub 9-8
Coolant temperature sensor (dashboard)....................................................................Sub 9-9
Air temperature dash (dashboard)...............................................................................Sub 9-9
Air temperature sensor (engine)................................................................................Sub 9-10
Ignition coils...............................................................................................................Sub 9-10
Checking the coils.......................................................................................................Sub 9-11
Spark plugs.................................................................................................................Sub 9-11
Throttle position sensor……………..…......................................................................Sub 9-12
R.p.m. / timing sensor................................................................................................Sub 9-12
Injection relay.............................................................................................................Sub 9-13

Sub 9-1

INJECTION - IGNITION

99.1 – SYSTEM COMPONENTSElectronic control unit
The ECU (1) is an electronic unit, digital type with microprocessor.

It controls the injectors and coils therefore adjusting the fuel injection and ignition, in according to
the engine operating conditions detected by sensors listed here below:-

absolute pressure sensor (measures the atmospheric pressure)
air temperature sensor (measures intake air temperature)engine temperature sensor (measures coolant temperature)timing/rpm sensor (measures the engine rotation speed and cylinder timing relative to TDC)
throttle position sensor (measure the throttle opening angle)

The ECU also monitors battery voltage so that it can adjust injector opening time and ignition coilcharging time accordingly.
The ECU determines the following values- Amount of fuel delivered to each cylinder with a sequential non-parallel control- Injector closing time and therefore injection timing relative to the end of the induction strokefor each cylinder.
- Ignition advance
The adjustment of CO can be done by using the Walbro diagnosis kit.

CAUTION
In case the ECU has been replaced is necessary to make the operation “Reset of the throttle
position” (TPS).

Sub 9-2

INJECTION - IGNITION

9

Battery support

1) nut M62) vibration damper3) vibration damper4) water cooler holder
5) screw M6x25 TBEI
6) rubber pad7) flanged nut M68) screw M6x16 TCEI CZ
9) screw M6x14 TCEI CZ10) washer11) battery box mount12) battery13) battery box cover14) starter motor wiring
15) screw M5x10 TCEI CZ16) D5 washer17) M5 nut18) input wiring
19) remote switch20) clamp

Sub 9-3

INJECTION - IGNITION

9

Battery support removal
The battery is placed on the motorcycle left side, under the side fairing.
Remove the L.H. fairing.
Remove the box cover (13) loosening the nuts (7).

Disconnect first the negative pole (22) then the positive one (23).
Remove the battery (12) from its box.

To reassembly the battery perform the same operation in reverse order, taking care to connect firstthe positive terminal (23) then the negative one (22).

Sub 9-4

INJECTION - IGNITION

9

Disconnect the connector (24) from the main wiring, slip the starter contactor (19) off from the two
fixing tongues and remove it.

Slip the fuses box (25) off from the fixing tongue and remove it.
Unscrew the screw (15) and remove the lights relay (26).

Unscrew the two screw (8) (9) and recover the washers. Remove the battery support (11).

Sub 9-5

INJECTION - IGNITION

9

Fuel injectors
The injectors (1) deliver the correct quantity of fuel required for optimal engine operation.

The ECU controls injector opening by feeding current to the coil of an electromagnet which createsa magnetic field to attract the armature, thereby generating fuel spray. If we take the physicalcharacteristics of the fuel to be constant (viscosity, density), as well as the injector delivery andpressure head (controlled by the fuel pressure regulator), the amount of fuel injected depends onthe duration for which the injector is open.
This time is determined by the ECU in accordance with the engine operating conditions.
In this way correct fuel delivery in ensured.
Do not leave the engine stopped for a long time with the fuel circuit full.
The fuel could clog the injectors and render them inoperable.
Periodically, after lengthy periods without running the engine, we recommend adding a special
additive to the fuel in the tank to help clean critical sections of the fuel circuit.

Sub 9-6

INJECTION - IGNITION

9

Stepper motor
The throttle body incorporates an automatic choke function performed by a stepper motor (1).
The stepper motor shaft is fitted with a valve which opens a communicating passage between two
ports; one of these ports (2) is connected to the intake manifold of the vertical cylinder while theother (4) is connected to the intake manifold of the horizontal cylinder. A third port (3) is connectedto the airbox.

The stepper motor simultaneously controls two by-pass ports having an air flow capacity of around
6 kg/h. The by-pass ports with adjuster screws are present because it is necessary to balance theair flow to the two cylinders.
In order to compensate for the quantity of supplementary air supplied by the stepper motor andconsequently deliver the correct amount of fuel, the ECU converts the stepper motor steps into
angular degrees of the throttle: this system means that opening the stepper motor is equivalent to
opening the throttle.
NOTES
The influence of the stepper motor air flow is present to approximately 30° throttle angle; nocorrection is required for greater angles.
The opening of the stepper motor is controlled by the engine temperature (the opening or closingof the stepper is determined by the engine temperature).

Sub 9-7

9

INJECTION - IGNITION

Air pressure sensor
This sensor (1) is integrated in the ECU and indicates the atmospheric pressure.
This data is managed by the ECU and is used to correct the calibration.
NOTES
The information about the atmospheric pressure is displayed through the use of the Service
Walbro.

Coolant temperature sensor
The sensor (2) is mounted on the horizontal cylinder head coolant outlet union and measures thecoolant temperature. The electrical signal obtained is sent to the ECU and it is used to correct thecalibration, so as to ensure optimal ignition and fuel supply at all times. It is composed of a bodycontaining an NTC thermistor (the resistance of the thermistor decreases as the temperature
increases)
water temperature sensor removal
To remove the coolant temperature sensor remove the L.H. fairing and the battery support as
explained in this section.
Disconnect the wiring connector.
Unscrew the sensor (2) from the coolant manifold (3).

Sub 9-8

INJECTION - IGNITION

9

Coolant temperature sensor (dashboard)
The sensor (1) is positioned along the horizontal hose of the coolant circuit, under the throttle body,and measures the water temperature which is then displayed on the dashboard.

Air temperature (dashboard)
The sensor (2) is positioned under the dashboard support and measures the external air
temperature which is displayed on the dashboard.

Sub 9-9

INJECTION - IGNITION

9

Air temperature sensor (engine)
The sensor (3) is positioned under the dashboard support frame and take the external temperatureof the air that is used by the ECU to make eventual calibration corrections.

Ignition coils
Remove the fuel tank.
Undo the nut (1) securing the coil to the cylinder head.
Remove the connector (2) and extract the coils (3) from the spark plugs on both cylinder heads.
Clean the area around the spark plug bores with a compressed air jet before removing the spark
plugs themselves.
Remove the spark plugs, making sure that dirt does not fall into the combustion chambers.

Sub 9-10

INJECTION - IGNITION

9

Checking the coils
The coils used on this model are known as “cigar” coils.
They are similar in appearance to a spark plug cap. They transform the low voltage from the ECU
into high voltage for the spark plugs.
To test the coils, proceed as follows:
Measure the resistance between the two pins (1-15).
The resistance should be 650 mΩ±50; if not, replace the coil.

Spark plugs
Check the colour of the ceramic insulation around the central electrode: an even, light brown colour
indicates the engine is in good condition and running at the right temperature.
Secondly, check the central electrode for wear and measure electrode gap, which should be:0,6÷0,7mm.

IMPORTANT
Check the gap between the central and side electrodes. If the gap is not as specified or if the spark
plug has heavy sooty deposits, renew it.
Refit the spark plug in the cylinder head, first tightening it fully by hand.
Tighten to the specified torqueRefit the tank.
IMPORTANTDo not use spark plugs with inadequate thermal rating or incorrect thread length.
The spark plug must be securely installed.
If a spark plug is loose, it can overheat and damage the engine.
Spark plug type
Brand: NGK
type: MAR10A-J

Sub 9-11

INJECTION - IGNITION

9

Throttle position sensor
The TPS (1) is powered by the ECU to which it sends a signal indicating the throttle position. This
information is an indirect measure of the engine load and is used by the ECU as one of the main
parameters for defining the fuel flow rate and spark advance.
NOTES
It is not possible to change the throttle position sensor as a single component. In the event of a
fault with this component, it will be necessary to replace the entire throttle body assembly andperform the TPS reset.

R.p.m. / timing sensor
This sensor (2) is of the inductive type: it faces the timing gear and is capable of reading the
46 teeth and the 2 -tooth gap.

The signal coming from the pickup on the camshaft gear is used by the ECU to determine theengine speed and as a timing reference point.

Sub 9-12

INJECTION - IGNITION

9Injection relay
The injection relay (1) is positioned behind the R.H. fairing, near the ECU.

To remove the relay (1) first remove the side fairing as previously described.
Disconnect the relay from the electrical system and apply 12 V (battery voltage) between contacts(86) and (85) (small contacts): you should hear a click that confirms that the internal electromagnet
has switched.
Connect a multimeter to contacts (30) and (87) (big contacts) to check for electrical continuity. The
resistance reading should be near zero and, if present, the continuity sound signal should beemitted. If this does not occur, the part must be renewed.

Sub 9-13

ELECTRICAL SYSTEM

10

CHAPTER 10
ELECTRICAL SYSTEM
10.1 - WIRING DIAGRAM
Sub 10-2
Utilities wiring diagram.............................................................................................. Sub 10-2
Injection wiring diagram............................................................................................ Sub 10-3
10.2 - FUSE BOX
Sub 10-4
10.3 - WIRING ARRANGEMENT ON MOTORCYCLE
Sub 10-5
10.4 - LIGHTING DEVICES
Sub 10-21
Low-beam bulb replacement…...............................................................................Sub 10-21
High-beam bulb replacement..................................................................................Sub 10-22
Parking light bulb replacement...............................................................................Sub 10-22
License plate light bulb replacement......................................................................Sub 10-23
Lights relay.............................................................................................................Sub 10-23
Headlight beam adjustment....................................................................................Sub 10-24
10.5 - INDICATING DEVICES
Sub 10-25
L.H. handlebar controls..........................................................................................Sub 10-25
Brake light switches................................................................................................Sub 10-26
Neutral indicator light..............................................................................................Sub 10-27
Oil pressure sensor.................................................................................................Sub 10-28
Coolant temperature sensor...................................................................................Sub 10-29
Turn signal bulb replacement.................................................................................Sub 10-30
Rear stop light replacement...................................................................................Sub 10-31
Rear view mirror adjustment..................................................................................Sub 10-32
10.6 - SAFETY DEVICES AND PROTECTIONS
Sub 10-33
Ignition switch........................................................................................................Sub 10-33
Sidestand switch....................................................................................................Sub 10-34
10.7 - DASHBOARD
Sub 10-35
Dashboard removal................................................................................................Sub 10-35
Dashboard system.................................................................................................Sub 10-36
Multifunction digital display....................................................................................Sub 10-37
10.8 - DIAGNOSIS INSTRUMENT
Sub 10-40
Using a multimeter to check the electrical systems....................................................Sub 10-40

Sub 10-1

ELECTRICAL SYSTEM

10

10.1 - WIRING DIAGRAM
Utilities wiring diagram

Sub 10-2

ELECTRICAL SYSTEM

10

Injection wiring diagram

Sub 10-3

ELECTRICAL SYSTEM

10

10.2 - FUSE BOX
The fuse box (1) is placed on the left side of the motorcycle, under the side fairing.
To replace the fuses:
Unhook the rubber fasteners (2) and open the fuse box cover (1).
Replace the damaged fuse with a new one.
The spare fuses (3) are placed in the fuse box.
The fuses specified are: 5A,10A,15A,30A.
NOTES
If the fuses burn frequently it means that there is a short-circuit or an overload of the electricalsystem.
CAUTION
Never use a fuse with a rating other than the specified value. Failure to observe this rule may
damage the electric system or even cause fire.

Sub 10-4

ELECTRICAL SYSTEM

10

10.3 - WIRING ARRANGEMENT ON MOTORCYCLE
The ways of the electrical wires have been optimized to have the minimum overall dimension.
Every passage has been studied to not interfere during the motorcycle use with parts whichmight damage them or create malfunctions. The pictures outlined here below evidence the correct
positioning of wires and of the cable ties.

Sub 10-5

ELECTRICAL SYSTEM

10

Sub 10-6

ELECTRICAL SYSTEM

10

Sub 10-7

ELECTRICAL SYSTEM

10

Sub 10-8

ELECTRICAL SYSTEM

10

Sub 10-9

ELECTRICAL SYSTEM

10

Sub 10-10

ELECTRICAL SYSTEM

10

Sub 10-11

ELECTRICAL SYSTEM

10

Sub 10-12

ELECTRICAL SYSTEM

10

Sub 10-13

ELECTRICAL SYSTEM

10

Sub 10-14

ELECTRICAL SYSTEM

10

Sub 10-15

ELECTRICAL SYSTEM

10

Sub 10-16

ELECTRICAL SYSTEM

10

Sub 10-17

ELECTRICAL SYSTEM

10

Sub 10-18

ELECTRICAL SYSTEM

10

Sub 10-19

ELECTRICAL SYSTEM

10

Sub 10-20

ELECTRICAL SYSTEM

10

10.4 - LIGHTING DEVICES
NOTES
The halogen light bulbs in the headlight become hot when switched on and remain hot for sometime after they are switched off. Allow bulbs to cool before replacing them.
If possible replace the light bulbs wearing clean gloves. If you touch the light bulb with naked
hands clean the bulb with alcohol to prevent overheating and breakage of the light bulb in a shorttime.
To substitute the light bulb, turn the power switch to OFF position.
Before proceeding to replace a burned light bulb it is necessary to be sure that the new bulb has
the voltage and the power values equal to those specified for that device.

Low-beam bulb replacement
Remove the front fairing covers.
Remove the rubber cover (1).
Push the two fixing springs (2) out.
Remove the burnt light bulb (3) disconnecting the connector (4) and replace it with a new one
reversing the order of removal.
Reassemble the rubber cover.
Reassemble the front fairing cover.

Sub 10-21

ELECTRICAL SYSTEM

10

High-beam light bulb replacement
Remove the front fairing covers.
Remove the rubber cover (1).
Push the two fixing springs (2) out.
Remove the burnt light bulb (3) disconnecting the connector (4) and replace it with a new one
reversing the order of removal.
Reassemble the rubber cover.
Reassemble the front fairing cover.

Parking light bulb replacement
The parking light bulb is accessible from the lower part of the front fairing
To renew it pull the light bulb socket (1) out.
Remove the light bulb (2).
Install a new light bulb reversing the order of removal.

Sub 10-22

ELECTRICAL SYSTEM

10

License plate light bulb replacement
The license plate light bulb is accessible from the back side of the license plate support.
Pull the light bulb socket (1) out.
Remove the license plate light bulb (2).
Install a new light bulb reversing the order of removal.

Lights relay
The lights relay (3) is placed on the right side of motorcycle and is fixed near to the ECU.
To have access to this component is necessary to remove the R.H. side fairing.
The lights relay is managed by the ECU that carry out the “light saving” function.

Sub 10-23

ELECTRICAL SYSTEM

10Headlight beam adjustment
The motorcycle must be perfectly upright with the tires inflated to the correct pressure and with arider seated, perfectly perpendicular to the longitudinal axis.
Position the motorcycle 10 metres from a wall or a screen.
On the wall or surface, draw a horizontal line at the same height from the ground as the centre of
the headlight and a vertical line aligned with the longitudinal axis of the motorcycle.
If possible, perform this check in conditions of low ambient light.
Switch on the low beam. The height of the upper limit between the dark area and the lit area mustnot be more than nine tenths of the height of the centre of the headlight from the ground.
NOTES
This is the procedure specified by Italian regulations for checking the maximum height of the lightbeam. Owners in other countries should adapt this procedure to the regulations in force in the
country where the motorcycle is used.
The headlight beam adjustment can be done by screwing/unscrewing the screws (1) and (2) asneeded.

Sub 10-24

ELECTRICAL SYSTEM

10

10.5 - INDICATING DEVICES
Left handlebar controls
Turn signal switch
Move the turn signal switch (1) to left to signalize the turn left and right to turn right.
Press to switch off the direction signal.
Horn button
Press the button (2) to operate horn.
Headlight switch
Push the switch of the headlight (3) on (HI) position to select the high beam and on (LO) position
to select the low beam.
Head light flasher switch
When you press the flasher control switch (4), the high beam flashes to signal to vehicles arriving
or for the passing.

Sub 10-25

ELECTRICAL SYSTEM

10Brake light switches
To check operation of the front (1) and rear (2) brake light switches, use a multimeter to check forelectrical continuity between the terminals of the corresponding switch when the front or rear brakeis applied. When the brake is released, there must be no electrical continuity between the terminalsof the corresponding switch. If these tests fail to produce positive results, the part in question must
be renewed.

Mounted on the rear master cylinder there is an hydraulic switch (2).

Sub 10-26

ELECTRICAL SYSTEM

10

Neutral indicator light
To check the neutral light switch (3) proceed as follows:- The neutral light does not illuminate on the instrument panel.
Remove the electric terminal connected to the neutral switch. Switch on the ignition switch(ignition key to ON position) and ensure that the light illuminates when the terminal isearthed. If the light switches on, the neutral light switch should be changed. If the light stays
off, switch off the ignition (ignition key set to OFF) to switch off the instrument panel andcheck for electric continuity between neutral switch and engine control unit with amultimeter.
- The neutral light on the instrument panel is permanently illuminated.
Switch on the ignition (ignition key set to ON) and remove the electrical terminal from theneutral switch. If the light switches off, the neutral light switch should be changed. If the lightstays off, switch off the ignition (ignition key set to OFF) and use a multimeter to check
whether the section of circuit between neutral switch and engine control unit is earthed.
1) neutral sensor

Sub 10-27

ELECTRICAL SYSTEM

10

Oil pressure sensor
If the engine oil pressure is not within the specified range, check the parts of the lubrication circuitand make the necessary repair.
If the oil pressure is not within the specified range and the engine oil pressure warning light stay off
turn on the dashboard (main switch position ON) without starting the engine, disconnect theelectrical terminal from the oil pressure sensor and connect it to ground. If the warning light now
illuminates this means that the sensor is not working (it must be replaced).
If the warning light fails to illuminate, use a multimeter to check for the electrical continuity of thesection of the circuit between sensor and warning light on the instrument panel (this check must be
performed with the ignition key set to OFF, i.e. with instrument panel off).
1) oil pressure sensor.

Sub 10-28

ELECTRICAL SYSTEM

10

Coolant temperature sensor
The coolant temperature sensor (1) sends an electrical signal to the engine ECU. To check that thesensor (1) is functioning correctly, read among the engine parameters represented on the display
the value of the coolant temperature of the engine.
With the engine completely cold, the air temperature should be similar to that of the coolant.
With the engine hot and the cooler fan only just activated, the coolant temperature should be moreor less equal to the fan activation temperature.
If these tests do not give a positive result, renew the coolant temperature sensor.
If this circuit is not faulty (not broken, not shorted and not earthed), renew the sensor.

Sub 10-29

ELECTRICAL SYSTEM

10

Turn signal bulb replacement (USA version only)
In the Europe version in case of malfunctioning it is necessary to replace the whole rear turn signal
or the rear view mirror group (which includes the front turn signal light), as they use LED and notbulbs.
Front turn signals
Unscrew the screw (1) from the internal part of the rear view mirror and remove the lens (2) paying
attention to the joint (3).
Press the bulb (4) softly and turn it counter-clockwise to remove it.
Replace the bulb (4) and re-insert it in the support. Reassemble the lens (2).
Re-screw the screw (1).

Rear turn signals
To replace the bulbs of the rear turn signals, unscrew the screw (1) and take the lens (2) out fromthe signal support.
Press the bulb (3) softly and turn it counter-clockwise to remove it.
Replace the bulb (3) and re-insert it in the bulb support.
Reassemble the lens (2) on the turn signal support.
Re-screw the screw(1).

Sub 10-30

ELECTRICAL SYSTEM

10Rear stop light replacement
USA version
To replace the rear stop light bulb, unscrew the screws (1) and take the red lens (2) out from thelight support.
Remove the light bulb (3) from the support.
Replace the bulb (3) and re-insert it in the bulb support.
Reassemble the red lens (2) on the light support.
Re-screw the screws (1).

Europe version
In the European version in case of malfunctioning it is necessary to replace the whole tail light, as it
use LED instead of bulbs.

Sub 10-31

ELECTRICAL SYSTEM

10Rear view mirror adjustment
Grasp the outer part of the mirror surface (1) and move it manually to the required position relative
to the mirror support (2).

Sub 10-32

ELECTRICAL SYSTEM

10

10.6 SAFETY DEVICES AND PROTECTIONS
Ignition switch
Disconnect the ignition switch (A) from the wiring loom by opening its connector and use a
multimeter to check its internal connections as follows:
turn the key to OFF and connect a multimeter to contacts (1) and (4) to check electrical continuity.
The resistance reading should be near zero and, if present, the continuity sound signal should beemitted.
Turn the key to ON and connect the multimeter to contacts (3) and (6) and then to (2) and (5) tocheck for electrical continuity. The resistance reading should be near zero and, if present, thecontinuity sound signal should be emitted.
Turn the key to PARK and connect the multimeter to contacts (1) and (4) and then to (3) and (5) tocheck for electrical continuity. The resistance reading should be near zero and, if present, thecontinuity sound signal should be emitted.
Turn the key to LOCK and connect the multimeter to contacts (1) and (4) to check for electricalcontinuity. The resistance reading should be near zero and, if present, the continuity sound signal
should be emitted.
Disconnect battery.
Disconnect the ignition switch electrical connection.
Check the continuity of the ignition switch contacts following the enclosed electrical schematic andusing a multimeter.

Sub 10-33

ELECTRICAL SYSTEM

10

Sidestand switch
This motorcycle is equipped with an ignition stop switch.
The engine cannot be started if the sidestand is opened, unless the gear is in neutral.
If the sidestand is raised, the engine can be started with the gear in neutral or engaged gear withthe clutch engaged.
After having started the engine with the sidestand opened, the engine stops if you try to engage
the gear.
1) sidestand switch.

Sub 10-34

ELECTRICAL SYSTEM

10

10.7 - Dashboard
Dashboard removal
Remove the front fairing.
Disconnect the wiring of the dashboard (1)Unscrew the three screws (2).
Remove the dashboard (3).

NOTES
The dashboard is supplied as spare part in a single component and therefore it is not possible toorder internal replacements.

Sub 10-35

ELECTRICAL SYSTEM

10

Dashboard

1)
2)
3)
4)
5)

Turn signals (when the turn signal is being operated, the indicator light will flash at the same time.)
high-beam light indicator (lit when high-beam light is on)
Neutral indicator (lit when the neutral gear is selected)
Injection malfunction indicator (lit when there's a malfunction in the injection system)
Oil pressure indicator (lit when the engine oil pressure drops under the normal operating range.
With the ignition switch in the “ON” position but the engine not started, the light is on. As soon as theengine is started, the indicator light switch off).
6) Fuel indicator (lit when the fuel level is under the reserve level)7) Coolant temperature indicator (lit when the coolant temperature goes over the normal operating
range.)
8) Maintenance indicator (lit when the motorcycle reach a scheduled maintenance stop. Read theMaintenance chapter to have more information about the intervals and the operations ofmaintenance).
9) R.p.m. Indicator (lit when the engine reach the maximum r.p.m. permitted).
10) Select button (it's used to select between air temperature/clock and to set the clock)11) Adjust button (This button is used to settle odometer/trip meters and to reset the trip meters)12) Multifunction display (when the main switch is turned on, it show a test screen for few seconds; so
the display shows the speedometer. The functions of the digital display are described in next pages)13) Coolant temperature indicator (shows the engine coolant temperature)14) R.p.m. counter (shows the engine speed in RPM. Each time the ignition switch is turned in “ON”
position, the indicator needle of the tachometer runs to maximum position then runs back to 0)15) Red zone on r.p.m. counter (Do not allow the needle of the tachometer to reach the red area, eventhough the break-in period for the engine is finished. NOTE: running the engine at high speed cancause damages).

Sub 10-36

ELECTRICAL SYSTEM

10

Multifunction digital display
When you turn ON the ignition switch, the display temporarily displays all the details and digitalsegments.
The display functions are accessible through 3 different pages; to go from one page to the next
one hold the starter button (placed on the right handlebar controls) for at least 3 seconds.
The functions available are described in the following pages.

NOTES
The display layout can change without notice.
PAGE 1
The first page shows the following functions:-

speedometer: displays the running speed
odometer: displays the total distance covered.
trip A/ trip B: displays the partial distance covered. Hold the ADJUST button to switch
among odometer, trip A and trip B. To reset the trips A and B hold the ADJUST button for
more than 3 seconds while the desired counter is displayed.
Clock: displays the time (hours and minutes). To set the clock hold the SELECT button for
more than 3 seconds and therefore use the SELECT button and the ADJUST button to set
the clock.
Air temperature: displays the ambient air temperature. Press the button SELECT to switch
between clock to air temperature.

Sub 10-37

ELECTRICAL SYSTEM

10

PAGE 2The second page shows the following functions:-

Speed
Chronometer: push the ignition button to start up the chronometer. Each time you press
the starter button, the time lap is recorded and the chronometer starts to register a new lap.
It may be registered up to 20 laps. Hold the starter button for more than 3 seconds to stop
the chronometer.

NOTES
To switch to the next page you must stop the chronometer first.

Sub 10-38

ELECTRICAL SYSTEM

10

PAGE 3
The third page shows the following functions:-Maximum speed: displays the maximum speed reached during the selected lap.
-Lap time: displays the lap time of the selected lap.
-Lap number: displays the selected lap of which you want to see the recorded data (it can berecorded up to 20 laps). To display the recorded data of each lap press the starter button.
For each lap are displayed:- maximum speed- lap time
- RPM maximum reached (displayed by the r.p.m. counter)- Selected lap

Sub 10-39

ELECTRICAL SYSTEM

10

10.8 - DIAGNOSIS INSTRUMENT
Using a multimeter to check the electrical systems

Introduction
This instrument allows you to measure resistances, voltages, and current values. Multimeters can be divided
into two basic types: those with an analogue display and those with a digital display Units of the first type are
equipped with a dial and needle. The dial is marked with the scales to be used for measurement of thevarious parameters. Digital units are equipped with a dial that displays numbers corresponding to the valuesof the measured parameters. The type of measurement to be carried out (voltage, current or resistance) is
set by means of a selector or by means of several different sockets in which to insert the two test probe
connector terminals. In certain cases it is essential to set the full scale value before proceeding. For
example, in order to measure a 12 V signal, you need to set a full scale that is close to this value (e.g. 15 V
or 20 V). It would be illogical to set a full scale value of 10 V; the same applies when setting current (Amps)or resistance (Ohms) full scale values. Sometimes the instrument can set the required full scale value
automatically. Never exceed the maximum value allowed by the tester when measuring voltage or current
signals.
Voltage measurement
Voltage measurements must be carried out by connecting the terminals of the tester in parallel to the load(e.g. to the wires feeding a light bulb or a relay, the two battery terminals, or the two wires supplying power toa control unit). Voltages can be constant over time (DC voltage) or variable over time (AC voltage). In thefirst case, it is important to consider the negative and positive polarity of the application. It is therefore
necessary to select on the multimeter the type of voltage you intend to measure. (DC voltage is shown by
the symbol = while AC voltage is denoted by ~).
Current measurement
Current measurements must be made by connecting the multimeter terminals in series with the load (e.g.
disconnect one of the wires feeding power to a light bulb and connect one terminal of the multimeter to thefree end of wire and the other terminal to the light bulb. When the lights switch is set to ON, the bulb will
illuminate normally and the tester will show the absorbed current, i.e. the amount of current passing throughthe wire). Warning: connections in series must be made and removed only when the power is switched off.
Never attempt to make or break a series connection when a device is powered. Always make sure that theconnection in series of the tester terminals on the electrical device is made is a safe manner in such a waythat it cannot be broken accidentally.

Sub 10-40

ELECTRICAL SYSTEM

10

Measurement of resistance values and electrical continuity
Resistance measurements must be taken only when the electrical device or section of the circuit is not
powered and isolated from the main electrical system (i.e. not connected to the main electrical system).
These measurements can be utilised to check the resistance value across several sensors. For example,
after disconnecting the electrical wiring to the rpm/ignition - injection system timing sensor (on the camshaft
drive gear) the relative internal resistance can be checked by connecting a multimeter to its terminals. This
makes it possible to check the electrical continuity of the winding inside the sensor (a reading of infinite
resistance indicates that the winding is interrupted). Resistance measurement can also be used to check thecontinuity of sections of the electrical circuit or relay type switches. For example, to check the condition of asection of the electrical circuit between two connections, disconnect the connections and connect theterminals of the multimeter to the ends of the electrical cable in question to check that the specified
resistance value is present. If this value is close to zero (i.e. lower than approximately 0.3 ohm) this meansthat the cable is not interrupted. Some instruments feature an audible signal that is emitted when theresistance approaches a value of zero. The same procedure must be adopted to check whether, forexample, two contacts of a switch (relay or manual type) are making the contact correctly when closed. In
this case the terminals of the multimeter must be connected to the switch terminals, checking that theresistance value is close to zero (or listening for the audible signal) when the switch is closed. To check thatthe multimeter is functioning correctly in “electrical continuity test” mode, short out the two test probes. The
resistance value indicated must be almost nil and the audible signal must be activated.
Protections and precautions
The multimeter is equipped with protective fuses and batteries. These components must always be in perfectcondition to ensure that the instrument is functioning correctly. When making electrical measurements
always use the maximum caution to avoid short circuits, which can otherwise cause irreparable damage tothe electrical system and constitute a personal injury hazard. All maintenance work must be performed
exclusively when the system is not live (disconnect the battery in advance). NEVER connect the multimeterin parallel to make current measurements, and NEVER connect it in series to carry out
voltage measurements.

Sub 10-41