PDF Service Manual Aprilia SL1000 Falco - 9 MB
This is the complete service and repair workshop manual for the Aprilia SL1000 Falco motorcycle.
It contains detailed instructions for all maintenance and repair procedures, from simple oil changes to complex engine work.
With clear diagrams and specifications, it's an essential tool for both home mechanics and professional technicians.
Keep your Falco performing at its peak with this comprehensive guide.
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GENERAL INFORMATION
SL mille
I
GENERAL INFORMATION
I TABLE OF CONTENTS
1.1 POSITION OF THE SERIAL
NUMBERS
1.1.1 FRAME NUMBER
1.1.2 ENGINE NUMBER
1-3-00
1-3-00
1-3-00
1.2 INSTRUCTIONS FOR USE OF
FUEL, LUBRICANTS, COOLANT AND
OTHER COMPONENTS 1-3-00
1.2.1 FUEL........................................................ 1-3-00
1.2.2 ENGINE OIL 1-4-00
1.2.3 FORK OIL 1-4-00
1.2.4 BRAKE FLUID 1-4-00
1.2.5 COOLANT 1-5-00
1.2.6 CLUTCH FLUID ; 1-5-00
1.2.7 CARBON MONOXiDE............................. 1-6-00
1.2.8 HOT C.OMPONENTS 1-6-00
1.3 RUNNING-IN RULES 1-6-00
1.4 SPARE PARTS 1-7-00
1.5 TECHNICAL SPECIFICATIONS 1-7-00
1.6 LUBRICANT CHART 1-10-00
1.7 SPECIAL TOOLS. 1-11-00
1.7.1 MISCELLANEOUS TOOLS 1-11-00
1.7.2 ENGINE TOOLS 1-12-00
1.8 POSITIONING THE VEHICLE ON
THE SUPPORT STAND 1-13-00
1.8.1 ASSEMBLING THE PINS FOR THE
REAR SUPPORT STAND •............... 1-13-00
1.8.2 POSITIONING THE VEHICLE ON THE
REAR SUPPORT STAND •............... 1-13-00
1.8.3 POSITIONING THE VEHICLE ON THE
FRONT SUPPORT STAND •............ 1-13-00
1.8.4 POSITIONING THE VEHICLE ON THE
CENTRE SUPPORT STAND •.......... 1-14-00
1.9 CONSUMABLES 1-15-00
1.9.1 PRODUCT PROPERTIES 1-15-00
1.9.2 USE OF CONSUMABLES ;.. 1-16-00
1.10 GENERAL SPECIFICATIONS OF
THE DRIVING TORQUES 1-18-00
1.11 FASTENING ELEMENTS 1-19-00
1.12 INSTRUCTIONS FOR APPLYING
TRANSFERS 1-24-00
1.13 ABBREVIATIONS /
SYMBOLS /INITIALS 1-26-00
0- 2 -00 - - - - - - - - - Release 00/2001-05
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GENERAL INFORMATION
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1.7.2 ENGINE TOOLS
NOTE The tools indicated below belong toa kit [aprilia
part# 8140175 (complete engine tool, kit)] including also
other tools, see aprilia part# 8140582 (Engine service
and repair manual V990 1051-1).
These tools are shown because they serve to ·carry out
some operations on the engine, either when this is in-
stalled on the vehicle and when it is removed from the
--------~--~----
same.
(complete engine tool kit)
1 8140177 (plug socket spanner)
2 8140256 (vacuometer)
3 8140181 (Fuel - oil pressure gauge)
4 8140183 (engine lifting eye hook)
5 8140188 (engine support)
6 8140187 (engine support stand)
7 8140197 (perforated bolt for fuel pressure test)
8 8140267 (intake flange for vacuometer)
11- 12-00 Release 00/2001-05
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GENERAL INFORMATION
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Follow ~
Description Screw I nut Nm kgm Note
Fuel return fitting M6 6 0.6 L243
Fastening of pump mount to flange M5 4 0.4
Fastening of electric terminals on flange M5 6 0.6
Closing of fuel return M6 10 1.0 L243
• Fastening of fuel delivery pipe on flange M12x1.5 22 2.2
Petrol level sensor on pump mount SWP 2.9x12 1 0.1
Fastening of fuel pump cables on flange M6 10 1.0
Description Q.ty Screw I nut Nm kgm Note
Fastening of cap on tank 4 M5 5 0.5
Fastening of fuel pump flange on tank 8 M5 6 0.6
Fastening of tank front on frame 2 M6 10 1.0
Fastening of tank rear on mount 1 M6 10 1.0
Description Q.ty Screw I nut Nm kgm Note
Tank upper fastening screw 1 M8 15 1.5
Tank fastening nuts 2 M6 10 1.0
Oil filter 1 M20x1.5 30 3.0
Oil drain plug 1 M8 15 1.5
Oil level pipe fittings 2 M10x1 20 2.0
Radiator fastening screws 3 M6 12 1.2
Description Q.ty Screw I nut Nm kgm Note
Radiator spoiler fastening 3 M6 4 0.4
Fastening of number plate holder to rear mudguard extension 2 M5 2 0.2
Fastening of reflector holder to number plate holder 2 M5 6 0.6
Front mudguard fastening 4 M5 5 0.5
Rearview mirror fastening screws 1+1 M6 4 0.4
Fastening of rearview mirror mounts and front fairing to mount 4 M6 4 0.4
Lower fastening of front fairing to conveyors 4 M5 2 0.2
Fastening of the rear lower part of the front part of the fairing to the upper 2 M5 4 0.4
part of the air conveyors
Fastening of the air conveyors to the frame 2 M6 3 0.3
Fastening of dashboards upper protection moulding 8 M5 1 0.1
Fastening of lower fairing to frame 2 M6 4 0.4
Fastening of saddle support lower moulded cover 6 M6 10 1.0
Fastening of rear fairing to saddle support lower moulded cover 4 M5 3 0.3
Fastening of the rear light-holders and of the rear part of the fairing to the 3 0.3
2 M6
saddle pillar
Fastening of the rear part of the fairing to the saddle pillar 2 M6 3 0.3
Fastening of internal fairing and side fairing 10 SWP 3.9 0.5 0.05
Fastening of dashboard to mount 3 M6 5 0.5
Fastening of riders's saddle 2 M6 5 0.5
Fastening of passenger seat lock 2 M6 10 1.0
Fastening of passenger seat lock key-operated control 2 M6 12 1.2
Fastening of passenger footrest supports 4 M8 25 2.5
Fastening of riders's footrest supports 4 M8 25 2.5
Fastening of riders's footrest protection 4 M5 6 0.6
Fastening of saddle support 4 M10 50 5.0
Fastening of coil mounts 4 M6 10 1.0
Follow~
0- 22-00 Release 00/2001-05
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SERVICE AND SETTING UP
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-2.1.1 REGULAR SERVICE INTERVALS CHART
OPERATIONS TO BE CARRIED OUT BY THE aprilia
Official Dealer (WHICH CAN BE CARRIED OUT EVEN
BY THE USER).
KEY
CD = check and clean, adjust, lubricate or change, if nec-
essary;
® = clean;
® = change;
@ = adjust.
NOTE Perform the maintenance operations with dou-
bled frequency if the vehicle is used in rainy or dusty are-
as, on uneven surfaces or on racetracks.
(*) = In case of use on racetracks, change every 3750 km
(2343 mi).
(**) = Check every two weeks or according to the. inter-
valsindicated.
Air cleaner CD ®
Engine oil filter (*) ® ®
Engine oil filter (on oil tank) ® ®
Fork CD CD
Light operation/direction CD
Light system
CD CD
Safety switches
Clutch fluid CD
Brake fluid CD
Coolant CD
Engine oil ® ® (*)
Tyres CD CD
Tyre pressure (**) @ @
Engine idling rpm @ @
Engine oil pressure warning light LED at every start: CD
Drive chain tension and lubrication every 1000 km (625 mi): CD
before every trip and every
Brake pad wear CD 2000 km (1250 mi): CD
0- 4 - 00 Release 00/2001-05
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SERVICE AND SETTING UP
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2.4 BATTERY
Carefully read 0.4.1 (PRECAUTIONS AND GENERAL
INFORMATIONS).
There are two kinds of commercially available batteries:
- batteries requiring maintenance featuring cell plugs;
- maintenance-free batteries with no cell plugs as they
do not call for the electrolyte level to be checked and
topped up.
NOTE This vehicle is provided with a maintenance-free
battery and no operation is necessary, excepting occa-
sional checks and the recharge when required.
When changing batteries, replace with a battery of the
same type.
For further information ,5ee6.1 t .(BAlfERY).
Never invert the connection battery cables.
Connect and disconnect the battery with the ignition
switch in position "JX[", otherwise some components
maybe damaged.
Connect first the positive cable (+) andthen the neg-
ative cable (-).
Disconnect following the reverse order.
NOTE Check battery voltage with a portable tester.
If voltage is less than 12V, the battery must be recharged.
If the voltage drops below 8V, the electronic unit is not
working and is preventing engine operation.
2.4.1 CHECKING AND CLEANING THE TERMINALS
Carefully read 2.4 (BATTERY).
+ Make sure that the ignition switch. is in position "JX[".
+ Put back the rider saddle, see 7.1.1 (REMOVING THE
RIDER SADDLE).
+ Remove the red protection element (1) .
• Make sure that the cable terminals (2) and the battery
terminals (3) are:
- in good conditions (and not corroded or covered
with deposits);
- covered with neutral grease or vaseline.
If necessary, proceed as follows:
+ Disconnect first the negative (-) and then the positive
cable (+).
+ Brush with a wire brush to eliminate any sign of corro-
sion.
+ Reconnect first the positive (+) and then. the negative
cable (-).
+ Cover the terminals of the cables and of the battery
with neutral grease or vaseline.
+ Put back the rider saddle, see 7.1.1 (REMOVING THE
RIDER SADDLE).
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SERVICE AND SETTING UP
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2.14 CHANGING THE ENGINE OIL AND THE
OIL FILTER
Carefully read 0.4.1 (PRECAUTIONS AND GENERAL
INFORMATIONS) and 1.2.2 (ENGINE OIL).
Periodically check the engine oillevel,see2.13 (CHECK-
ING'THE ENGINE OIL LEVEL AND TOPPING UP)
change the oil after the first 1000 km (625 mi) and suc-
cessively every 7500 km (4687 mi) or 8 month.
If the vehicle is used in dusty areas, change the oil
more frequently.
Incase of use on racetracks, change every 3750· km
(2343 mi).
ENGINE OIL DRAIN
NOTE The oil flows out completely and without prob-
lems when it is warm and therefore more fluid: to achieve
this condition, the engine should run for approximately
twenty minutes.
When warmed up, the engine contains hot oil; there-
fore, while carrying out the operations described
here below be particularly careful, in order to avoid
burns.
NOTE Position the vehicle on the side stand on firm
and level ground.
• Position a container (1) with more than 4000 ern" ca-
pacity in correspondence with the drain plug (2) posi-
tioned on the tank.
Driving torque of the engine oil drain plug positioned
on the tank: 15 Nm (1.5 Kgm).
• Unscrew and remove the drain plug (2), positioned on
the tank.
• Unscrew and remove the filling plug (3).
• Drain the' oil and let it .drip into the container (1) for a
few minutes.
• Check and if necessary replace the sealing washer of
the drain plug (2) positioned on the tank.
• Screw and tighten the drain plug (2) on the tank.
Driving torque of the engine oil drain plug positioned
on the tank: 15 Nm (1.5 Kgm).
NOTE Upon reassembly, apply LOCTITE® 572 to the
drain plug thread.
• Move the container (1) and position it under the engine
base, in correspondence with the drain plug positioned
on the engine (4). .
• Unscrew and remove the drain plug positioned on the
engine (4).
• Drain the oil and let it drip into the container (1) for a
few minutes. '
Do not dispose of the in the environment.
Deliver it to or have it collected by the nearest oil sal-
vage center or by the supplier.
• Remove the metal residues from the drain plug (4)
magnet.
• Screw and tighten the drain plug (4).
Driving torque of the drain plug positioned on the en-
gine: 12 Nm(1.2 kgm).
Follow~
fJ -24- 00 Release 00/2001-05
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SERVICE AND SETTING UP
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2.23 CHANGING THE REAR BRAKE FLUID
Carefully read 0.4.1 (PRECAUTIONS AND GENERAL
INFORMATIONS) and 1.2.4 (BRAKE FLUID).
Change the rear brake fluid every two year.
Handle fluid with care; it may chemically alter painted
surfaces and the parts in plastic, rubber, etc.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRON-
MENT.
• Remove the plastic protection cap.
• Insert a transparent plastic tube on the bleeder (1) of
the caliper and put the other end of the tube in a con-
tainer.
• Loosen the bleeder (1) approx. one turn.
NOTE Make sure that there is always fluid in the tank
during ·the operation; otherwise, once finished, the sys-
tem will need bleeding, see 2.20 (BLEEDING THE BRAK-
ING SYSTEMS).
• Keep an eye on the tank (2) as the fluid flows out and
tighten the bleeder (1) before it empties entirely.
• Top up the tank (2), see 2.18 (CHECKING AND TOP-
PING UP THE REAR BRAKE FLUID).
• Loosen the bleeder (1) again approx. half a turn.
• Watch as the liquid flows out through the tube and as
soon as the colour of the fluid starts to change (from
dark to light), tighten the bleeder (1) again and remove
the tube. -.
Brake caliper bleeder valve driving torque:15 Nm·(1.5
Kgm).
• Refit the rubber protection cap.
• Top up the fluid tank (2) to the right level, see 2.18
(CHECKING AND TOPPING UP THE REAR BRAKE
FLUID).
11- 34- 00 Release 00/2001-05
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SERVICE AND SETTING UP
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2.31 INSPECTING THE REAR SUSPENSION
2.31.1 REAR SUSPENSION
The rear suspension consists of a spring-shock absorber
unit, fixed to the frame by means of a uni-ball and to the
rear fork by means of lever systems.
For the setting of the vehicle attitude, the shock absorber
is provided with a screw adjuster (1) for the adjustment of
the hydraulic braking with extended shock absorber, a
ring nut (2) for the adjustment of the spring preload and a
locking ring nut (3).
Carefully read 0.4.1 (PRECAUTIONS AND GENERAL
INFORMATIONS).
Check .' after.the.. . first . . . tQQQ .;km.. (62Eirn i} qnd.: successiveIy
every 15000 km (9375 mi) or 16 months.
• Check all the rear suspension joints are working prop-
erly and that the relevant components are properly
tightened.
2.31.2 ADJUSTING THE REAR SHOCK ABSORBER
The standard setting of the rear shock absorber is such
as to satisfy most driving conditions at low and high
speed, either with reduced load and full load.
However, it is possible to adjust the setting according to
how the vehicle is going to be used.
Do not rotate the screw adjusterIt) beyond its limit
position, to avoid damaging the thread.
Make sure that the screw adjuster (1) always snaps
and is not in any intermediate position.
The adjusting ring nut must not be screwed more
than 44.mm from the beginning of the thread (see fig-
ure). . . \ .
MIN =38 mm
MAX = 44 mm
If this measure is exceeded, even the slightest une-·
venness on the road surface will cause sudden jerks
and it will be useless to adjust the screw (1).
• Slightly unscrew the locking ring nut (3) bymeans of
the appropriate spanner.
• Act on the adjusting ring nut (2) (shock absorber
spring preload adjustment) (see figure).
• If necessary, adjust the screw (1) (adjustment of the
hydraulic braking with extended shock absorber) (see
table).
• Once the optimal attitude has been obtained, tighten
the locking ring nut (3) completely.
Follow.~
EI- 44 - 00 Release 00/2001-05
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SERVICE AND SETTING UP
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NOTE
fJ -54- 00 - - - - - - - - - Release 00/2001-05
--- Page 12 ---
ENGINE
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Follow~
To clean the outer parts of the engine use a degreas-
er, brushes and wipers.
Avoid damaging rubber and plastic parts with corro-
sive or penetrating detergents and solvents.
Should the use of a steam cleaner prove necessary,
do not point the high-pressure jets of water, steam or
air at the following parts: wheel hubs, controls on the
right and left handlebars, brake pumps, instruments
and gauges, silencer openings, document compart-
ment, ignition switch/steering lock, electrical compo-
nents.
• Clean the outside of the engine thoroughly.
Free all the cables and pipes from the respective
clamps located at intervals along their routes.
Procure an equal number of clamps to be used for re-
fitting.
Plug all openings on the engine, pipes and couplings
to prevent foreign bodies getting in.
• Gather the electric cables together and secure them in
place with adhesive tape so that they do not get in the
way of the engine being lifted out from underneath.
• Release the three pipes (16) from the cable guide
(17).
Membrane cover fastening screw driving torque:
5 Nm (0.5 kgm).
• Unscrew and remove the screws (18).
Upon reassembly, correctly position the two cable
guides (19) and (20).
• Disconnect the electric connectors (21) (22) from the
thermal switch (23).
Upon reassembly, make sure that the electric con-
nectors (21) (22) are correctly coupled with the ther-
mal switch (23).
• Disconnect the electric connector (24) of the stand
switch,
• Unscrew and remove the screws (25) and recover the
plate. '
Head plate screw driving torque: 40 Nm (4.0 kgm).
NOTE Have the appropriate special tool. to hand:
- aprilia part# 8140183 (engine lifting eye hook) (26), a
hoist (27) and lifting straps (28).
The hoist (27) and the bands (28) for the lifting opera-
tion must be suitable for safely bearing the weight of
the engine. The engine weight approx. 67 kg.
• Fasten the special engine lifting hook (26) [aprilia part#
8140183 (engine lifting eye hook) mil] on and secure it
in place with the screws (24).
Follow~
B- 10-00 Release 00/2001-05
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FUEL SUPPLY SYSTEM
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FUEL SUPPLY SYSTEM
TABLE OF CONTENTS
4.1 FUEL TANK 4-3-00
4.1.1 MAINTENANCE....................................... 4-4-00
4.1.2 CHECKING THE FUEL SUPPLy 4-4-00
4.2 DRAINING THE FUEL TANK 4-5-00
4.3 REMOVING THE WHOLE FUEL
SUPPLY PUMP UNIT 4-5-00
4.4 REMOVING THE FUEL LEVEL
SeNSOR 4~5-00
4.5 REMOVING THE FUEL SUPPLY
PUMP ; !•••••••••• 4-6-00
4.6 REMOVING THE DELIVERY
FILTER 4-6-00
I 4.7 ENGINE MANAGEMENT
4.7.1 FOREWORD
4.7.2 SENSORS
4.7.3 INJECTION SYSTEM DIAGRA,M
4.7.4 ENGINE CONTROL UNIT
4-7-00
4-7-00
4-8-00
4-10-00
CONNECTORS · 4-11-00
4.7.5 AUTOMATIC TESTING 4-12-00
4.7.6 ELIMINATING ELECTRONIC SYSTEM
FAULTS ACCORDING TO THE
INFORMATION SENT UP ON THE
DISPLAY 4-12-00
4.7.7 CAMSHAFT POSITION SENSOR 4-12-00
4.7.8 DRIVING SHAFT POSITION SENSOR. 4-12-00
4.7.9 INTAKE PRESSURE SENSOR 4-12-00
4.7.10 INTAKE PRESSURE SENSOR 4-12-00
4.7.11 THROTTLE VALVE
POTENTIOMETER 4-13-00
4.7.12 COOLANT THERMISTORS 4 ..13-00
4.7.13 AIR THERMISTOR 4-13-00
4.7.14 IGNITION COILS 4-13-00
4.8 THROTTLE BODy 4-14-00
4.8.1 REMOVING THE INJECTORS 4-14-00
4.8.2 REMOVING THE THROTTLE BODY 4-14-00
4.8.3 DISASSEMBLING THE
THROTTLE BODy 4-16-00
4.8.4 INSPECTING THE THROTTLE BODY. 4-18-00
4.8.5 REFITTING THE THROTTLE
BODY 4-19-00
4.8.6 REPLACING THE THROTTLE
VALVE CONTROL LEVER .. n ••••••••••••••••4-21-00
4.8.7 CHECKING THROTTLE VALVE
CONTROL SHAFT END PLAy 4-23-00
4.8.8 ADJUSTING THE THROTTLE
BODy..................................................... 4-24-00
4.8.9 ADJUSTING THE THROTTLE VALVE
POTENTIOMETER 4-25-00
4.8.10 SYNCHRONIZING CYLINDERS 4-26-00
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FUEL SUPPLV SYSTEM
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4.7.5 AUTOMATIC TESTING
See 6.4 (IGNITION SYSTEM).
4.7.6 ELIMINATING ELECTRONIC SYSTEM FAULTS
ACCORDING TO THE INFORMATION SENT UP
ON THE DISPLAY
Take care around the high voltage in the ignition sys-
tem.
Never disconnect connections with the engine run-
ning.
Whenever work isperformea in the .igrHtiolisystel'1'1,
always .make sure the ignition switch is set to "gr"
and the battery disconnected, unless otherwise indi-
cated (when disconnecting the battery, disconnect
the negative pole "-"first).
All measurements must be taken with the compo-
nents at a temperature of 20°C (68°F).
General instructions regarding the elimination of
faults: as soon as the fault has been located, remove
the defective component.
4.7.7 CAMSHAFT POSITION SENSOR
Fault code "11".
See 6.4.6 (CHECKING THE CAMSHAFT POSITION·
SENSOR).
4.7.8 DRIVING SHAFT POSITION SENSOR
Fault code "12".
See 6.4.5 (CHECKING THE PICK-UP).
4.7.9 INTAKE PRESSURE SENSOR
Fault code "13".
See 6.4.11 (CHECKING THE INTAKE PRESSURE SEN""
SOR).
4.7.10 INTAKE PRESSURE SENSOR
Fault code "14".
• Check for pressure loss in the connection pipes (1) (2)
(3) and make sure the flow is regular.
• Check the wiring and connections of the pressure sen-
sor.
NOTE Where necessary, replace the pressure sensor
or engine control unit.
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FUEL SUPPL'y SYSTEM
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Follow~
• Fit the two bushes (3) and torsion spring (4) on the
th rottle body.
• Fit the throttle valve control lever (2) on the throttle
valve spindle.
NOTE Spray a temporary lubricant AP-LUBE on the
spring (4), see 1.9.2 (USE OFCONSUMABLES).
Make sure the the torsion spring are
hooked onto the throttle body and throttle valve con-
trol lever (2).
• Fit the spring washer.
NOTE Apply LOCTITE® 243 on the thread of the nut
(1).
• Screw the nut (1) and tighten it.
Driving torque of the throttle valve control lever nut:
3 Nm (0.3 kgm).
NOTE Once assembly is complete, make sure the le-
vers rotate freely.
The throttle valve controllever (2) must be returned to its
original position by the torsion spring.
Check for end play on the throttle valve control shaft, see
4.8.7 (CHECKING THROTTLE VALVE CONTROL
SHAFT END PLAY) and adjust as necessary, see 4.8.8
(ADJUS.TING THE THROTTLE BODY).
11- 22 - 00 - - - - - - - Release 00/2001-05
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COOLING SYSTEM
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COOLING SYSTEM
TABLE OF CONTENTS
5.1 DESCRIPTION 5-3-00
5.2 REMOVING THE RADIATORS 5-5-00
5.3·REMOVING THE ASSEMBLED
RADIATORS COMPLETE WITH
ENGINE OIL COOLER 5-6-00
5.4 REMOVING THE COOLING
~···-EI..ECTROFINS ~ 5=7~iJiJ
5.5 REMOVING THE COOLANT
THERMAL SWITCH 5-8-00
5.6 REMOVING THE COOLANT
THERMISTORS 5-9-00
5.7 REMOVING THE THERMAL
EXPANSION VALVE 5-10-00
5.7.1 CHECKING THE THERMAL
EXPANSION VALVE 5-10-00
I 5.8 REMOVING THE FILLER NECK
5.9 REMOVING THE THREE·
WAY MANIFOLD
5.10 PARTIAL REMOVING THE
5-11-00
5-12-00
EXPANSION TANK 5-13-00
5.11 COOLANT PUMP.................................. 5-13-00
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COOLING SYSTEM
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5.9 REMOVING THE THREE-WAY MANIFOLD
Carefully read 0.4.1 (PRECAUTIONS AND GENERAL
INFORMATIONS) and 1.2.5 (COOLANT).
• Turn the ignition switch to position "JXi".
• Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).
• Drain the cooling circuit completely, see 2.16 (CHANG-
ING THE COOLANT).
• Disconnect the electric connectors (1) (2) from the ther-
mal switch (3).
When reassembling, make sure the electric connec-
tors (1) (2) are plugged in properly.
NOTE Obtain appropriate pliers to attach the clamps,
or screwdriver-type pipe clamps to replace the original
ones (special type without screw).
• Release the head off the pipe clamps (4) (5) (6).
• Pull the three pipes (7) (8) (9) off the manifold (10).
Clamp driving torque: 7 Nm (0.7 kgm).
• Loosen the pipe clamp (11) and move it downwards.
• Grip the manifold (10) and slide it up off the coupling
(12) one small step at a time.
Plug the coupling openings, in such a way as to pre-
.vent any foreign matters from getting in.
If necessary, proceed as follows:
Driving torque of thermal switch: 30 Nm (3.0 kgm).
• Unscrew and remove the thermal switch (3) and re-
trieve the gasket.
NOTE When reassembling, apply LOCTITE® 572 on
the thread of the thermal switch (3).
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ELECTRIC SYSTEM
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6.3.4 CHECKING THE VOLTAGE REGULATOR
• Remove the rear fairing, see 7.1.36 (REMOVING THE
SADDLE SUPPORT LOWER MOULDED COVER).
• Disconnect the three-way connector (1) (coloured
brown).
• Disconnect the six-way connector (2) (coloured white).
When reassembling, make sure the electric connec-
tors (1-2) are plugged in properly.
• Using a pocket tester (scale x 1MQ), measure the re-
sistance between the cables indicated in the table be-
low from the regulator side (internal female terminals).
NOTE The green (V) and white/red (Bi/R) cables are
double, though connected together.
Take the measurements on either of the two ..
00 00 00
00 00 2 - 00 00
00 00 2 - 00 00
00 00 00 00
2-00 2-00 3-00
This measuring method is approximate; if possible,
check the correct operation of the recharging system
using another regulator in perfect condition.
If the resistance measured is incorrect, replace the
voltage regulator (3).
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ELECTRIC SYSTEM
SL mille
6.4.11 CHECKING THE INTAKE PRESSURE SENSOR
With the engine switched off:
• Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).
• Disconnect the three-way connector (1) (coloured
. black).
Upon reassembly, make sure that the electric con-
nector (1) is correctly coupled.
• Turn the ignition switch to position "0".
• By means of a tester, measure the supply voltage be-
tween the external terminals of the connector (1);
measure (A).
Standard value: 4.5 - 5.5 V.
• Turn the ignition switch to position "gC'.
• Using a pocket tester (scale kQ), measure the resist-
ance between the terminals of the sensor (2).
NOTE Measurements (B), (C) and (0) must be taken
individually, not at the same time.
o
Measurements (B), (C) and (D) must produce the follow-
ing values:
Standard values:
- .measurement (B) 12 kQ ± 10 % ;
- measurement (C) 11.50 kQ ± 10°10;
- measurement (0) 4 kQ ±1 0°10.
If the resistance proves to be any value other than
that prescribed, the sensor (2) mustbe changed.
®
® ©
11- 18 - 00 Release 00/2001-05
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ELECTRIC SYSTEM
SL mille
6.8.2 CHECKING THE LIGHTS RELAY