Aprilia Dorsoduro 750 – 2007 Factory Service Manual (P/N 854202)

Aprilia’s Service Station Manual (P/N 854202) covers the Dorsoduro 750 with the liquid-cooled M551M DOHC V-twin engine. The publication carries a 2007 Aprilia copyright notice.

Searchable Text and Wiring Diagram Detail

Search and chapter access: The document text is searchable. Embedded bookmarks cover chapters and individual procedures, but several chapter entries have no working destination, and some procedure links land on the preceding page. The general wiring diagram has image-based labels that are not searchable; some small labels remain difficult to read even when enlarged.

The ZIP download contains one printable English PDF with 357 pages, including the front matter, index, and one blank page.

Engine Rebuilds, EFI Faults, and Chassis Service

These selected workshop topics outline part of the manual’s coverage. Other examples include pre-delivery checks and handguard installation.

• Engine repair: Step-by-step procedures for engine removal and installation, cylinder-head work, cam timing, piston inspection, crankcase splitting, and crankshaft assembly.

• Gearbox and clutch: Gearbox disassembly and refitting, selector checks, clutch dismantling, component inspection, and reassembly.

• EFI and electrical diagnosis: Axone-guided fault tracing, sensor and actuator checks, CAN diagnosis, throttle self-learning, and throttle-grip autodetection.

• Routine maintenance: Service schedules, spark-plug replacement, engine oil and filter changes, air-filter service, and valve-clearance inspection and adjustment.

• Suspension and chassis: Front-fork rebuilding, steering-bearing adjustment, wheel checks, rear-shock and swingarm removal, drive-chain maintenance, and exhaust removal.

• Brakes: Front and rear brake-pad removal, hydraulic bleeding procedures, and component-specific fastening data.

• Cooling system: Coolant replacement, radiator and fan removal, expansion-tank removal, and water-pump shaft and seal replacement.

Its level of detail and dependence on coded Aprilia tools and Axone diagnostics make it suited to experienced motorcycle technicians with the proper measuring, lifting, and electronic test equipment.

Engine Matching, Timing, and Lubrication

Rebuild data covers A–D piston-to-cylinder matching, first- and second-generation crankcase markings, crankshaft-journal and main-bearing selection, crankpin bushing classes, connecting-rod weight matching, and base-gasket selection from piston projection. These matching tables help identify compatible components before engine assembly.

Gearbox-shaft and selector drawings identify the internal arrangements. Clutch inspection covers plate thickness, distortion, spring length, and housing wear. Starter-motor removal and flywheel/freewheel service are also documented. Oil-pump procedures distinguish old- and new-generation assemblies.

Component-specific torque tables cover cylinder-head studs, connecting-rod screws, oil-pump fasteners, and chassis attachments. Special-tool references include flywheel extractor 020713Y, timing tool 020720Y, and overhead-camshaft timing jig 020723Y.

The timing section warns that applying final camshaft-gear nut torque with the shaft mounted can irreparably damage the cylinder head. The crankcase assembly section identifies excess ThreeBond as a cause of blocked internal oil passages.

Marelli EFI, Ride-by-Wire, and Electrical Diagnosis

The Marelli 5DM injection ECU and separate EFI throttle controller are explained through their Ride-by-Wire operating logic and safety strategies. Dedicated troubleshooting paths address EFI warnings, abnormal engine behavior, and no-start faults. The procedures specify Axone version 5.1.5 or later.

Sensor coverage spans engine and vehicle speed, intake pressure, engine and air temperature, lambda, and oil pressure. Injector and coil diagnosis is supported by activation tests and circuit checks. Neutral, clutch, side-stand, bank-angle, and RUN/STOP inputs are covered alongside the cooling-fan circuit and CAN communication.

Replacement-related self-learning and autodetection checks distinguish ECU, throttle-body, and throttle-grip sensor work. Dashboard material covers immobilizer faults, key programming, stored-error clearing, instrument-panel updates, and service reset.

Front, center, and rear harness-routing references identify critical connector checks. Relay identification uses both diagram position and wire color, helping relate the fault-tracing instructions to the installed harness.

Forks, Wheels, and Brake Service

Fork procedures extend through internal inspection, seal installation, reassembly, and oil-level setting. Steering-bearing preload, wheel-bearing condition, axle and rim runout, and drive-chain wear have their own checks.

Rear-shock coverage stops at removal rather than internal overhaul. Brake procedures cover pad removal and hydraulic bleeding; ABS modulator service and ABS fault diagnosis are outside this manual’s coverage.

Brake, wheel, steering, and suspension fasteners are safety-critical, and the manual calls for specified torque values and post-repair checks before the motorcycle returns to service.

Cooling Repairs and Regional Tank Access

Cooling documentation includes the thermostat circuit and water-pump shaft and integrated-seal replacement, with seal-kit reference 020661Y. Radiator, fan, and expansion-tank removal procedures accompany coolant replacement.

Bodywork access covers the airbox, lighting assemblies, instrument support, and fuel tank. A separate USA/CDN tank-removal procedure distinguishes the regional arrangement.

Assembly Drawings and Circuit References

Visual references include the general wiring diagram, front/center/rear harness-routing tables, gearbox-shaft diagram, injection and Ride-by-Wire assembly diagram, front-fork exploded diagram, and cooling-system circuit diagram. Connector views and ECU pinout tables accompany the electrical checks.

Examples of Sensor Test Data and Fork Settings

The engine-temperature sensor specifications include 2.05 kΩ ± 100 Ω at 25°C. Injector resistance is listed as 14.8 Ω ± 5% at 20°C, illustrating the temperature-specific component data supplied with the electrical diagnosis.

Fork refill data specifies an oil level 147 mm below the sleeve rim, measured without the spring and with the pumping member compressed.