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

• Aprilia Service Station Manual no. 854202, supplied in English as a 357-page PDF, with a 2007 Aprilia copyright notice.
• Built around the Dorsoduro 750 / M551M V-twin platform, including the six-speed gearbox, wet clutch, Marelli 5DM injection ECU, separate EFI throttle controller, and Ride-by-Wire system.
• Follows major engine repair procedures from removal and installation through gearbox and clutch work, cylinder-head service, cam timing, piston and cylinder inspection, crankcase splitting, crankshaft and connecting-rod assembly, and oil-pump service.
• Provides Axone-guided troubleshooting for EFI and no-start faults, ECU and dashboard errors, sensor and actuator circuits, CAN communication, throttle self-learning, throttle-grip autodetection, and system resets.
• Extends beyond the engine to front-fork rebuilding, steering adjustment, wheels, swingarm, drive chain, exhaust, brake-pad service and bleeding, water-pump repair, radiator removal, and bodywork access.
• Distinguishes first- and second-generation crankcases, old- and new-generation oil pumps, and a separate USA/CDN fuel-tank removal procedure.
• Supplies component-specific torque tables, clearances, wear limits, fluid and lubricant data, electrical test values, wiring and routing references, and Aprilia special-tool numbers.

Factory Repair Depth

The manual identifies the covered engine as the 749.9 cc M551M, a liquid-cooled 90-degree DOHC V-twin with four valves per cylinder. 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.

Routine maintenance covers the service schedule, spark plugs, engine oil and filter, air filter, and valve-clearance inspection and adjustment. The internal engine chapters go much further. They document the gearbox shafts and selector, starter motor, flywheel and freewheel, clutch pack, heads, valves, camshafts, timing chains, cylinders, pistons, crankshaft, connecting rods, crankcases, and lubrication system. 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.

EFI, Ride-by-Wire, and Electrical Diagnosis

The troubleshooting section starts with dedicated decision trees for an EFI warning or abnormal engine behavior and for an engine that will not start. The procedures expect Axone version 5.1.5 or later and tie fault codes to connector pinouts, circuit continuity, ground, voltage, and component checks. Coverage spans the engine-speed and wheel-speed sensors, dual intake-pressure sensors, engine and air-temperature sensors, lambda sensor, injectors, coils, throttle grip, throttle bodies, oil-pressure switch, neutral, clutch, side-stand and bank-angle switches, cooling fan, RUN/STOP switch, and CAN line.

ECU replacement, throttle-body replacement, and throttle-grip sensor replacement are backed by the corresponding self-learning or autodetection checks. Dashboard material covers immobilizer faults, key programming, stored-error clearing, instrument-panel updates, and service reset. Harness installation is mapped across the front, center, and rear of the motorcycle, with critical connector checks and relay locations identified by both wiring-diagram position and cable color.

Chassis, Cooling, Diagrams, and Scope

Suspension coverage includes front-wheel inspection, fork-leg removal, oil draining, internal fork disassembly and inspection, seal installation, reassembly, refill, and steering-bearing play adjustment. The rear section covers wheel checks, shock removal, swingarm removal, chain adjustment and inspection, and exhaust removal. Brake material covers front and rear pad removal and hydraulic bleeding. Cooling procedures address coolant replacement, fan and radiator removal, the expansion tank, thermostat circuit, and water-pump shaft and seal replacement.

Named visual references include the general wiring diagram, front/center/rear harness-routing tables, gearbox-shaft diagram, injection and Ride-by-Wire diagram, front-fork exploded diagram, and cooling-system circuit diagram. Tool references include the flywheel extractor 020713Y, timing tool 020720Y, overhead-camshaft timing jig 020723Y, and water-pump seal kit 020661Y.

The scope has two useful limits: rear-shock coverage stops at removal rather than internal overhaul, and the brake chapter contains no ABS modulator service or ABS fault diagnosis. The engine section warns that applying final torque to a camshaft gear nut while the shaft remains mounted can irreparably damage the cylinder head; excess ThreeBond between the crankcase halves can obstruct internal oil passages. 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.