Aprilia SL 750 SHIVER Service manual

SERVICE STATION MANUAL

854146

SL 750 SHIVER

SERVICE STATION

MANUAL

SL 750 SHIVER

THE VALUE OF SERVICE

Thanks to continuous technical updates and specific training programs on aprilia products, only aprilia

Official Network mechanics know this vehicle fully and have the special tools necessary to carry out

maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before

riding, its regular maintenance and the use of Original aprilia Spare Parts only are essential factors!

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

search directly on the inset map in our Official Website:

www.aprilia.com

Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design

stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and

duration. The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts

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

manufacturing or construction reasons.

Not all versions shown in this publication are available in all countries. The availability of individual

versions should be confirmed with the official aprilia sales network.

prohibited. aprilia - After sales service.

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

SERVICE STATION MANUAL

SL 750 SHIVER

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

SPECIAL TOOLS S-TOOLS

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

POWER SUPPLY P SUPP

SUSPENSIONS SUSP

CHASSIS CHAS

BRAKING SYSTEM BRAK SYS

CLUTCH SYSTEM CLU SYS

COOLING SYSTEM COOL SYS

BODYWORK BODYW

INDEX OF TOPICS

CHARACTERISTICS CHAR

Characteristics

SL 750 SHIVER

Rules

Safety rules

Carbon monoxide

If you need to keep the engine running in order to carry out any procedure, please ensure that you do

so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work

in an enclosed area, make sure to use a smoke-extraction system.

CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.

Fuel

CAUTION

FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE. DO NOT DISPERSE FUEL IN THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN

Hot components

The engine and the exhaust system components get very hot and remain in this condition for a certain

time interval after the engine has been shut off. Before handling these components, make sure that you

are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.

Coolant

The coolant contains ethylene glycol which, under certain conditions, can become flammable.

When it burns, ethylene glycol produces an invisible flame which however can cause burns.

CAUTION

PAY ATTENTION NOT TO POUR COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPONENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. EVEN IF IT IS TOXIC, THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT.

CHAR - 2

SL 750 SHIVER Characteristics

KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. ENGINE OR TRANSMISSION OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN

Brake and clutch fluid

THE BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. KEEP OUT OF THE REACH OF CHILDREN

Battery electrolyte and hydrogen gas

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTROLYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS INTO CONTACT WITH YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY. KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

CHAR - 3

Characteristics

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

carefully.

BEFORE DISASSEMBLING COMPONENTS

•

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

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

COMPONENTS REMOVAL

•

Do not loosen and/or tighten screws and nuts using pliers or other tools other than the

especially designed wrench.

•

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

identify them with distinctive symbols.

•

Each component needs to be clearly marked in order to be identified during assembly.

•

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

•

Keep coupled parts together since they have "adjusted" to each other due to normal wear

SL 750 SHIVER

and tear.

•

Some components must be used together or replaced altogether.

•

Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY NEED REPLACING.

•

Only use ORIGINAL APRILIA SPARE PARTS.

•

Comply with lubricant and consumables usage guidelines.

•

Lubricate parts (whenever possible) before reassembling them.

•

When tightening nuts and screws, start from the ones with the largest section or from the

internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-

plying the tightening torque.

•

Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and

screws with new ones if their tread is damaged.

•

When fitting bearings, make sure to lubricate them well.

•

Check that each component is fitted correctly.

•

After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-

hicle on private grounds or in an area with low traffic density.

•

Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light

layer of lithium-based grease on the oil guard rims. Reassemble the oil guard and the bear-

ings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below as non-compliance with the procedure

so described causes irreparable damage to both the connector and the cable harness:

CHAR - 4

SL 750 SHIVER Characteristics

Press the relevant safety hooks, if any.

•

Grip the two connectors and disconnect them by pulling them in opposite directions.

•

If there are signs of dirt, rust, humidity, etc., clean the connector internal parts carefully using

a pressurised air jet.

•

Make sure that the cables are correctly linked to the connector internal terminal ends.

•

Then insert the two connectors making sure that they couple correctly (if the relevant hooks

are provided, you will hear them "click" into place).

CAUTION

TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.

NOTE

THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY ROUND.

TIGHTENING TORQUE

CAUTION

DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUE OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

Running-in

Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients

are ideal to run in engine, brakes and suspensions effectively. Vary your driving speed during run-in.

In this way, you allow for the work of components to be "loaded" and then "unloaded", thus cooling

engine parts.

CAUTION

ONLY AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD CAN THE BEST PERFORMANCE OF YOUR VEHICLE BE OBTAINED.

Follow the guidelines detailed below:

•

Do not twist the throttle grip abruptly and completely when the engine is working at a low

revs, either during or after run-in.

•

During the first 100 km (62 miles) operate the brakes with caution, avoid rough and long

braking. That is to permit the adequate adjustment of the pad friction material to the brake

discs.

AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND/OR DAMAGING THE VEHICLE.

CHAR - 5

Characteristics SL 750 SHIVER

Vehicle identification

Write down the chassis and engine number in the specific space of this booklet. The chassis number

is handy when purchasing spare parts.

CAUTION

ALTERING IDENTIFICATION NUMBERS IS AN OFFENCE WHICH CAN RESULT IN SEVERE CRIMINAL AND ADMINISTRATIVE CHARGES. PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY.

This number is composed by numbers and letters, as in the example shown below.

ZD4RA0000YSXXXXXX

KEY:

ZD4: WMI (World manufacturer identifier) code;

RA: model;

000: version variation;

0: digit free

Y year of manufacture

S: production plant (S= Scorzè);

XXXXXX: progressive number (6 digits);

ENGINE NUMBER

The engine number is printed on the base of the

left side engine crankcase.

Engine No. ....................

CHASSIS NUMBER

The chassis number is stamped on the right side of the headstock.

Chassis No. ....................

Dimensions and mass

Specification Desc./Quantity

Max. length 2100 mm (82.68 in)

Max. width 800 mm (31.50 in)

Max. height (to top fairing) 1135 mm (44.69 in)

Saddle height 810 mm (31.89 in)

CHAR - 6

DIMENSIONS

SL 750 SHIVER Characteristics

Specification Desc./Quantity

Wheelbase 1440 mm (56.69 in)

Kerb weight (full fuel tank) 210 kg (463 lb)

Engine

ENGINE

Specification Desc./Quantity

Model M551M

Type 90° longitudinal V-twin, 4-stroke, 4 valves per cyl-

inder, 2 overhead camshafts.

Cylinder quantity 2

Overall engine capacity 749.9 cm³ (45.76 cu.in)

Bore / stroke 92 x 56.4 mm (3.62 x 2.22 cu.in)

Valve clearance at intake 0.11 - 0.18 mm (0.0043 - 0.0071 in)

Outlet valve clearance 0.16 - 0.23 mm (0.0063 - 0.0091 in)

Compression ratio 11.0: 1

Start-up electric

Engine revs at idle speed 1400 ± 100 rpm

Clutch Multiple-disk, oil-bathed clutch with control on the

left side of the handlebar

Lubrication system Wet crankcase. Pressure system regulated by tro-

choidal pump Air filter with dry cartridge filter Cooling Fluid

Transmission

Final drive gear ratio 16/44

Capacities

Fuel (reserve included) 15 l (3.30 UKgal; 3.96 USgal)

GEAR

Specification Desc./Quantity

Type Mechanical, 6 speeds with foot lever on the left-

hand side of the engine

GEAR RATIOS

Specification Desc./Quantity

Gear ratio Gear primary drive 38/71

1st gear ratio 14/36 (secondary)

2nd gear ratio 17/32 (secondary)

3rd gear ratio 20/30 (secondary) 4th gear ratio 22/28 (secondary) 5th gear ratio 23/26 (secondary) 6th gear ratio 24/25 (secondary)

CAPACITY

Specification Desc./Quantity

Fuel reserve 3 l (0.66 UKgal; 0.79 USgal)

CHAR - 7

Characteristics SL 750 SHIVER

Specification Desc./Quantity

Engine oil 3.0 l (without oil filter change) (0.66 UKgal; 0.79

USgal)

3.2 l (without oil filter change) (0.70 UKgal; 0.85 USgal)

Fork oil quantity (for each stem): 535 cm³ (32.65 cu.in)

Coolant 1.8 l (0.40 UKgal; 0.48 USgal)

Seats 2

Vehicle max. load 190 kg (418.9 lb) (Rider + passenger + luggage)

Drive chain

DRIVE CHAIN

Specification Desc./Quantity

Type Endless (without master link) and with sealed

links. No. of links 108

Model 525 ZRPK

Electrical system

Specification Desc./Quantity

Main fuses 30A

Auxiliary fuses 3A, 10A, 15A, 20A

(Permanent magnet) Generator 13.5 V - 450 W at 6000 rpm

Specification Desc./Quantity

Standard spark plugs NGK CR7EKB

Spark plug electrode gap 0.6 ÷ 0.7 mm (0.024 ÷ 0.028 in)

Resistance 5 kOhm

Specification Desc./Quantity

Low-beam light 12 V - 55 W H7

High-beam light 12 V - 55 W H7

Front tail light 12V - 5W x 2

Turn indicator lights 12V - 10W

License plate light 12V - 5W

Rear tail light / stop light 12V - 5/21W x 2

Rpm indicator lighting LED

Multifunction display lighting LED

ELECTRICAL SYSTEM

Battery 12V - 10 Ah

SPARK PLUGS

BULBS

CHAR - 8

WARNING LIGHTS

Specification Desc./Quantity

High-beam light LED

Right turn indicator LED

Left turn indicator LED

General warning LED

Gear in neutral LED

SL 750 SHIVER Characteristics

Specification Desc./Quantity

Side stand down LED

Fuel reserve LED

ABS LED

Frame and suspensions

CHASSIS

Specification Desc./Quantity

Type Die-cast aluminium plates and high-strength steel

tubular chassis.

Steering inclination angle 24.9°

Trail 109.6°

SUSPENSIONS

Specification Desc./Quantity

Front Upside-down hydraulic action telescopic fork, Ø

43 mm (1.69 in) stems

Travel 120 mm (4.72 in)

Rear Oscillating swingarm and single adjustable hy-

draulic shock absorber

Wheel travel 122 mm (4.80 in)

Brakes

SIZES A AND B

Specification Desc./Quantity

Size A 658.5 mm (25.93 in) Size B 373.4 mm (14.70 in)

BRAKES

Specification Desc./Quantity

Front Double floating disc, Ø 320 mm (12.60 in), radially-

mounted callipers with four plungers- two of them Ø 27 mm (1.06 in), the other two Ø 32.03 (1.26 in)

and 4 pads

Rear Ø 240 mm (9.45 in) disc brake, Ø 35 mm (1.38 in)

twin-plunger calliper

CHAR - 9

Characteristics SL 750 SHIVER

Wheels and tyres

WHEEL RIMS

Specification Desc./Quantity

Type Light alloy rims with extractable bolt

Front 3.50 x 17"

Rear 6.00 x 17"

TYRES

Specification Desc./Quantity

Tyre type (standard) DUNLOP SPORTMAX QUALIFIER - METZELER

Front 120/70 ZR17" (58W)

Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI)

2 passengers: 2.5 bar (250 kPa) (36.26 PSI)

Rear 180/55 ZR17" (73W) or 190/50 ZR17" (73W)

Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)

2 passengers: 2.8 bar (280 kPa) (40.61 PSI)

Supply

FUEL SUPPLY SYSTEM

Specification Desc./Quantity

Type Electronic injection (Multipoint)

Throttle valves diameter Ø 52 mm (2.05 in)

Fuel Premium unleaded petrol, minimum octane rating

of 95 (NORM) and 85 (NOMM)

Tightening Torques

FRAME ASSEMBLY

Name Torque in Nm

TCEI screw fixing Shock Absorber Counterplate to

right chassis bracket - M10x30 (1)

TCEI screw fixing Fairings to engine - M12x282 (3) 80 Nm (59 lbf ft)

Self-tapping nut fixing left Fairing to engine and

Framework to chassis fairings - M12 (7)

TC TORX screw fixing Perimeter frame to the

chassis fairings - M12x53 (4)

TCEI upper screw fixing Saddle pillar to chassis -

M8x30 (2)

TCEI lower screw fixing Saddle pillar to chassis -

M8x40 (2)

Lower self-tapping nut fixing Saddle pillar to chas-

sis - M8 (2)

TCEI screw fixing lambda probe plate to right-side

chassis (pre-fit on right fairing - M4x10 (2)

50 Nm (36.88 lbf ft)

80 Nm (59 lbf ft)

25 Nm (18.44 lbf ft)

3 Nm (2.3 lbf ft)

CHAR - 10

SL 750 SHIVER Characteristics

FOOTREST UNIT

Name Torque in Nm

TCEI sunken screw fixing Footrest Support to

chassis - M8x30 (6)

Non-slip bolt (fit on driver footrest) - M8 (2) 25 Nm (18.44 lbf ft)

Self-tapping TE screw for Footrest finish - M6x12

(8)

STAND UNIT

Name Torque in Nm

Screw for Stand - M10x1.25 (1) 10 Nm (10.34 lbf ft)

Lower nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)

Self-tapping TE screw fixing Stand Plate on engine

- M8x30 (3)

SWINGARM UNIT

Name Torque in Nm

TCEI screw Swing Arms coupling - M8x70 (7) 25 Nm (18.44 lbf ft)

Swingarm Pin adjustment Bushing (1) 12 Nm (8.85 lbf ft)

Swingarm Pin Ring Nut (1) 60 Nm (44.25 lbf ft)

Chain tensioner set screw (2) -

SERPRESS nut (on chain tensioner pad set

screw) - M8 (2)

TPSI screw fixing rear stand bushing - M6x40 (2) 10 Nm (7.37 lbf ft) TBEI screw fixing chain tensioner pad - M5x12 (3) 3 Nm (2.21 lbf ft) Self-tapping TBEI screw fixing chain guard, brake

pipe protection and counterslider - M5x9 (5)

Calliper support lock pin - M12 (1) 50 Nm (36.88 lbf ft) - Loctite 243

18 Nm (13.27 lbf ft)

10 Nm (7.37 lbf ft)

25 Nm (18.44 lbf ft)

4 Nm (2.95 lbf ft)

FRONT SUSPENSION UNIT

Name Torque in Nm

Stainless steel TCC screw fixing fork stems on up-

per and lower plates - M8x30 (6)

Headstock Ring nut - M25x1 (1) 7 Nm (5.16 lbf ft)

Headstock Cap - M22x1 (1) 100 Nm (73.75 lbf ft)

Screw (fasten on Fork Hub caps) - M8x40 (4) 25 Nm (18.44 lbf ft)

Screw fixing the stem in wheel carrier - M10x1.5

(2)

25 Nm (18.44 lbf ft)

20 Nm (14.75 lbf ft)

REAR SUSPENSION UNIT

Name Torque in Nm

TCEI screw - M10x50 (1) 50 Nm (36.88 lbf ft) TCEI screw - M10x59 (1) 50 Nm (36.88 lbf ft)

Nut - M10 (1) 50 Nm (36.88 lbf ft)

ENGINE SMALL PARTS UNIT

Name Torque in Nm

Self-tapping TE screw fixing negative on engine -

M6x12 (3)

10 Nm (7.37 lbf ft)

CHAR - 11

Characteristics SL 750 SHIVER

FILTER CASE UNIT

Name Torque in Nm

SWP Self-tapping screw - M2.9x12 TCCR (2) 3 Nm (2.21 lbf ft)

TCEI screw fixing negative on engine - M6x12 (1) 10 Nm (7.37 lbf ft)

FILTER CASING SMALL PARTS UNIT

Name Torque in Nm

SWP Self-tapping Crosshead screw - M5x20 (21) 3 Nm (2.21 lbf ft)

EXHAUST SYSTEM UNIT

Name Torque in Nm

SERPRESS self-locking nut fixing Plate on head -

M8 (4)

Primary Clamp (between front/rear manifolds and

central manifold) - M6 (2)

Silencer Clamp (between central manifold and si-

lencer) - M6 (1)

Self-tapping TE screw fixing Muffler holding Brack-

et to saddle pillar - M8x20 (2)

Self-tapping TE screw fixing Silencer front attach-

ment to muffler holding bracket - M8x35 (2)

TBEI screw fixing right/left cover to silencer -

M6x20 (4)

TBEI lower screw fixing Licence Plate Holder

curved support - M6x20 (2)

25 Nm (18.44 lbf ft)

7 Nm (5.16 lbf ft)

25 Nm (18.44 lbf ft)

35 Nm (25.81 lbf ft)

10 Nm (7.37 lbf ft)

COOLING SYSTEM UNIT

Name Torque in Nm

Self-tapping TE screw fixing Radiator, left-side, to

frame and radiator bracket to engine - M6x25 (2)

Electric fan fixing screw (3) 3 Nm (2.21 lbf ft)

Screw fixing air deflector to radiator, right and left

side (2)

FRONT WHEEL UNIT

Name Torque in Nm

Wheel Pin Nut (1) 80 Nm (59 lbf ft)

Self-tapping TE screw fixing front Disc - M8x20

=S= (12)

REAR WHEEL UNIT

Name Torque in Nm

Self-tapping TE screw fixing rear Disc - M8x20

=S= (5)

TCEI screw fixing Anti-vibration buffer on wheel -

M10x30 (5)

Lower Self-locking nut fixing Crown to sprocket

carrier - M10 (5)

Wheel Pin Nut - M25x1.5 (1) 120 Nm (88.5 lbf ft)

10 Nm (7.37 lbf ft)

30 Nm (22.13 lbf ft) (Loctite 243)

50 Nm (36.88 lbf ft) (Loctite 2701)

50 Nm (36.88 lbf ft)

CHAR - 12

SL 750 SHIVER Characteristics

FRONT BRAKE UNIT

Name Torque in Nm

Brake pipe union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)

Filler with bleed (Heng Tong) - M10x1 (2) 25 Nm (18.44 lbf ft)

Self-tapping TE screw fixing Calliper -

M10x1.25x55 (4)

REAR BRAKE UNIT

Name Torque in Nm

TCEI screw fixing Pin to brake lever - M6x16 (1) 10 Nm (7.37 lbf ft)

Rear brake Lever pin - M6 (1) 25 Nm (18.44 lbf ft) Brake pipe union - M10x1 (2) 25 Nm (18.44 lbf ft)

Lock nut for fork - M6 (1) 10 Nm (7.37 lbf ft)

Self-tapping TE screw fixing Pump to footrest sup-

port - M6x20 (2)

TBEI screw fixing oil pipe to swingarm and rubber

pipe to footrest support - M5x12 (4)

Self-locking nut - M6 (1) 10 Nm (7.37 lbf ft)

Self-tapping TE screw - M6x16 (1) 10 Nm (7.37 lbf ft)

50 Nm (36.88 lbf ft)

10 Nm (7.37 lbf ft)

6 Nm (4.42 lbf ft)

HANDLEBAR / CONTROLS / TRASM. UNIT

Name Torque in Nm

Anti-vibration weight terminal - M8x1 (2) 35 Nm (25.81 lbf ft)

TCEI screw - M6x40 (2) 10 Nm (7.37 lbf ft)

RH light switch (1) 2.5 Nm (1.47 lbf ft)

LH light switch (1) 2.5 Nm (1.47 lbf ft)

TCEI screw fixing lower U-bolt on fork plate -

M10x60 (2)

Stainless steel TCC screw fixing upper to lower U-

bolt - M8x25 (4)

50 Nm (36.88 lbf ft)

25 Nm (18.44 lbf ft)

ELECTRICAL COMPONENTS UNIT

Name Torque in Nm

SWP Self-tapping screw fixing Demand Support to

Demand - M5x14 (4)

Self-tapping TE screw fixing Demand sensor to

chassis - M6x20 (3)

3 Nm (2.21 lbf ft)

10 Nm (7.37 lbf ft)

LIGHTS UNIT / INSTRUMENT PANEL

Name Torque in Nm

SWP Self-tapping screw fixing Instrument Panel -

M5x14 (6)

Special screw fixing steering head with Instrument

panel supporting plate - M6 (2)

TCEI screw fixing steering head with Instrument

panel supporting plate - M6x16 (4)

Self-locking nut - M6 (3) 10 Nm (7.37 lbf ft)

TBEI screw fixing Headlight bracket to steering

base - M6x15 (2)

Lower TBEI screw fixing Rear Light - M5 (1) 4 Nm (2.95 lbf ft)

Lower TCB screw fixing Rear Light - M4.2x20 (2) 4 Nm (2.95 lbf ft)

Self-locking nut - M6 (4) 3 Nm (2.21 lbf ft)

3 Nm (2.21 lbf ft)

10 Nm (7.37 lbf ft)

CHAR - 13

Characteristics SL 750 SHIVER

TANK UNIT

Name Torque in Nm

Self-locking nut - M5 (6) 6 Nm (4.42 lbf ft)

Self-tapping TE screw - M6x30 (2) 6 Nm (4.42 lbf ft)

FRONT BODYWORK UNIT

Name Torque in Nm

TBEI screw fixing Under grab handles/ Tail sec-

tions / Saddle Pillar - M5x16 (2)

Self-tapping TBEI screw - M5 (7) 3 Nm (2.21 lbf ft)

SWP Self-tapping Crosshead screw fixing Tail

sections to battery compartment and to fairings -

M5x20 (6)

Self-tapping TE screw fixing Grab handle - M8x20

(4)

TCB screw fixing battery Cover - M4x16 (2) 3 Nm (2.21 lbf ft)

TBEI screw fixing Mudguard to appendix - M5x9

(2)

TBEI screw fixing Mudguard to stems - M5x9 (4) 4 Nm (2.95 lbf ft)

TBEI screw fixing battery compartment to saddle

pillar - M6 (2)

TBEI screw - M5x9 (14) 3 Nm (2.21 lbf ft)

TBEI screw fixing air deflectors to radiator - M6x16

(2)

4 Nm (2.95 lbf ft)

25 Nm (18.44 lbf ft)

3 Nm (2.21 lbf ft)

5 Nm (3.69 lbf ft)

7 Nm (5.16 lbf ft)

FINISHING SMALL PARTS UNIT

Name Torque in Nm

TCEI screw - M8x40 (1) 25 Nm (18.44 lbf ft)

Self-tapping TE screw - M6x25 (2) 10 Nm (7.37 lbf ft)

TCE screw fixing fuel cap - M5x16 (4) 5 Nm (3.69 lbf ft)

TCEI screw fixing fuel cap - M5x30 (3) 5 Nm (3.69 lbf ft)

TCEI screw fixing saddle lock to tail section -

M5x16 (2)

4 Nm (2.95 lbf ft)

ENGINE UNIT

Name Torque in Nm

TCEI screw fixing Pin to gearbox lever and Gear-

box Lever to knurled shaft- M6x16 (2)

Left lock nut for ball joint - M6 (1) 10 Nm (7.37 lbf ft)

Lock nut for ball joint - M6 (1) 10 Nm (7.37 lbf ft)

Pin fixing screw (2) -

Countersunk screw fixing pin (1) -

Brake pipe union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)

Filler with bleed (Heng Tong) fixing pipe to pin -

M10x1 (1)

Self-tapping TE screw fixing Pinion - M10x1.25x55

(1)

50 Nm (36.88 lbf ft) - Loctite 243

10 Nm (7.37 lbf ft)

25 Nm (18.44 lbf ft)

Cam cap/head fixing screws - M6 (16) Pre-tightening: (4.90 - 6.86) Nm ((3.61 - 5.06) lbf

CHAR - 14

COMPLETE HEAD

Name Torque in Nm

ft) Tightening: (9.81 - 12.75) Nm ((7.24 - 9.40) lbf

ft)

SL 750 SHIVER Characteristics

Name Torque in Nm

Map sensor fitting (brass) (2) 2 Nm (1.48 lbf ft) (Loctite 243)

Map sensor fitting (steel) (2) 3.50 Nm (2.58 lbf ft) (Loctite 243)

H20 Bleed fitting (brass) (1) 2 Nm (1.48 lbf ft) (Loctite 243)

H20 Bleed fitting (steel) (1) 3.50 Nm (2.58 lbf ft) (Loctite 243)

Cap - M6 (1) To fit flush

Oil cap - M10x1.25 (2) 7 Nm (5.16 lbf ft) (3M SCOTCH GRIP 2353)

Screw fixing fitting to bleed - M5 (4) 5.50 Nm (4.06 lbf ft)

Special screw fixing Head Cover - M6 (8) 8 Nm (5.90 lbf ft)

H20 Temperature sensor - M12x1.5 (1) 23 Nm (16.96 lbf ft)

Water sensor housing threaded cap - M12x1.5 (1) 10 Nm (7.38 lbf ft) (Loctite Drise AL 506)

Nut fixing Stud Bolts to Head - M10x1.25 (8) Pre-torque 10 Nm (7.38 lbf ft) - Torque 13 Nm

(9.59 lbf ft) + 90° + 90° (Lubricate threads before

tightening)

Head / Cylinder / Crankcase internal side retainer

- M6 (4)

Head / Cylinder / crankcase external side retainer

- M6 (2) Nut fixing Stud Bolts to Head - M6 (4) 12 Nm (8.85 lbf ft) Nut fixing Stud Bolts to Head - M8 (2) 26 Nm (19.18 lbf ft)

Spark plug (2) 13 Nm (9.59 lbf ft)

Screw fixing Pencil to Eldor coil - M6 (2) 5.50 Nm (4.06 lbf ft)

Screw fixing camshaft retaining plate - torx M3 (8) 3 Nm (2.21 lbf ft) (Loctite 270)

Camshaft locking threaded cap 11 Nm (8.11 lbf ft)

12 Nm (8.85 lbf ft)

TIMING SYSTEM

Name Torque in Nm

Nut fixing camshaft gears (pre-tightening) - M15x1

(4)

Nut fixing camshaft gears - M15x1 (4) 90 Nm (66.38 lbf ft)

Screw fixing Timing system Gear - M24x1.5 (2) 40 Nm (29.50 lbf ft) (3M SCOTCH GRIP 2353)

Special screw fixing Mobile / Fixed Pads - M8 (4) 19 Nm (14.01 lbf ft) (Loctite 242)

Chain tensioner fixing screw - M6 (4) 12 Nm (8.85 lbf ft)

Cylinder Plate fixing screw - M6 (4) 12 Nm (8.85 lbf ft)

Screw for Chain tensioner adjustment - M6 (2) 5.50 Nm (4.06 lbf ft)

30 Nm (22.13 lbf ft)

COMPLETE CRANKCASE AND OTHER ELEMENTS

Name Torque in Nm

Oil drainage plug - M16x1.5 19 Nm (14.01 lbf ft)

Special screw for oil calibration on flywheel side

crankcase half - M10x1 (1)

Conical cap for crankshaft support lubrication -

M8x1 (4)

Brass Calibrated dowel fixed on crankcase unit -

M8 (2)

Screw fixing piston oil Jet - M5 (2) 5.50 Nm (4.06 lbf ft) (Loctite 242)

Screw fixing Gear sensor - M5 (2) 5.50 Nm (4.06 lbf ft) (Loctite 243)

Screw fixing Revolution sensor - M6 (1) 5.50 Nm (4.06 lbf ft) (Loctite 243)

Tone Wheel tightening on Secondary Transmis-

sion Shaft - M16x1 (1)

Oil pressure adjustment valve, 3/4" Unf 16 (1) 43 Nm (31.72 lbf ft)

Oil Pump fixing screw - M6 (2) 5.50 Nm (4.06 lbf ft) (Loctite 242)

Screw fixing Oil Pump Cover - M3 (2) 0.80 Nm (0.59 lbf ft)

Screw fixing oil Pump with Gear - M5 (1) 8 Nm (5.90 lbf ft) (Loctite 270)

16 Nm (11.80 lbf ft)

15 Nm (11.06 lbf ft)

5.50 Nm (4.06 lbf ft)

43 Nm (31.72 lbf ft) (Loctite 270)

CHAR - 15

Characteristics SL 750 SHIVER

Name Torque in Nm

Screw fixing Gear locking pawl - M6 (1) 12 Nm (8.85 lbf ft)

Screw fixing Desmodromic / Sprocket Selector -

M8 (1)

Selector Plate fixing screw - M5 (3) 5.50 Nm (4.06 lbf ft)

Selector pin retainer on clutch side crankcase half

- M10x1.5 (1)

Screw fixing clutch / flywheel side crankcase half

- M6 (8)

Screw fixing clutch / flywheel side crankcase half

- M8 (9)

Oil sensor retainer on clutch side crankcase half

(1)

Suction rose fixing screw (2) 12 Nm (8.85 lbf ft)

Oil Filter fitting retainer on clutch side crankcase

half (1)

Oil filter (1) 14 Nm (10.33 lbf ft)

Screw fixing bearing retainer - M6 (3) 10 Nm (7.38 lbf ft) (Loctite 270)

23 Nm (16.96 lbf ft)

16 Nm (11.80 lbf ft)

12 Nm (8.85 lbf ft)

26 Nm (19.18 lbf ft)

13 Nm (9.59 lbf ft)

20 Nm (14.75 lbf ft)

SHAFT / FLYWHEEL / CLUTCH

Name Torque in Nm

Nut fixing Crankshaft primaries - M24x1.5 (1) 270 Nm (199.14 lbf ft)

Freewheel ring fixing screw - M6 (6) 14 Nm (10.33 lbf ft) (Loctite 242)

Screw fixing Rotor - Crankshaft - M12x1.25 (1) 120 Nm (88.51 lbf ft)

Screw fixing Retaining Plate - M5 (1) 8 Nm (5.90 lbf ft)

Clutch fixing nut - M24x1.5 (1) 180 Nm (132.76 lbf ft) (Caulking)

Clutch spring fixing screw - M6 (6) 12 Nm (8.85 lbf ft)

Self-tapping TE screw fixing Pinion - M10x1.25x55

(1)

Connecting rod screw - M10 (4) 20 + 50 + 70 Nm (14.75 + 36.89 + 51.63 lbf ft)

(Lubricate threads before tightening)

50 Nm (36.88 lbf ft)

FLYWHEEL COVERS / CLUTCH

Name Torque in Nm

Screw fixing Stator / Flywheel Cover - M6 (3) 9 Nm (6.64 lbf ft)

Screw fixing Pick-up / Flywheel Cover - M5 (2) 3.50 Nm (2.58 lbf ft)

Screw fixing Flywheel Cover - M6 (11) 12 Nm (8.85 lbf ft)

Nut fixing Shaft pump Control inlet - M6 (1) 12 Nm (8.85 lbf ft) (Loctite 244)

Oil drainage cap retainer on Clutch Cover (1) 2 Nm (1.48 lbf ft)

Screw fixing Clutch side Cover - M6 (13) 12 Nm (8.85 lbf ft)

Screw fixing Pump Cover / Clutch side Cover - M6

(3)

Screw fixing Pump Cover / Clutch Cover / clutch

side crankcase half - M6 (2)

Screw fixing Clutch Cover / Clutch side Cover - M6

(6)

Screw fixing "split" clutch cover gasket retainer -

M4 steel A2 (6)

Screw fixing Plate / Clutch Control Support - M5

(3)

Screw fixing Clutch Control Support / flywheel side

crankcase half - M6 (1)

Screw fixing Clutch Control Support / flywheel side

crankcase half - M6 (2)

Screw fixing Bracket / Starter motor - M6 (2) 12 Nm (8.85 lbf ft)

12 Nm (8.85 lbf ft)

3 Nm (2.21 lbf ft)

5.50 Nm (4.06 lbf ft)

12 Nm (8.85 lbf ft)

CHAR - 16

SL 750 SHIVER Characteristics

Name Torque in Nm

Screw fixing engine Bracket / clutch side crank-

case half - M6 (2)

Crankshaft access cover (1) 4 Nm (2.95 lbf ft)

H20 Pump Rotor (1) 4.50 Nm (3.32 lbf ft)

Screw fixing Stick-coil / Head cover - M6 (2) 5.50 Nm (4.06 lbf ft)

Screw fixing plate / "split" clutch cover - M4 steel

A2 (6)

THROTTLE BODY / FILTER HOUSING

Name Torque in Nm

Intake Fitting fixing screw - M6 (8) 12 Nm (8.85 lbf ft) (Loctite 242)

Screw fixing Injection Throttle Body - M6 (8) 12 Nm (8.85 lbf ft) (Loctite 242)

rbw control unit fixing screw - M5 (2) 3.50 Nm (2.58 lbf ft) (Loctite 242)

Injectors fixing screw - M6 (2) 12 Nm (8.85 lbf ft) (Loctite 242)

Crosshead self-tapping screw fixing cover/ filter

casing - M5x20 (8)

Crosshead self-tapping screw fixing partition / filter

casing - M5x20 (10)

Crosshead self-tapping screw fixing side cover /

filter casing - M5x20 (3)

Crosshead self-tapping screw 5x10 (2) 3 Nm (2.21 lbf ft)

12 Nm (8.85 lbf ft)

3 Nm (2.21 lbf ft) (Loctite 243)

3 Nm (2.21 lbf ft)

Overhaul data

Assembly clearances

Cylinder - piston assy.

The pistons are available in four size types (A, B,

C, D) to be coupled to the four cylinder types (A,

B, C, D).

Only one type of piston ring is available.

CHAR - 17

Characteristics SL 750 SHIVER

CYLINDER - PISTON COUPLING

Specification Desc./Quantity

Piston - cylinder coupling Type A Cylinder: 91.990 - 91.977 mm (3.6216 - 3.6219 in)

Piston: 91.933 - 91.940 mm (3.6217 - 3.6197 in)

Piston - cylinder coupling Type B Cylinder: 91.997 - 92.004 mm (3.6219 - 3.6222 in)

Piston: 91.940 - 91.947 mm (3.6197 - 3.6199 in)

Piston - cylinder coupling Type C Cylinder: 92.004 - 92.011 mm (3.6222 - 3.6225 in)

Piston: 91.947 - 91.954 mm (3.6199 - 3.6202 in)

Piston - cylinder coupling Type D Cylinder: 92.011 - 92.018 mm (3.6225 - 3.6227 in)

Piston: 91.954 - 91.961 mm (3.6202 - 3.6205 in)

Fitting clearance 0.050 - 0.064 mm (0.00197 - 0.00252 in)

Crankcase - crankshaft - connecting rod

Two types of crankcase (1 or 2) are determined according to the diameter of the bearing hole.

The types are written on the engine crankshaft with a felt-tip pen and can be seen by removing the

clutch cover and the flywheel cover.

•

Two letters representing the main bushings and the primary wheelbase are written on the

clutch side.

•

A letter indicating the main bushing type is written on the flywheel side.

CRANKCASE SELECTION TYPE

Specification Desc./Quantity

Crankcase type 1 Bushing seat diameter: 53.954 - 53.960 mm

(2.1241 - 2.1244 in)

Crankcase type 2 Bushing seat diameter: 53.960 - 53.966 mm

(2.1244 - 2.1246 in)

CHAR - 18

SL 750 SHIVER Characteristics

There are two types of crankshaft for each bearing:

•

4 - 5 for flywheel side;

•

7 - 8 for clutch side.

The category type is stamped on one crankshaft

counterweight.

NOTE

THE SHAFT MAY HAVE TWO DIFFERENT CLASSES ON THE TWO BEARINGS.

CRANKSHAFT SELECTION TYPE

Specification Desc./Quantity

Crankshaft type 4 - 7 Main journals - diameter: 49.978 - 49.984 mm

(1.9676 - 1.9679 in)

Crankshaft type 5 - 8 Main journals - diameter: 49.972 - 49.978 mm

(1.9674 - 1.9676 in)

Once the categories below are checked:

•

crankcase

•

flywheel side main journal

•

clutch side main journal

choose the bushings to be used for coupling according to the following table.

MAIN BUSHINGS

Specification Desc./Quantity

Main journal type 4 (flywheel side) crankcase type 1 - half-bushings A (red) Main journal type 4 (flywheel side) crankcase type 2 - half-bushings B (blue) Main journal type 5 (flywheel side) crankcase type 1 - half-bushings B (blue) Main journal type 5 (flywheel side) crankcase type 2 - half-bushings C (yellow)

Main journal type 7 (clutch side) crankcase type 1 - half-bushings A (red) Main journal type 7 (clutch side) crankcase type 2 - half-bushings B (blue) Main journal type 8 (clutch side) crankcase type 1 - half-bushings B (blue) Main journal type 8 (clutch side) crankcase type 2 - half-bushings C (yellow)

Crankcase category

Crankcase can be selected from two types (A or

B) according to the centre to centre distance be-

tween the primary reduction gears.

The category can be checked out on clutch-side

crankcase half, at the back.

NOTE

SHOULD THE CRANKCASE BE REPLACED, THIS IS SUPPLIED WITH THE PRIMARY REDUCTION GEAR ALREADY COUPLED.

CHAR - 19

Characteristics

CRANKCASE SELECTION TYPE

Specification Desc./Quantity

Type A crankcase Centre to centre distance: 110.50 - 110.54 mm

Type B crankcase Centre to centre distance: 110.46 - 110.50 mm

Primary category

Pinion can be selected from two types (A or B) ac-

cording to the centre to centre distance between

the primary reduction gears.

The category can be checked out on the pinion it-

self.

SL 750 SHIVER

(4.3504 - 4.3519 in)

(4.3488 - 4.3504 in)

Crankshaft category

Shaft can be selected from two types (1 or 2) ac-

cording to the crank pin diameter.

Shaft can be selected from seven types (E1,

E2, ...) according to connecting rod weight.

CRANKSHAFT SELECTION TYPE

Specification Desc./Quantity

Crankshaft type 1 Crank pin diameter: 41.994 - 42.000 mm (1.65330

- 1.65354 in)

Crankshaft type 2 Crank pin diameter: 41.988 - 41.994 mm (1.65307

- 1.65330 in)

Bushing selection

The connecting rod has only one size category. Therefore, bushings are chosen only based on crank-

shaft type.

BUSHINGS

Specification Desc./Quantity

Crankshaft type 1 Connecting rod type 1: half-bushings A (red) Crankshaft type 2 Connecting rod type 1: half-bushings B (blue)

Connecting rod selection

Not all weight types are available as spare parts; only the main two. Refer to the following table for your

choice:

CHAR - 20

SL 750 SHIVER Characteristics

CONNECTING RODS

Specification Desc./Quantity

Type E1 crankshaft Original connecting rod type: brown

Spare connecting rod type: brown

Type E2 crankshaft Original connecting rod type: blue

Spare connecting rod type: blue

Type E3 crankshaft Original connecting rod type: yellow

Spare connecting rod type: yellow

Type E4 crankshaft Original connecting rod type: green

Spare connecting rod type: green

Type E5 crankshaft Original connecting rod type: pink

Spare connecting rod type: pink

Type E6 crankshaft Original connecting rod type: black

Spare connecting rod type: black

Type E7 crankshaft Original connecting rod type: white

Spare connecting rod type: white

CAUTION

THE CONNECTING RODS OF THE SAME CRANKSHAFT MUST BE THE SAME COLOUR AND HAVE THE SAME TYPE OF COUPLING AS THE CRANKSHAFT. UPON REFITTING, MAKE SURE THAT THE HALF-BUSHINGS ARE OF THE SAME TYPE.

Aprilia SL 750 SHIVER Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual