A - Description

0A - Description

0B - Model-specific information

0C - Specifications

0D - Use and maintenance operations

0F - Controls - Devices

0G - Wheels - Suspensions - Brakes

0L - Fuel system / Exhaust system

0M - Injection - ignition system

0P - Electric system

0GENERAL SUMMARY

0A - Description

1 - How to use the manual 3

Manual layout 4

2 - Symbols - Abbreviations - References 5

Product specifications 6

3 - Dangerous products – Warnings 8

General safety rules 8

General maintenance indications 9

0B - Model-specific information

1 - Identification data 3

Identification data for Hypermotard 3

0C - Specifications

1.1 - Technical specifications 3

Timing/valves 4

Exhaust system 5

Cylinder / piston 5

Cooling system 6

Front suspension (1100) 6

Front suspension (1100S) 6

Rear suspension (1100) 7

Rear suspension (1100S) 7

Hydraulic brakes 7

Charging system / generator 8

Ignition system 8

Lights / instrument panel 9

1.2 - Dimensions 10

2 - Fuels and lubricants 11

3 - Torque settings 12

Frame torque settings 12

Engine torque settings 17

4 - Service tools 20

Engine special tools 20

Frame special tools 25

0D - Use and maintenance operations

1 - Preliminary checks 3

Running-in precautions 3

Pre-ride checks 4

2 - Starting – Engine warm-up 5

Starting the engine 5

3 - Routine maintenance table 7

Scheduled maintenance chart: operations to be performed by the dealer 7

Scheduled maintenance chart: operations to be performed by the customer 8

4 - Maintenance operations 9

Checking the engine oil level 9

Changing the engine oil and filter cartridge 10

Checking valve clearances 13

Adjusting valve clearances 14

Changing and cleaning the air filter 15

Changing the brake fluid 17

Draining the brake circuits 20

Filling the brake circuits 22

Changing the clutch fluid 26

Draining the clutch circuit 27

Filling the clutch circuit 29

Adjusting steering bearing play 31

Adjusting the clutch lever and front brake lever 33

Adjusting chain tension 34

Checking brake pad wear. Changing brake pads 37

Adjusting the throttle cables 41

Adjusting the position of the gear change and rear brake pedals 43

Adjusting the front fork (1100) 45

Adjusting the front fork (1100S) 46

Adjusting the rear shock absorber (1100) 47

Adjusting the rear shock absorber (1100S) 49

Changing motorcycle track alignment (1100S) 50

5 - Test equipment 52

Tester description 53

Instrument power supply 56

DDS diagnosis instrument 60

Checking and adjusting timing belt tension 61

Zero setting the throttle position sensor (TPS) 66

Adjusting idling condition 70

Checking engine oil pressure 74

Checking cylinder compression 79

Checking fuel pressure 82

Procedure to override the immobilizer system 85

Guided diagnosis 89

Checking the charging system 92

Turning off the "Service" warning on the instrument panel 95

1 - Headlight fairing - hand guard - rear-view mirrors 3

Removing the hand guard - rear-view mirrors 4

Refitting the hand guard - rear-view mirrors 5

Removing the headlight fairing 6

Refitting the headlight fairing 9

Removing the side fairings 11

Refitting the side fairings 12

3 - Seat - side body panels 13

Removing the seat 14

Refitting the seat 15

Removing the rear side body panels 16

Refitting the rear side body panels 17

4 - Front mudguard 18

Removing the front mudguard 19

Refitting the front mudguard 20

0F - Controls - Devices

1 - Throttle control 3

Adjusting the throttle cable 4

Disassembling the throttle control 4

Reassembling the throttle control 5

2 - Clutch hydraulic control 7

Removing the clutch master cylinder assembly 8

Refitting the clutch master cylinder assembly 9

Removing the clutch transmission unit 10

Refitting the clutch transmission assembly 12

3 - Front brake control 15

Removing the front brake master cylinder 16

Refitting the front brake master cylinder 17

4 - Rear brake control 19

Removing the rear brake master cylinder 20

Refitting the rear brake master cylinder 23

5 - Gear change control 28

Removing the gear change control 29

Disassembling the gear change control 30

Refitting the gear change control 31

0G - Wheels - Suspensions - Brakes

1 - Front wheel 4

Removing the front wheel 5

Overhauling the front wheel 7

Refitting the front wheel 10

2 - Front fork (1100) 12

Removing the front fork 13

Overhauling the front fork 14

Refitting the front fork 23

2 - Front fork (1100S) 25

Removing the front fork 26

Overhauling the front fork 27

Refitting the front fork 36

3 - Front brake 38

Braking system maintenance 39

Removing the front brake system 39

Overhauling the front brake components 42

Refitting the front brake system 43

4 - Rear wheel 46

Removing the rear wheel 47

Overhauling the rear wheel 48

Refitting the rear wheel 49

5 - Rear swingarm 51

Removing the rear eccentric hub 52

Refitting the rear eccentric hub 54

Removing the rear swingarm 56

Swingarm shaft inspection 60

Overhauling the rear swingarm 61

Refitting the rear swingarm 66

6 - Rear brake 68

Removing the rear brake system 69

Refitting the rear brake system 72

7 - Rear suspension (1100) 74

Rear suspension 75

Removing the rear shock absorber 76

Overhauling the rear shock absorber (1100) 77

Removing the rear suspension rocker arm 79

Overhauling the rear suspension rocker arm 81

Refitting the rear suspension 83

7 - Rear suspension (1100S) 85

Rear suspension 86

Removing the rear shock absorber 87

Overhauling the rear shock absorber 88

Removing the rear suspension rocker arm 89

Overhauling the rear suspension rocker arm 90

Removing and overhauling the shock absorber linkage 92

Refitting the rear suspension 94

8 - Final drive 96

Final drive inspection 97

Removing the chain front sprocket 98

Replacing the gearbox secondary shaft seal 100

Removing the rear sprocket 101

Washing the chain 104

Chain lubrication 104

1 - Handlebar 3

Removing the handlebar 4

Refitting the handlebar 6

Adjusting steering bearing play 10

Adjusting the steering angle 11

Disassembling the steering tube components 12

Refitting the steering tube components 15

4 - Footpeg supports 19

Removing the footpegs 20

Refitting the footpegs 23

Removing the side stand 29

Refitting the side stand 32

6 - Frame inspection 33

Removing the frame and related components 34

Removing the rear subframe 35

Checking the frame 36

Refitting the rear subframe 37

7 - Tail light and number plate holder 38

Removing the tail light 40

Refitting the tail light 41

Removing the number plate holder 42

Refitting the number plate holder 43

0L - Fuel system / Exhaust system

2 - Fuel tank 3

Removing the fuel tank 4

Removing the tank plug 7

Refitting the tank plug 8

Removing the tank flange 9

Refitting the tank flange 10

Refitting the fuel tank 11

6 - Throttle body 17

Removing the throttle body 18

Refitting the throttle body 22

Removing the airbox 27

Removing the oil breather valve 30

Refitting the oil breather valve 31

Refitting the airbox 32

8 - Exhaust system 35

Removing the exhaust system 36

Refitting the exhaust system 40

10 - Canister Filter 45

Canister Filter System (for USA versions only) 46

Removing the Canister filter 47

Refitting the Canister Filter 48

0M - Injection - ignition system

2 - Injection - ignition system 3

3 - Fuel injection-ignition system components 4

Electronic control unit 4

Removing the electronic control unit 5

Refitting the electronic control unit 6

Electric injector 9

Stepper motor 10

Lambda sensor 11

Throttle position sensor 13

Rpm/timing sensor 14

Air temperature / pressure sensor 15

Injection relay 20

1 - Removing - reassembling the complete engine 5

Removing the engine 6

Reassembling the engine 8

2.1 - Lubrication system: oil pump 9

Removing the oil pump 10

Disassembling the oil pump gear 11

Reassembling the oil pump gear 12

Refitting the oil pump 13

2.2 - Lubrication system: oil cooler 14

Removing the oil cooler 15

Oil cooler inspection 17

Refitting the oil cooler 17

2.3 - Lubrication system: oil breather 21

Removing the oil breather 22

Refitting the oil breather 23

4.1 - Head unit: checks and adjustments 25

Checking and adjusting valve clearance 26

Checking engine timing 30

4.2 - Cylinder heads: side covers / timing system 32

Removing the timing side covers 33

Disassembling the timing system 34

Disassembling the mobile tensioner 38

Disassembling the belt rollers 38

Reassembling the timing system 39

Refitting the timing side covers 48

4.3 - Head unit: camshafts 49

Removing the engine oil temperature sensor 51

Refitting the engine oil temperature sensor 51

Disassembling the intake manifolds 52

Refitting the intake manifolds 53

Removing the cam covers 54

Removing the valve covers 56

Refitting the valve covers 57

Camshafts disassembly 58

Checking the camshafts 59

Checking the oil seals 59

Refitting the camshaft 60

Refitting the cam covers 62

4.4 - Head unit: valves - rocker arms 64

Disassembling the engine heads 65

Overhauling the head parts 70

Reassembling the head 79

5 - Cylinder / piston assy 89

Removing cylinder / piston assy 90

Overhauling the cylinder / piston assy 93

Refitting cylinder / piston assy 99

6.1 - Clutch unit: clutch 102

Clutch unit 103

Disassembling the clutch 104

Checking and overhauling the components 108

Reassembling the clutch 110

6.2 - Clutch unit: clutch cover 113

Removing the clutch cover 114

Disassembling the clutch cover 115

Reassembling the clutch cover 116

Refitting the clutch cover 118

6.3 - Clutch unit: primary gears 120

Disassembling the primary drive gears 121

Primary drive gear pair installation – Meshing play inspection 124

7.1 - Gearbox assembly: gear selector levers 126

Removing gear selector levers 127

Removing the gear stopper and ratchet 129

Reassembling gear stopper and ratchet 130

Reassembling the gear selector lever 131

7.2 - Gearbox assembly: gearbox shafts 132

Removing the gearbox 134

Disassembling the gearbox shafts 136

Overhauling the gearbox 141

Inspecting the gear selector forks 142

Inspecting the fork selector drum 143

Reassembling the gearbox shafts 144

Reassembling the gearbox 148

8 - Flywheel - generator 149

Removing the generator cover 151

Disassembling the generator cover 154

Removing the flywheel - generator assembly 155

Checking the flywheel - generator assembly 157

Refitting flywheel / generator assembly 160

Reassembling generator cover 162

9.1 - Casing unit: outer components 165

Removing outer components 167

Reassembling the outer components 170

Removing the timing lay gear 173

Reassembling the timing lay gear 174

Removing the starter motor driven gear 175

Reassembling the starter motor driven gear 176

Checking the engine sensor air gap 177

9.2 - Casing unit: crankcases 178

Opening the casings 179

Overhauling the casings 182

Main bearings 184

Reassembling the casings 186

Shimming the shafts 188

Closing the casings 200

9.3 - Casing unit: connecting rods 203

Removing the connecting rods 204

Disassembling the connecting rods 204

Overhauling the connecting rods 205

Reassembling the connecting rods 211

Refitting the connecting rod unit 213

0P - Electric system

1 - Wiring diagram 4

Wiring diagram key 5

Legend of fuse box 6

Wire color coding - wiring diagram 6

Arrangement of wiring on frame 7

2 - Charging system – battery 35

Checking the charging system 35

Recharging the battery 36

Adding electrolyte 37

Rectifier - regulator 46

3 - Electric starting 48

Electric starting system 48

Starter motor 49

Starter contactor 52

4 - Lighting devices 55

Removing the instrument panel 55

Changing light bulbs 56

High beam relay 59

Beam setting 60

5 - Indicators and lighting system 62

Checking the indicators and lighting system components 62

Changing light bulbs 68

6 - Protection and safety devices 69

Checking protection and safety devices components 69

Checking the fuses 71

7 - Instrument panel 72

Instrument panel system 72

Display settings and functions 74

8 - Immobilizer and transponder 96

9 - Test equipment 100

How to use the multimeter to check electric systems 100

10 - USB data logger 102