1100 Evo workshop manual errata

Luddite · 19-04-2020, 06:08 PM

Having exhausted my current lockdown reading matter of Bike Magazine and Practical Sportsbikes*, I have turned to reading the 1100 Evo workshop manual for entertainment (desperate times...!).

It's been reported elsewhere on the forum that these manuals contain errors, some of which have already been highlighted. I noticed quite a few myself while browsing through so thought I'd list them here in one place for ease of reference. Most of the errors are discrepancies between torque values given in the text and those given separately in the table.

http://www.ukmonster.co.uk/monster/s...5&postcount=14

http://www.ukmonster.co.uk/monster/s...5&postcount=15

http://www.ukmonster.co.uk/monster/s...5&postcount=16

http://www.ukmonster.co.uk/monster/s...5&postcount=17

http://www.ukmonster.co.uk/monster/s...5&postcount=18

Sump plug
In the text the torque value is 42Nm but is is actually only 20Nm as per the table.

Belt tensioner
In the text there are two references to tightening torque; one of 10Nm and one of 26Nm. The correct figure is 26Nm, which is what is shown in the table.

Fork bottom pinch bolts
In the text the figure is 18Nm but the correct figure is given in the table as 14Nm.

Top and bottom yoke pinch bolts
In the text, the top yoke bolts are given as 22Nm while the bottom yoke is 24Nm. However, in the table, the values are reversed with the bottom yoke bolts being 22Nm and the top yoke, (confusingly described as "Screw securing steering head to pivot") at 24Nm. I believe the table figures are correct since there are two bolts each side for the bottom yoke and only one on the top. Also, the top yoke clamps directly over the fork cap, so can withstand more force.

Fuel filter replacement
This isn't an error as such, but could be confusing. The instructions in the manual say when replacing the filter, "...position it so that the arrow on the external housing is pointing towards the flange." With the filter in position, the arrow actually points away from the flange but the fuel flow, (which is what's indicated by the arrow) is towards the flange, so bear that in mind.

Exhaust stud/nut
In the torque values table, the exhaust nut is described as being "M7 x 1" but in fact it is M8 x 1.25, which is the same as the cylinder head end of the stud.

If I find any more errors/discrepancies, I'll add them as and when they appear.

*A good issue this month for Ducatiphiles with three Ducati articles on a 996, V2 Panigale and 888 restoration.

boris · 20-04-2020, 09:13 AM

Been pondering about replacing the exhaust studs/nuts next time its off. The manual says the nuts are M7x1. That's certainly not what's on there atm (nor the last 8 years). Any observation Vince (and all other EvO-ites)?

Luddite · 20-04-2020, 09:58 AM

Hi, Boris.

The exhaust stud has a different thread at each end, which might be confusing matters. The cylinder head thread is M8 x 1.25 torqued to 15Nm while the exhaust nut thread is the M7 x 1 you mentioned earlier, tightened to 24Nm.

The intake manifold stud, on the other hand, is M8 x 1.25 at each end.

You can see the different threads in these photos:

Exhaust stud

Intake stud

Hope that helps!

Luddite · 20-04-2020, 10:21 AM

IGNORE THE ABOVE!

That's what the manual says but I've just popped in the garage and measured the studs with a micrometer and thread gauge and the exhaust nut end is actually M8 x 1.25 not M7 x 1 - so another error to add to the collection!

Thanks for flagging it up, Boris.

Darren69 · 20-04-2020, 10:43 AM

Quote:

Originally Posted by Luddite

Having exhausted my current lockdown reading matter of Bike Magazine and Practical Sportsbikes*, I have turned to reading the 1100 Evo workshop manual for entertainment (desperate times...!).

It's been reported elsewhere on the forum that these manuals contain errors, some of which have already been highlighted. I noticed quite a few myself while browsing through so thought I'd list them here in one place for ease of reference. Most of the errors are discrepancies between torque values given in the text and those given separately in the table.

http://www.ukmonster.co.uk/monster/s...5&postcount=14

http://www.ukmonster.co.uk/monster/s...5&postcount=15

http://www.ukmonster.co.uk/monster/s...5&postcount=16

http://www.ukmonster.co.uk/monster/s...5&postcount=17

http://www.ukmonster.co.uk/monster/s...5&postcount=18

Sump plug
In the text the torque value is 42Nm but is is actually only 20Nm as per the table.

Belt tensioner
In the text there are two references to tightening torque; one of 10Nm and one of 26Nm. The correct figure is 26Nm, which is what is shown in the table.

Fork bottom pinch bolts
In the text the figure is 18Nm but the correct figure is given in the table as 14Nm.

Top and bottom yoke pinch bolts
In the text, the top yoke bolts are given as 22Nm while the bottom yoke is 24Nm. However, in the table, the values are reversed with the bottom yoke bolts being 22Nm and the top yoke, (confusingly described as "Screw securing steering head to pivot") at 24Nm. I believe the table figures are correct since there are two bolts each side for the bottom yoke and only one on the top. Also, the top yoke clamps directly over the fork cap, so can withstand more force.

Fuel filter replacement
This isn't an error as such, but could be confusing. The instructions in the manual say when replacing the filter, "...position it so that the arrow on the external housing is pointing towards the flange." With the filter in position, the arrow actually points away from the flange but the fuel flow, (which is what's indicated by the arrow) is towards the flange, so bear that in mind.

If I find any more errors/discrepancies, I'll add them as and when they appear.

*A good issue this month for Ducatiphiles with three Ducati articles on a 996, V2 Panigale and 888 restoration.

+1 for PS mag this month. I'm trying not to read it all too quickly but failing badly. It's always a good read I find.

boris · 20-04-2020, 04:36 PM

Thanks for that second post Vince. My heart sank when I read your first one

Rrawlings · 20-04-2020, 06:51 PM

Fork rebuild details in the manual are incorrect as I showed with photos and oil air gap when I did mine Vince

slob · 20-04-2020, 07:07 PM

Quote:

Originally Posted by Rrawlings

Fork rebuild details in the manual are incorrect as I showed with photos and oil air gap when I did mine Vince

http://ukmonster.co.uk/monster/showthread.php?t=58003

Luddite · 20-04-2020, 07:37 PM

Quote:

Originally Posted by Rrawlings

Fork rebuild details in the manual are incorrect as I showed with photos and oil air gap when I did mine Vince

Thanks, Ryan, I'd forgotten about the forks! I was going to add a link to your fork rebuild thread but slob beat me to it. Thanks, Rob.

Rrawlings · 20-04-2020, 08:03 PM

Can’t remember if the oil quantity is different to what manual says and also no mention of brake bleeding being a pain in the backside

manwithredbike · 20-04-2020, 08:27 PM

Quote:

Originally Posted by Luddite

Having exhausted my current lockdown reading matter of Bike Magazine and Practical Sportsbikes*, I have turned to reading the 1100 Evo workshop manual for entertainment (desperate times...!).

It's been reported elsewhere on the forum that these manuals contain errors, some of which have already been highlighted. I noticed quite a few myself while browsing through so thought I'd list them here in one place for ease of reference. Most of the errors are discrepancies between torque values given in the text and those given separately in the table.

http://www.ukmonster.co.uk/monster/s...5&postcount=14

http://www.ukmonster.co.uk/monster/s...5&postcount=15

http://www.ukmonster.co.uk/monster/s...5&postcount=16

http://www.ukmonster.co.uk/monster/s...5&postcount=17

http://www.ukmonster.co.uk/monster/s...5&postcount=18

Sump plug
In the text the torque value is 42Nm but is is actually only 20Nm as per the table.

Belt tensioner
In the text there are two references to tightening torque; one of 10Nm and one of 26Nm. The correct figure is 26Nm, which is what is shown in the table.

Fork bottom pinch bolts
In the text the figure is 18Nm but the correct figure is given in the table as 14Nm.

Top and bottom yoke pinch bolts
In the text, the top yoke bolts are given as 22Nm while the bottom yoke is 24Nm. However, in the table, the values are reversed with the bottom yoke bolts being 22Nm and the top yoke, (confusingly described as "Screw securing steering head to pivot") at 24Nm. I believe the table figures are correct since there are two bolts each side for the bottom yoke and only one on the top. Also, the top yoke clamps directly over the fork cap, so can withstand more force.

Fuel filter replacement
This isn't an error as such, but could be confusing. The instructions in the manual say when replacing the filter, "...position it so that the arrow on the external housing is pointing towards the flange." With the filter in position, the arrow actually points away from the flange but the fuel flow, (which is what's indicated by the arrow) is towards the flange, so bear that in mind.

Exhaust stud/nut
In the torque values table, the exhaust nut is described as being "M7 x 1" but in fact it is M8 x 1.2&, which is the same as the cylinder head end of the stud.

If I find any more errors/discrepancies, I'll add them as and when they appear.

*A good issue this month for Ducatiphiles with three Ducati articles on a 996, V2 Panigale and 888 restoration.

Spoiler alert!
That's one book off my 'must read' list : )

crawsue · 13-01-2023, 02:55 PM

Vince forwarded me this supplement re the anomalies in torque settings and I was reminded of a letter in a recent “JAMPOT” magazine ( AJS & Matchless owners club) from a member who, as an apprentice was warned about the difference between torquing up dry or wet fixings. I must admit that this was news to me….Is it a thing? Or have modern alloy steel fixings changed the thinking?

slob · 13-01-2023, 02:59 PM

no, nothing has changed, most of the torque you put in is to overcome the friction of the threads, very little force actually goes into loading the fastener. Of course if you lubricate the thread and reduce the friction, when you apply the same torque you’re putting far more tension on the fastener.

Luddite · 13-01-2023, 03:16 PM

^^^^ what Rob said!

If you look in the right hand column of the tables I sent you, it will say whether the fastener should be lubricated or fitted dry.

bigredduke · 13-01-2023, 09:58 PM

Thank you Vince. Your boredom is an Evo owners treasure chest!

You are a star!

19-04-2020, 06:08 PM	#1
Luddite Registered User Join Date: Aug 2011 Location: Southampton Bike: M1100evo Posts: 2,465	1100 Evo workshop manual errata Having exhausted my current lockdown reading matter of Bike Magazine and Practical Sportsbikes, I have turned to reading the 1100 Evo workshop manual for entertainment (desperate times...!). It's been reported elsewhere on the forum that these manuals contain errors, some of which have already been highlighted. I noticed quite a few myself while browsing through so thought I'd list them here in one place for ease of reference. Most of the errors are discrepancies between torque values given in the text and those given separately in the table. http://www.ukmonster.co.uk/monster/s...5&postcount=14 http://www.ukmonster.co.uk/monster/s...5&postcount=15 http://www.ukmonster.co.uk/monster/s...5&postcount=16 http://www.ukmonster.co.uk/monster/s...5&postcount=17 http://www.ukmonster.co.uk/monster/s...5&postcount=18 Sump plug* In the text the torque value is 42Nm but is is actually only 20Nm as per the table. Belt tensioner In the text there are two references to tightening torque; one of 10Nm and one of 26Nm. The correct figure is 26Nm, which is what is shown in the table. Fork bottom pinch bolts In the text the figure is 18Nm but the correct figure is given in the table as 14Nm. Top and bottom yoke pinch bolts In the text, the top yoke bolts are given as 22Nm while the bottom yoke is 24Nm. However, in the table, the values are reversed with the bottom yoke bolts being 22Nm and the top yoke, (confusingly described as "Screw securing steering head to pivot") at 24Nm. I believe the table figures are correct since there are two bolts each side for the bottom yoke and only one on the top. Also, the top yoke clamps directly over the fork cap, so can withstand more force. Fuel filter replacement This isn't an error as such, but could be confusing. The instructions in the manual say when replacing the filter, "...position it so that the arrow on the external housing is pointing towards the flange." With the filter in position, the arrow actually points away from the flange but the fuel flow, (which is what's indicated by the arrow) is towards the flange, so bear that in mind. Exhaust stud/nut In the torque values table, the exhaust nut is described as being "M7 x 1" but in fact it is M8 x 1.25, which is the same as the cylinder head end of the stud. If I find any more errors/discrepancies, I'll add them as and when they appear. A good issue this month for Ducatiphiles with three Ducati articles on a 996, V2 Panigale and 888 restoration. Last edited by Luddite; 13-01-2023 at 10:14 PM.. Reason: Exhaust stud added*

20-04-2020, 09:13 AM	#2
boris More Tools! Join Date: Jun 2004 Location: Forres Bike: Multiple Monsters Posts: 297	Been pondering about replacing the exhaust studs/nuts next time its off. The manual says the nuts are M7x1. That's certainly not what's on there atm (nor the last 8 years). Any observation Vince (and all other EvO-ites)? __________________ Boris from Forres

20-04-2020, 04:36 PM	#6
boris More Tools! Join Date: Jun 2004 Location: Forres Bike: Multiple Monsters Posts: 297	Thanks for that second post Vince. My heart sank when I read your first one __________________ Boris from Forres

13-01-2023, 02:55 PM	#12
crawsue Bronze Member Join Date: Nov 2016 Location: Glasgow Bike: M1100evo Posts: 278	Torque settings Vince forwarded me this supplement re the anomalies in torque settings and I was reminded of a letter in a recent “JAMPOT” magazine ( AJS & Matchless owners club) from a member who, as an apprentice was warned about the difference between torquing up dry or wet fixings. I must admit that this was news to me….Is it a thing? Or have modern alloy steel fixings changed the thinking?

13-01-2023, 02:59 PM	#13
slob . Join Date: Jul 2003 Location: East London Bike: Multiple Monsters Posts: 9,736	no, nothing has changed, most of the torque you put in is to overcome the friction of the threads, very little force actually goes into loading the fastener. Of course if you lubricate the thread and reduce the friction, when you apply the same torque you’re putting far more tension on the fastener. Last edited by slob; 13-01-2023 at 03:45 PM.. Reason: bad grammar

20-04-2020, 09:58 AM	#3
Luddite Registered User Join Date: Aug 2011 Location: Southampton Bike: M1100evo Posts: 2,465	Hi, Boris. The exhaust stud has a different thread at each end, which might be confusing matters. The cylinder head thread is M8 x 1.25 torqued to 15Nm while the exhaust nut thread is the M7 x 1 you mentioned earlier, tightened to 24Nm. The intake manifold stud, on the other hand, is M8 x 1.25 at each end. You can see the different threads in these photos: Exhaust stud Intake stud Hope that helps!

20-04-2020, 10:21 AM	#4
Luddite Registered User Join Date: Aug 2011 Location: Southampton Bike: M1100evo Posts: 2,465	IGNORE THE ABOVE! That's what the manual says but I've just popped in the garage and measured the studs with a micrometer and thread gauge and the exhaust nut end is actually M8 x 1.25 not M7 x 1 - so another error to add to the collection! Thanks for flagging it up, Boris.

20-04-2020, 06:51 PM	#7
Rrawlings Member Join Date: May 2019 Location: Bradford Bike: M1100evo Posts: 175	Fork rebuild details in the manual are incorrect as I showed with photos and oil air gap when I did mine Vince

20-04-2020, 08:03 PM	#10
Rrawlings Member Join Date: May 2019 Location: Bradford Bike: M1100evo Posts: 175	Can’t remember if the oil quantity is different to what manual says and also no mention of brake bleeding being a pain in the backside

13-01-2023, 03:16 PM	#14
Luddite Registered User Join Date: Aug 2011 Location: Southampton Bike: M1100evo Posts: 2,465	^^^^ what Rob said! If you look in the right hand column of the tables I sent you, it will say whether the fastener should be lubricated or fitted dry.

13-01-2023, 09:58 PM	#15
bigredduke Nothing to see here Join Date: May 2005 Location: brough Bike: M1100evo Posts: 1,550	Thank you Vince. Your boredom is an Evo owners treasure chest! You are a star!