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MOTO GUZZI Griso V1100, Workshop Manual

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MOTO GUZZI Griso V1100 Workshop Manual Download Page 30

 

 

GENERAL TECHNICAL INFORMATION

2 - 11

Griso V1100 

DESCRIPTION 

Q.ty 

SCREW / NUT 

TIGHTENING 

TORQUE  

(Nm) 

Note 

FUEL TANK 

FUEL PUMP FLANGE 

Tank breather fitting 

2 

M6 

6 

 

Pump support to tank fastener 

6 

M5x16 

6 

 

 

TANK 

Union to tank fastener 

4 

M5x16 

5 

 

Plug ring nut to tank fastener 

4 

M5X15 

5 

 

Screws to plug ring nut (aesthetic) 

4 

M5X15 

5 

 

Tank to frame front fastening 

2 

M6X35 

10 

 

Battery box and tank to frame rear fastener 

2 

M6X25 

6 

 

BODYWORK 

FRONT 

Front mudguard fastener 

2+2 

M5 

6 

 

Electronic control unit fastener 

2 

M5 

6 

 

Conveyor to frame upp. front fastener 

1+1 

M5 

Man   

Conveyor to frame low. front fastener 

1+1 

M5 

Man   

Conveyors to frame rear fastener 

1+1 

M5 

Man   

Conveyors to conveyor clos.fastener 

2X3 

self-

tapping 

Man 

 

REAR 

Cat's eye to support fastener 

1 

M5 

4 

 

Cat's eye support to number plate holder fastener 

2 

M5x12 

4 

 

Reinforcement to number plate holder and light
fastener 

1 

M5 4 

 

Number plate holder to low.clos. fastener 

2 

self-tapp.

Man   

Tail guard low.clos. to frame fastener 

4 

M8x35 

25 

 

Fuse bracket and relay supp. fastener 

4 

M5 

4 

 

ACCESSORIES 

Ignition switch fastener – shear bolt 

2 

M8x28 

 

Shear completely 

 

 

Summary of Contents for Griso V1100

Page 1: ...workshopmanual 00 2005 11 UK Cod UK Cod 8140904 1288 5...

Page 2: ...INTRODUCTION 0 1 Griso V1100 INTRODUCTION 0...

Page 3: ...INTRODUCTION 0 2 Griso V1100 SUMMARY 0 1 INTRODUCTION 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5...

Page 4: ...procedures please contact the Moto Guzzi SERVICE DEPT they will be glad to give you any information on the matter or supply you with any detail on updates and technical changes applied to the vehicle...

Page 5: ...guzzi part description GU078_00 OWNER S MANUALS guzzi part description 06 90 00 00 06 90 00 01 CHASSIS WORKSHOP MANUAL guzzi part description 8140900 8140901 8140902 8140903 8140904 8140905 8CM0095 8...

Page 6: ...revolutions per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardization Organization kg kilograms kgm kilogram metre 1 kgm 10 Nm km kilometres km h kilometres per hour...

Page 7: ...0 6 Griso V1100 TEST diagnostic check T B E I crown head Allen screw T C E I cheese head Allen screw T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V Volt W W...

Page 8: ...GENERAL INFORMATION 1 1 Griso V1100 GENERAL INFORMATION 1...

Page 9: ...3 1 1 1 CONVENTIONS USED IN THE MANUAL 3 1 1 2 SAFETY WARNINGS 4 1 2 GENERAL RULES 5 1 2 1 BASIC SAFETY RULES 5 1 3 DANGEROUS ELEMENTS 8 1 3 1 WARNINGS 8 1 4 RUNNING IN 11 1 4 1 RUNNING IN 11 1 5 POS...

Page 10: ...ght are referred to the motorcycle when viewed from the riding position Motorcycle operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identified with the...

Page 11: ...otential risk of personal injury Disregarding the instructions identified by this symbol may compromise the safety of the user the motorcycle and third parties DANGER Indicates a potential hazard whic...

Page 12: ...KEEP AWAY FROM CHILDREN HOT COMPONENT PARTS The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped Wear insulat...

Page 13: ...stem which may still be hot to the touch to avoid scalds or burns Never put mechanical parts or other vehicle components in your mouth when you have both hands busy None of the motorcycle components a...

Page 14: ...skets before assembly Apply a thin layer of lithium grease along the edges of oil seals Fit oil seals and bearings with the marking or serial number facing outwards in view ELECTRICAL CONNECTORS Disco...

Page 15: ...he motorcycle Failure to maintain the lubricant level or the use of incorrect old or dirty lubricant can cause the engine or transmission to seize resulting in accident serious injury or death Prolong...

Page 16: ...ical attention DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN Avoid spillage Brake fluid can damage plastic or painted parts DANGER Do not use brake fluids other than the spe...

Page 17: ...atment products on the tyres In particular do not allow the tyre to come in contact with liquid fuel which rapidly deteriorates the tyre rubber In case of contact with oil or fuel do not clean but cha...

Page 18: ...the engine is running at low speed both during and after the running in period Until you have covered the first 100 km 62 mi use the brakes gently and avoid harsh prolonged braking This will help the...

Page 19: ...mber voids the warranty This number consists of figures and letters as shown in the example below ZGULP00005MXXXXXX Key ZGU WMI World manufacture identifier code LP model 000 version 0 free digit 5 ye...

Page 20: ...GENERAL TECHNICAL INFORMATION 2 1 Griso V1100 GENERAL TECHNICAL INFORMATION 2...

Page 21: ...E SETTINGS 8 2 1 5 SPECIAL TOOLS 12 2 1 6 ARRANGEMENT OF THE MAIN ELEMENTS 14 2 1 7 LOCATION OF INSTRUMENTS CONTROLS 16 2 2 MAINTENANCE OPERATIONS 18 2 2 1 CHANGING ENGINE OIL AND OIL FILTER 18 2 2 2...

Page 22: ...spection clearance between rocker arms and valve intake 0 10 mm 0 0039 in exhaust 0 15 mm 0 0059 in CAPACITIES Fuel reserve included 17 2 litres Fuel reserve 3 3 litres Engine oil Engine oil and oil f...

Page 23: ...port Pirelli diablo corsa Michelin pilot power Front Size 120 70 ZR 17 58 W Inflating pressure 2 3 atm 230 kPa Inflating pressure with passenger 2 3 atm 230 kPa Rear Size 180 55 ZR 17 73 W Inflating p...

Page 24: ...25 mi if used for racing Check every two weeks or at indicated intervals Component After running in 1500 km 621 mi Every 10000 km 6250 mi or 12 months Every 20000 km 12500 mi or 24 months External plu...

Page 25: ...cables 1 1 Steering bearings and steering play 1 1 Wheel bearings 1 Brake discs 1 1 Air filter 1 3 Vehicle general operation 1 1 Brake systems 1 1 Brake fluid 3 Front fork fluid after the first 10000...

Page 26: ...recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C to 140 C 22 F to 284 F with dripping point 150 C to 230 C 302 F to 446 F high corrosion protection...

Page 27: ...A4 70 Brake switch to plate fastener 1 M8 Man Pitch 1 Chromed ring to plate fastener 6 M5x10 6 Cable rings to rh footrest plate fastener 3 M5x10 6 FOOTRESTS AND LEVERS Footrest rubber mat fastener 8 M...

Page 28: ...ing tube ring nut 1 M35x1 40 Steering tube lock ring nut 1 M35x1 Man 0 to 90 degrees Steering head plug 1 M29x1 100 Use a torque wrench Fork clamps blanking 2 2 M8X40 25 REAR SUSPENSION SHOCK ABSORBER...

Page 29: ...teering head fastener 2 M10X40 50 Handlebar upper U bolts fastener 2 2 M8X30 25 stainl steel A4 80 Counterweights fasteners 2 M6x60 10 Brake and clutch master cylinder U bolts fasteners 2 2 M6 10 Rh a...

Page 30: ...fastener 2 2 M5 6 Electronic control unit fastener 2 M5 6 Conveyor to frame upp front fastener 1 1 M5 Man Conveyor to frame low front fastener 1 1 M5 Man Conveyors to frame rear fastener 1 1 M5 Man C...

Page 31: ...rect disassembly and reassembly and a good set up The use of special tools avoids possible damage that could result from using unsuitable tools and or improvised techniques Following is a list of spec...

Page 32: ...Bevel gear pair support 05902736 10 Belt tensioning tool 06948600 11 Tool for fitting 41 mm seal AP8140145 12 Disassembly operations protections AP8140149 13 Drilled rod for bleeding air from damper r...

Page 33: ...anel 3 Left rear view mirror 4 Fuel tank filler plug 5 Fuel tank 6 Left side body panel 7 Battery 8 Main fuse carrier 30A 9 Rider passenger seat 10 Passenger grab handle 11 Tool kit compartment 12 Pas...

Page 34: ...Glove compartment 3 Rear brake fluid reservoir 4 Right body panel 5 Right rear view mirror 6 Front brake fluid reservoir 7 Oil cooler 8 Engine oil filter 9 Rear brake lever 10 Rider right footrest 11...

Page 35: ...ONTROLS Key 1 Clutch control lever 2 Ignition switch steering lock 3 Instruments and indicators 4 Front brake lever 5 Throttle grip 6 Light dimmer switch 7 Display functions selector 8 High beam flash...

Page 36: ...ev counter 2 Green neutral light 3 Orange fuel reserve warning light 4 Red engine oil pressure warning light 5 Yellow side stand warning light 6 Green turn indicator warning light 7 Blue high beam war...

Page 37: ...heels on the ground Unscrew and remove the dipstick 1 Check the oil level using the dipstick 1 The level is correct when it is near the MAX mark MAX maximum level MIN minimum level If necessary top up...

Page 38: ...l debris sticking to the drain plug 2 magnet Refit the drain plug 2 and tighten Fill with fresh engine oil see LUBRICANT TABLE until the level is above the minimum mark MIN CHANGING THE ENGINE OIL FIL...

Page 39: ...not the correct procedure to warm the engine and engine oil up to operating temperature for an oil check Oil is best checked after taking a short ride 15 Km 10 mi will be enough Place a container hol...

Page 40: ...s the hole of the inspection plug 1 WARNING Do not add additives or other substances to the fluid If you use a funnel or other tool ensure it is perfectly clean CHANGE NOTE Change oil when it is hot a...

Page 41: ...ON 2 22 Griso V1100 2 2 4 CLEANING THE AIR FILTER Disconnect the connector on the end of the air temperature sensor Slide out and move the main fuse box from its housing Loosen and remove the six scre...

Page 42: ...lter frame Remove the air filter Plug the intake duct with a clean cloth to prevent dirt from falling into the intake ducts DANGER Do not start the engine when the air filter is not in place Use compr...

Page 43: ...en the engine is cold with the piston at top dead centre TDC during the compression stroke valves closed Loosen and remove the three screws and remove the side protection Working on either side loosen...

Page 44: ...r until the following clearances are set intake valve 0 10 mm 0 0039 in exhaust valve 0 15 mm 0 0059 in Measure clearance using a suitable feeler gauge 3 NOTE If clearance is greater than specified th...

Page 45: ...rvoir throughout the process Remove the rubber cap from bleeding valve and the reservoir plug Insert one end of a transparent plastic tubing inside the front brake calliper bleed valve and the other e...

Page 46: ...r housing thus causing brake fluid leakage Install two new pads fit them so the holes match those on the calliper WARNING Always change both pads and ensure that they are correctly in place inside the...

Page 47: ...reservoir throughout the process Remove the bleed valve rubber cap Insert one end of a transparent plastic tubing inside the rear brake calliper bleed valve and the other end in a container Remove the...

Page 48: ...t pushing on the worn pads Remove one pad at a time WARNING Do not operate the brake lever when the pads are not in place or the calliper pistons might come out of their housing thus causing brake flu...

Page 49: ...he pin Fit the split pin Push the rear brake lever until the pistons are against the new pads Check the brake fluid level Fit the calliper to the disc and tighten the two screws Fit new ties and secur...

Page 50: ...en and remove the three screws securing the side body panels Working on the right side loosen and remove the two nuts securing the exhaust manifold collect two washers per nut Loosen the manifold clam...

Page 51: ...ATION 2 32 Griso V1100 Loosen and remove the two screws securing the control unit Remove the control unit Disconnect the two connectors Loosen and remove the ground cable bolt Loosen and remove engine...

Page 52: ...ERAL TECHNICAL INFORMATION 2 33 Griso V1100 Loosen and remove the spacer Loosen and remove timing cover screw Loosen and remove the four screws on timing cover Remove the timing cover Loosen the lock...

Page 53: ...lt tensioning tool part no 06948600 tension the belt to the specified value Tighten the adjuster Tighten the lock nut Follow the procedure as previously indicated in the reverse order for refitting th...

Page 54: ...FUEL SYSTEM 3 1 Griso V1100 FUEL SYSTEM 3...

Page 55: ...FUEL SYSTEM 3 2 Griso V1100 SUMMARY 3 1 FUEL SYSTEM 3 3 1 1 FUEL SUPPLY SYSTEM DIAGRAM 3 3 1 2 REMOVING THE FUEL TANK 4 3 1 3 REMOVING THE AIR BOX 7 3 2 INJECTION 9 3 2 1 INJECTION SYSTEM DIAGRAM 9...

Page 56: ...FUEL SYSTEM 3 3 Griso V1100 3 1 FUEL SYSTEM 3 1 1 FUEL SUPPLY SYSTEM DIAGRAM Key 1 Complete fuel pump 2 Flanged screw M5x16 3 Fitting 4 Clamp 5 Fuel hose 6 Three way union 7 Clamp 12 5x8 8 Hose...

Page 57: ...TANK Working on either side loosen and remove the three screws and remove the side body panel Remove the seat Loosen and remove the two screws Loosen and remove the two screws and set aside the two T...

Page 58: ...FUEL SYSTEM 3 5 Griso V1100 Disconnect the battery positive lead Loosen and remove the two screws Remove the battery bracket Remove the battery and the cover collect the breather hose...

Page 59: ...n from behind and rest it onto the brackets welded to the frame provided with rubber blocks Disconnect the quick release fitting Disconnect the connector Remove the fuel tank For fuel tank installatio...

Page 60: ...ove the fuel tank see REMOVING THE FUEL TANK Disconnect the connector on the end of the air temperature sensor Slide out and move the main fuse box from its housing Loosen and remove the four screws S...

Page 61: ...e vacuum tube Disconnect the blow by reservoir breather hose Remove the hose ties Remove the tie from water breather hose on air box right side and remove the hose Working on either side loosen and re...

Page 62: ...FUEL SYSTEM 3 9 Griso V1100 3 2 INJECTION 3 2 1 INJECTION SYSTEM DIAGRAM...

Page 63: ...rol unit 2 Ignition switch 3 Battery 4 Fuel pump 5 Coils 6 Instrument panel 7 Air temperature sensor 8 Throttle position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor 1...

Page 64: ...LUBRICATION SYSTEM 4 1 Griso V1100 LUBRICATION SYSTEM 4...

Page 65: ...LUBRICATION SYSTEM 4 2 Griso V1100 SUMMARY 4 1 LUBRICATION SYSTEM 3 4 1 1 LUBRICATION SYSTEM DIAGRAM 3 4 1 2 REMOVING THE OIL COOLER 4...

Page 66: ...plete oil cooler 2 Restrictor 3 Aluminium gasket 4 Drilled screw 5 Right tube 6 Left tube 7 Conveyor 8 Flanged TE screw M6x30 9 Washer 10 Bushing 11 Spacer 12 Rubber seal 13 Cover 14 Spacer 15 TCC scr...

Page 67: ...iner and empty the lubrication system Loosen and remove the screw and set aside the washer Loosen and remove the two screws and set aside the washers Loosen and remove the screw and set aside the wash...

Page 68: ...LUBRICATION SYSTEM 4 5 Griso V1100 Remove the oil cooler...

Page 69: ...ENGINE 5 1 Griso V1100 ENGINE 5...

Page 70: ...MOTORE 5 2 Griso V1100 SUMMARY 5 1 REMOVING AND REFITTING THE ENGINE 3 5 1 1 REMOVING THE ENGINE FROM THE FRAME 3 5 1 2 FITTING THE ENGINE ON THE FRAME 15...

Page 71: ...HE FRAME Support the vehicle front end using the suitable stand and its rear end using slings and a hoist Position the engine support stand under the oil sump Remove the complete exhaust system and th...

Page 72: ...crews and remove the side body panel Working on either side loosen and remove the two outer screws and remove the spark plug protection Working on either side loosen and remove the two inner screws an...

Page 73: ...ENGINE 5 5 Griso V1100 Working on either side disconnect the injector connectors Disconnect the throttle cables...

Page 74: ...6 Griso V1100 Disconnect the idle motor connector Disconnect the engine temperature sensor connector Disconnect the throttle position sensor connector Loosen and remove the two screws and collect the...

Page 75: ...sconnect the rpm sensor connector and connect the gasket Disconnect the generator connectors Disconnect the neutral sensor connector Loosen and remove the two screws and collect the washers Remove the...

Page 76: ...TORE 5 8 Griso V1100 Unscrew and remove the screw Disconnect the ground cables Disconnect the starter motor connectors Prepare a container Release the clutch bleed hose Let clutch fluid fully drain ou...

Page 77: ...and move aside the clutch slave cylinder Slide out the gearbox fluid breather line Working on either side disconnect the clamp and slide out the oil breather line Loosen and remove the two screws sec...

Page 78: ...V1100 Disconnect the stand sensor connector and move it until clear of the ties Loosen and remove the two screws and remove the control unit protection Loosen and remove the two screws and move the c...

Page 79: ...o V1100 Loosen and remove the screw and move aside the oil vapour recovery tank Unscrew and remove the stud bolt Loosen and remove the engine lower nut and collect the washer Remove the lower shaft co...

Page 80: ...er side loosen and remove the front screw and collect the washer Loosen and remove the engine upper nut and collect the washer Remove the upper shaft collect the washer Loosen and remove the nut and s...

Page 81: ...sen and remove the screw and remove the plate NOTE The following operations shall be performed together with a second operator Partially lower the engine Disconnect the oil pressure sensor connector C...

Page 82: ...MOTORE 5 14 Griso V1100 Raise the vehicle rear end Remove the front stand Release the slings from the hoist supporting the vehicle rear end and remove the frame from the engine...

Page 83: ...NG THE ENGINE ON THE FRAME Secure the vehicle frame to a lift lift the engine and set in position Connect the oil pressure sensor connector Position the plate and tighten the screw Position the screw...

Page 84: ...0 Working on the right side fit the washer and the upper pin Fit the washer and fit the engine top nut Working on either side position the washer and fit the screw Working on the right side fit the wa...

Page 85: ...INE 5 17 Griso V1100 Fit the washer and tighten the engine bottom nut Working on either side tighten the screw to the specified torque Tighten the stud bolt Fit the oil vapour tank and tighten the scr...

Page 86: ...MOTORE 5 18 Griso V1100 Fit the ECU and tighten the two screws Fit the ECU guard and tighten the two screws Connect the stand sensor connector and secure it to the frame with new ties...

Page 87: ...19 Griso V1100 Fit the oil vapour hose and tighten the two screws Fit the oil bleed hose and secure it with a new tie Fit the gearbox fluid breather tube Fit the clutch slave cylinder Tighten the thre...

Page 88: ...MOTORE 5 20 Griso V1100 Position the clutch bleed hose in the cable guide Fill the clutch system with fluid Connect the starter motor connectors Connect the earth cables and tighten the screw...

Page 89: ...so V1100 Fit the starter motor protection Fit the two washers and tighten the two screws Connect the neutral sensor end connector Connect the generator connectors Fit the gasket and connect the rpm se...

Page 90: ...RE 5 22 Griso V1100 Fit the washer and tighten the two screws Connect the connector on the throttle position sensor end Connect the engine temperature sensor connector Connect the stepper motor connec...

Page 91: ...ENGINE 5 23 Griso V1100 Connect the throttle cables Working on either side connect the injector connectors Working on either side connect both spark plug caps...

Page 92: ...d tighten the two internal screws Working on either side fit the spark plug protection and tighten the two external screws Install the fuel tank see REMOVING THE FUEL TANK Install the seat Working on...

Page 93: ...ENGINE 5 25 Griso V1100 Fit the swingarm together with the cardan joint Fit the complete exhaust system the air box the tank and the seat...

Page 94: ...CHASSIS 6 1 Griso V1100 CHASSIS 6...

Page 95: ...1 6 REMOVING THE OIL DUST SEALS 16 6 1 7 REFITTING THE OIL DUST SEALS 23 6 1 8 CHECKING THE COMPONENTS 30 6 1 9 ADJUSTMENTS 32 6 2 ADJUSTING THE STEERING BEARINGS PLAY 33 6 2 1 ADJUSTING THE STEERING...

Page 96: ...4 Sleeve upper plug 5 Washer 6 Slider 7 Complete damper rod 8 Centring bushing 9 Spring spacer tube 10 Spring 11 Spring rest washer 12 Lower collar 13 Sleeve 14 Sliding bushing 15 Guide bushing 16 Sto...

Page 97: ...screws and remove the calliper from its housing Support the front end of the vehicle Loosen and remove the wheel shaft fixing nut and set aside the washer Working on either side loosen the screws of...

Page 98: ...0 Remove the wheel shaft using a screwdriver inside the shaft holes During this operation support and remove the wheel Remove the front wheel spacer on the right side Working on either side loosen and...

Page 99: ...CHASSIS 6 6 Griso V1100 Remove the front mudguard Support the fork and loosen the top and bottom yoke screws Slide out the fork leg...

Page 100: ...100 6 1 3 INSTALLING THE FORK LEGS NOTE The operations below apply to both fork legs Fit the fork leg Support the fork leg and tighten the screws on the top and bottom yokes to the specified torque Fi...

Page 101: ...o V1100 Working on either side tighten the two screws Fit the spacer in its housing on the right hand side of the front wheel Fit the front wheel and insert the wheel shaft by lightly tapping it with...

Page 102: ...ome the wheel shaft pinch bolts Support the front end of the motorcycle then fit and tighten the wheel shaft nut and sealing washer Tighten the wheel shaft pinch bolts to the specified torque Working...

Page 103: ...100 6 1 4 DRAINING THE FORK OIL Vice the outer sleeve using the suitable tool part no AP8140149 Set the spring preload to its minimum Unscrew the sleeve upper plug Clamp the fork bottom end with care...

Page 104: ...part no AP8140191 to spring joint Push the tool downward to compress the spring and then fit the tool spacer under the cartridge check nut Loosen the plug by applying a wrench to the flats and holding...

Page 105: ...CHASSIS 6 12 Griso V1100 Remove the spacer and the washer Press downward against spring force and slide out the spacer Slide out the spring joint Empty the oil into a container and remove the spring...

Page 106: ...ILLING THE FRONT FORK FLUID Fill the fork so the air bubbles trapped inside are released Fit the spring joint Fit the relevant tool part no AP8140147 to the spring joint so as to lock the cartridge ro...

Page 107: ...CHASSIS 6 14 Griso V1100 Tighten the upper plug on the cartridge rod Vice the outer sleeve using the suitable tool part no AP8140149...

Page 108: ...CHASSIS 6 15 Griso V1100 Tighten the upper plug to the indicated torque...

Page 109: ...6 1 6 REMOVING THE OIL DUST SEALS Vice the outer sleeve using the suitable tool part no AP8140149 Set the spring preload to its minimum Unscrew the sleeve upper plug Clamp the fork bottom end with ca...

Page 110: ...l part no AP8140147 to spring joint Push the tool downward to compress the spring and then fit the tool spacer under the cartridge check nut Loosen the plug by applying a wrench to the flats and holdi...

Page 111: ...CHASSIS 6 18 Griso V1100 Remove the spacer and the washer Press downward against spring force and slide out the spacer Slide out the spring joint Empty the oil into a container and remove the spring...

Page 112: ...CHASSIS 6 19 Griso V1100 Remove the lower spacer and the washer Loosen the cartridge fixing screw on the fork bottom end Set aside the centring bushing...

Page 113: ...screwdriver for leverage When doing this take care not to damage the edge of the sleeve Remove the snap ring Remove the sleeve from the slider using the sleeve as a stop Remove the sliding bushing fi...

Page 114: ...CHASSIS 6 21 Griso V1100 Remove the ring and the dust seal...

Page 115: ...CHASSIS 6 22 Griso V1100...

Page 116: ...DUST SEALS Clamp the leg in a vice with care to avoid damaging its surfaces Protect the ends of the leg with adhesive tape Lubricate the sliding edges with fork fluid or seal grease Fit the dust seal...

Page 117: ...CHASSIS 6 24 Griso V1100 The stamped side of the sealer ring must be facing the dust seal Proceed to fit the ring the movable bushing and after having removed the tape the fixed bushing...

Page 118: ...ve on the leg and using the specific tool place the oil guard in position Insert the snap ring in its housing Fit the dust seal with the specific tool Fit the centring bushing on the cartridge and pla...

Page 119: ...CHASSIS 6 26 Griso V1100 Tighten the cartridge fixing screw on the fork bottom end to the specified torque Fit the lower spacer and the washer Fit the fork spring...

Page 120: ...1100 Fill the fork so the air bubbles trapped inside are released Fit the spring joint Fit the suitable tool part no AP8140147 to the spring joint so as to lock the cartridge leg in position Fit the s...

Page 121: ...CHASSIS 6 28 Griso V1100 Tighten the upper plug on the cartridge rod Vice the outer sleeve using the suitable tool part no AP8140149...

Page 122: ...CHASSIS 6 29 Griso V1100 Tighten the upper plug to the indicated torque...

Page 123: ...e service limit Buckling limit 0 2 mm 0 079 in SLEEVE Inspect for damage and or cracking Replace if damaged DANGER NEVER attempt to straighten a buckled stanchion as this would weaken the overall stru...

Page 124: ...ket dust seal gasket WARNING Remove any impurities from the bushing pay attention not to damage the surface the two O rings on the regulator Oil quantity 520 2 5 cu cm 31 7 0 15 cu in Oil level 118 2...

Page 125: ...during organised races or sporting events held on tracks far from road circulation and with the authorisation of the proper authorities It is strictly prohibited to make racing adjustments and ride t...

Page 126: ...TEERING BEARINGS PLAY 6 2 1 ADJUSTING THE STEERING BEARINGS PLAY Release and remove the two front screws Loosen and remove the two outer screws and move the instrument panel forward Loosen and remove...

Page 127: ...move the two screws and collect the left U bolt Move the handlebar forward ensuring not to tip over the front brake and clutch fluid tanks Unscrew and remove the screw Keep the right handlebar support...

Page 128: ...g on either side loosen and remove the screw securing the top plate to fork legs Raise the fork top plate sliding it off the fork legs Straighten the safety washer on steering tube WARNING When reasse...

Page 129: ...only the specific special tool AP8140190 tool to tighten steering head Loosen and remove the upper ring nut with the specific tool Remove the safety washer Set the steering bearing preload using the s...

Page 130: ...CHASSIS 6 37 Griso V1100 Tighten the top ring nut finger tight and then continue tightening until ring nut notches are aligned Bend the safety washer Position the fork top plate on the fork legs...

Page 131: ...Double connecting rod gudgeon pin L40 5 Roller case 6 Oil seal D18x24x3 7 Double connecting rod gudgeon pin L47 8 Double connecting rod gudgeon pin 10 1x18x25 9 TCEI screw M10x82 10 T bushing 11 Flan...

Page 132: ...100 6 3 2 REMOVING THE REAR SUSPENSION Fasten the handlebar at the front using a hoist Support the bottom of the vehicle with suitable means Support the front of the vehicle with a suitable stand Loos...

Page 133: ...Remove the screw by lightly tapping it with a rubber mallet and ease the connecting rod assembly out of its housing Loosen and remove the screw Loosen and remove the screw and slide out the complete...

Page 134: ...ASSIS 6 41 Griso V1100 6 4 FRAME 6 4 1 REMOVING THE RIGHT FOOTREST PLATE Loosen and remove the two lower screws and set aside the nuts and the spacers Remove the ties and cable guide from the brake li...

Page 135: ...CHASSIS 6 42 Griso V1100 Loosen and remove the two screws Remove the rear brake calliper from the disc Loosen and remove the upper screw and set aside the nut Loosen and remove the upper screw...

Page 136: ...Griso V1100 Remove the air box see REMOVING THE AIR BOX Disconnect the rear brake lever switch connector and remove the ties Remove the right footrest plate keeping the brake fluid reservoir in verti...

Page 137: ...FT FOOTREST PLATE Remove the exhaust silencer Loosen and remove the screw and set aside the nut and the spacer Loosen and remove the screw and set aside the nut Loosen and remove the screw Loosen and...

Page 138: ...ELECTRIC SYSTEM 7 1 Griso V1100 ELECTRIC SYSTEM 7...

Page 139: ...ELECTRIC SYSTEM 7 2 Griso V1100 SUMMARY 7 1 ELECTRIC SYSTEM 3 7 1 1 ELECTRICAL PARTS CHECKS TABLE 3 7 1 2 WIRING DIAGRAM 11...

Page 140: ...ELECTRIC SYSTEM 7 3 Griso V1100 7 1 ELECTRIC SYSTEM 7 1 1 ELECTRICAL PARTS CHECKS TABLE...

Page 141: ...OR 10 AIR TEMPERATURE SENSOR 11 BATTERY 12 LEFT INDICATOR CONTROL 13 14 15 16 GENERAL EARTH 17 OIL PRESSURE SENSOR INPUT 18 SENSOR EARTH 19 GENERAL EARTH OPTIONAL 20 GENERAL EARTH OPTIONAL The pinout...

Page 142: ...measured across pins 3 and 4 with fuel level equal to 0 litres 4 INJECTOR Resistance 14 2 measured at 20 C 68 F 5 THROTTLE POSITION SENSOR output voltage 0 55 4 4 V variable according to the throttle...

Page 143: ...30 A b From battery to key and auxiliary fuses c d 30 A NOTE There is one spare fuse 9 OXYGEN SENSOR Oxygen sensor with heater Sensor voltage between 0 and 0 9 V to be measured across pins 1 and 2 Hea...

Page 144: ...e 3 7 K at 20 C 68 F 13 ENGINE SPEED SENSOR Inductive type sensor with shielding cable Winding resistance 650 to be measured across pins 1 and 2 Output voltage 0 5 V to be measured when cranking Air g...

Page 145: ...25 Engine speed sensor signal 26 Not used 27 Not used 28 Left cylinder injector control 29 TPS power supply 30 Not used 31 Not used 32 TPS negative 33 Not used 34 Rpm sensor wave trap 35 Engine speed...

Page 146: ...p signal input 28 Starting signal input 29 CAN L line ECU instrument panel 30 Not used 31 Not used 32 Oxygen sensor power supply 33 Clutch sensor signal 34 Not used 35 Bank angle sensor signal 36 Not...

Page 147: ...Active inductive sensor 3 pin connector Power supply Signal Ground 21 AUXILIARY FUSES c Stop horn Hazard button light light relay coil 15 A d Parking lights starter relay coil passing 15 A e Fuel pump...

Page 148: ...ELECTRIC SYSTEM 7 11 Griso V1100 7 1 2 WIRING DIAGRAM...

Page 149: ...y relay 30 Oil pressure bulb 31 Gearbox in neutral switch 32 Oxygen sensor 33 Side stand switch 34 Fuel reserve sensor 35 Fuel pump 36 Intake air temperature thermistor 37 Head temperature thermistor...

Page 150: ...TRANSMISSION 8 1 Griso V1100 TRANSMISSION 8...

Page 151: ...8 2 Griso V1100 SUMMARY 8 1 REAR TRANSMISSION 3 8 1 1 DISASSEMBLING THE SWINGARM 3 8 1 2 CHECK 7 8 1 3 REASSEMBLING THE SWINGARM 8 8 2 TRANSMISSION BOX 11 8 2 1 REMOVAL 11 8 2 2 REASSEMBLY 13 8 2 3 DI...

Page 152: ...LING THE SWINGARM Support the vehicle front end using the suitable stand and its rear end using slings and a hoist Position the engine support stand under the oil sump To remove the swingarm first rem...

Page 153: ...rst gear Loosen and remove the four retaining screws set aside the spacers Remove the rear wheel Loosen and remove the reinforcement bar nut Remove the screw Secure the reinforcement bar to the frame...

Page 154: ...n the swingarm clamp Loosen and remove the connecting rod securing nut set aside the screw Disconnect the speed sensor connector and remove the ties securing the cable to the frame Loosen the ring nut...

Page 155: ...TRANSMISSION 8 6 Griso V1100 With the help of a second person slide out the shaft and remove the swingarm together with the cardan joint...

Page 156: ...n If so change the joint Check that the rubber bellow is not cut or pierced Change if necessary Check that the threadings of the swingarm shafts and nuts are in good condition are not damaged or flat...

Page 157: ...s with the recommended product see LUBRICANTS TABLE Support the swingarm fit the cardan joint match the holes and simultaneously fit the shaft completely with the help of a second person Tighten the s...

Page 158: ...e the dust cover using a new clamp Fit the reinforcement bar in its seat Fit the screw Tighten the reinforcement bar nut Fit the connecting rod to the swingarm Fit the screw Tighten the connecting rod...

Page 159: ...TRANSMISSION 8 10 Griso V1100 Fit the rear wheel on the swingarm Tighten the four screws together with the spacers Fit the cover...

Page 160: ...2 1 REMOVAL Before removing the transmission box first remove the exhaust silencer and the rear wheel Loosen and remove the reinforcement bar nut Remove the screw Secure the reinforcement bar to the f...

Page 161: ...TRANSMISSION 8 12 Griso V1100 Remove the cardan joint and the transmission box...

Page 162: ...ansmission box on the swingarm ensure that the cardan joint fits correctly Tighten the four screws to the specified torque follow a cross pattern Place the reinforcement bar in its seat Insert the scr...

Page 163: ...ts filters OIL FILLING OR OIL LEVEL OIL DRAIN LUBRICATION GREASING ADJUSTMENTS MEASUREMENTS tightening torques preloads backlash SPECIAL TOOLS SEALING LOCKING FLUIDS APPLICATION MARKING DISASSEMBLY AS...

Page 164: ...TRANSMISSION 8 15 Griso V1100 TIGHTENING TORQUES A 20 Nm B 30 Nm B A Sez A A 30 Nm B 35 Nm B 170 Nm B 2 Nm C 0 6 Nm A...

Page 165: ...TRANSMISSION 8 16 Griso V1100 HOUSING GROUP DISASSEMBLY Remove the plug 20 Remove the plug 3 to drain the oil 21 7 2 3 12 13 14 15 16 19 20 11 1 8 9 10 18 17 4 5 6...

Page 166: ...TRANSMISSION 8 17 Griso V1100 Lift the boot 10 Remove the clamps 9 and 11 Remove the boot 14 Remove the screws 16 Collect the ring 15...

Page 167: ...TRANSMISSION 8 18 Griso V1100 Remove the bolts 7 Remove the housing 4 Remove the clamp 12 Remove the boot 14 Collect the ring 13 7...

Page 168: ...move the support group 8 ASSEMBLY Assemble the dowel pin 21 to the housing 18 with the special tool and a hammer Assemble the housing 18 on the special fastening tool Clean with care the housings cont...

Page 169: ...ISSION 8 20 Griso V1100 Insert the support group 8 into the housing 18 Assemble the ring 13 with the boot 14 Assemble the boot 14 to the support 8 Assemble the clamp 12 Lock the clamp 12 with suitable...

Page 170: ...ed sealant to the housing 18 Assemble a new seal ring 1 using the special tool Lubricate the seal ring 1 Assemble two stud bolts with thread in the threaded holes on the housing 18 as shown in figure...

Page 171: ...rews 7 Tighten the screws 7 to the prescribed torque Remove the exceeding sealant Assemble the ring 15 to the housing Assemble the fastening screws 16 to the prescribed torque Assemble the plug 3 and...

Page 172: ...he washer 5 Tighten the breather 6 to the prescribed torque Fill the transmission with the prescribed oil Assemble the plug 3 and the washer 2 Tighten the plug to the prescribed torque Assemble the bo...

Page 173: ...SSEMBLY Remove the bearing 1 from the wheel shaft 3 with suitable extractor Overturn the group Remove the bearing 10 from the wheel shaft 3 with suitable extractor ASSEMBLY Heat the bearings 1 and 10...

Page 174: ...TRANSMISSION 8 25 Griso V1100 Overturn the group Assemble the bearing 10 to the wheel shaft 3...

Page 175: ...ng 1 from the ring nut 2 Unscrew the ring nut 2 with the special wrench s4 Remove the ring nut 2 then remove the seal ring from the ring nut Nota destructive operation for the seal ring Assemble the s...

Page 176: ...o V1100 Grease the seal ring 3 Assemble the ring nut 2 Tighten the ring nut 2 with the special wrench s4 to the prescribed torque Insert the locking ring 1 into the ring nut 2 in the shown position Ve...

Page 177: ...TRANSMISSION 8 28 Griso V1100 Assembly position of the locking ring 1 Warning the locking ring 1 must be pushed in its seat...

Page 178: ...TRANSMISSION 8 29 Griso V1100 SUPPORT GROUP DISASSEMBLY Remove the bush 1 with a punch Overturn the support 5 and remove the other bush 8 4 5 3 2 1 8 7 6...

Page 179: ...al ring Remove from the support 5 the lock rings 3 and 6 with a suitable pliers Remove the spherical joint 4 with a suitable pad and a hammer ASSEMBLY Insert into the support 5 the lock ring 6 with a...

Page 180: ...Insert into the support 5 the lock ring 3 with a suitable pliers Assemble the new seal rings 2 and 7 by hand Assemble the bush 1 Drive in the bush 1 with a plastic hammer Overturn the support 5 and a...

Page 181: ...ug 1 Dirt between sealing ring and housing 2 An old sealing ring was used 3 Plug not tightened to specified torque 1 Clean and tighten to prescribed torque 2 Use new sealing ring 3 Tighten plug to spe...

Page 182: ...Moto Guzzi S p a Via E V Parodi 57 23826 Mandello del Lario LECCO Italy Tel 39 0341 709111 Fax 39 0341 709220 www motoguzzi it www servicemotoguzzi com...

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