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MOTO GUZZI Griso1200 8V, Service Station Manual

The MOTO GUZZI Griso1200 8V is a remarkable motorcycle designed to captivate and thrill every rider. To ensure its optimum performance and maintenance, you can effortlessly access the comprehensive Service Station Manual. Download it for free from manualshive.com and unlock valuable insights and instructions to enhance your riding experience.

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Removing

•

Place a collecting container and empty the lubrication system.

•

Undo and remove the two screws; col-

lect the pipes and the four washers.

•

Undo and remove the rear screw; col-

lect the washer.

•

Undo and remove the two screws; col-

lect the washers.

•

Undo and remove the screw; collect

the washer.

•

Remove the oil radiator.

Chassis

GRISO 8V - 1200

CHAS - 240

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Summary of Contents for Griso1200 8V

Page 1: ...SERVICE STATION MANUAL 854378 GRISO 8V 1200 ...

Page 2: ... bike designing phase Moto Guzzi Original Spare Parts are subject to systematic quality control procedures so that their reliability and performance over time is guaranteed The descriptions and illustrations given in this publication are not binding While the basic features as described and illustrated in this booklet remain unchanged Moto Guzzi reserves the right at any time and without being req...

Page 3: ...mmunicated to all Moto Guzzi Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Moto Guzzi CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the...

Page 4: ...Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 5: ...IN 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 BODYWORK BODYW PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 7: ...M TO IGNITE OR EXPLODE DO NOT DISPOSE OF FUEL INTO 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...

Page 8: ...ED BY MILK OF MAGNESIA OR VEGETA BLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCE ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BAT TERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTI...

Page 9: ... 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 des...

Page 10: ...L AND WILL DISAPPEAR AS SOON AS THE CLUTCH PLATES GET ADAPTED IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION ONLY AFTER THE SERVICE AT THE END OF THE RUN IN PERIOD CAN THE BEST PERFORM ANCE 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 lo...

Page 11: ...de close to the engine oil level check cap Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Length 2260 mm 89 0 in Max width 830 mm 32 68 in Maximum height 1070 mm 42 1 in Saddle height 800 mm 31 5 in Minimum ground clearance 185 mm 7 3 in Wheelbase 1554 mm 61 2 in Kerb weight 240 kg 529 lb Engine ENGINE Specification Desc Quantity Type 90 transversal V twin four stroke Cylind...

Page 12: ...353 2nd gear ratios 20 34 1 1 7 3rd gear ratios 23 31 1 1 3478 4th gear ratios 26 29 1 1 1154 5th gear ratios 31 30 1 0 9677 6th gear ratios 29 25 1 0 8621 Final drive cardan shaft Ratio 12 44 1 3 6667 Capacities CAPACITY Specification Desc Quantity Engine oil Oil change and oil filter replacement 3 500 cm 214 cu in Gearbox oil 500 cm 30 5 cu in Transmission oil 380 cm 23 2 cu in Fuel reserve incl...

Page 13: ...ake calliper adjustable spring pre loading hydraulic compression and rebound damping Wheel travel 120 mm 4 72 in Rear single sided arm suspension with progressive rising rate link age single shock absorber with fully adjustable compression and rebound damping and spring preloading Wheel travel 110 mm 4 33 in SIZES A AND B Specification Desc Quantity Size A 793 4 mm 31 24 in Size B 344 5 mm 13 56 i...

Page 14: ...ing 42 Nm 31 lbf ft Screw fixing head to chain compartment M6x120 4 10 Nm 7 38 lbf ft Oil temperature sensor 11 Nm 8 11 lbf ft Loctite 243 Oil temperature sensor container 11 Nm 8 11 lbf ft Loctite 601 Head covers fixing screws 8 8 Nm 5 9 lbf ft Spark plug 2 30 Nm 22 13 lbf ft Molykote CRANKCASE Name Torque in Nm Crankcase stud bolt cylinder 8 25 Nm 18 44 lbf ft Transmission side flange stud bolt ...

Page 15: ...6x14 2 8 Nm 5 9 lbf ft Timing system gear nut on service shaft M18 1 150 Nm 110 6 lbf ft Timing system gear nut on crankshaft M25 1 200 Nm 147 51 lbf ft Belt tension 50 Nm 36 88 lbf ft Timing system upper gear TE screw 2 30 Nm 22 13 lbf ft Screw fixing timing system upper gear closing cap TBEI M5x10 4 7 Nm 5 16 lbf ft Cylinder chain tensioner cap 2 30 Nm 22 13 lbf ft Screw fixing movable chain sli...

Page 16: ...t footrest plate to chassis lower retainer 18 Nm Brake switch on plate retainer Manual Plate ring to plate retainer 6 Nm Retainer for cable guide on right footrest plate 6 Nm FOOTRESTS AND LEVERS Name Torque in Nm Footrest rubber retainer 10 Nm Rider footrest sliding pin M8 25 Nm Passenger footrest support to lateral plates retainer 38 Nm Rider heelrest to plates retainer 6 Nm Passenger heelrest r...

Page 17: ...pansion tank spacer to engine retainer 10 Nm Blow by expansion tank to spacer retainer 10 Nm Filter housing to chassis retainer 10 Nm EXHAUST Name Torque in Nm Exhaust pipe to engine retainer 25 Nm Silencer to chassis connecting pipe retainer 25 Nm Silencer to footrest support retainer 25 Nm Protection to connecting pipe retainer 10 Nm Lambda probe retainer 38 Nm Clamp retainer 10 Nm FRONT WHEEL N...

Page 18: ...r 6 Nm Tank breather joint 6 Nm FUEL TANK Name Torque in Nm Filler to tank retainer 5 Nm Cap ring nut to tank retainer 5 Nm Screws on cap ring nut aesthetic 5 Nm Tank to chassis front retainer 10 Nm Battery housing and tank to chassis rear retainer 6 Nm CHASSIS FAIRINGS FRONT Name Torque in Nm Front mudguard retainer 6 Nm Control unit protection retainer 6 Nm Deflectors to chassis front upper reta...

Page 19: ...on diameter selection D 94 935 94 945 mm 3 73759 3 73798 in Cylinder diameter selection D 95 000 95 010 mm 3 74015 3 74054 in Piston diameter selection E 94 945 94 955 mm 3 73798 3 73837 in Cylinder diameter selection E 95 010 95 020 mm 3 74054 3 74093 in Piston diameter selection F 94 955 94 965 mm 3 73837 3 73877 in Cylinder diameter selection F 95 020 95 030 mm 3 74093 3 74133 in PIN PISTON COU...

Page 20: ... 959 mm 1 49507 1 49444 in Inside diameter of crankshaft bushing timing system side 38 016 38 0 mm 1 49669 1 49606 in Clearance between bushing and main journal timing system side 0 025 0 057 mm 0 00098 0 00224 in CRANKSHAFT SEAT CLUTCH SIDE Specification Desc Quantity Diameter of crankshaft main journal clutch side 53 97 53 961 mm 2 12480 2 12444 in Inside diameter of crankshaft bushing on clutch...

Page 21: ...ation Rotate the crankshaft by 90 until the right cylinder piston reaches the TDC Lock crankshaft rotation Place the tool on the right cylinder stud bolts to determine the squish X Specific tooling 020676Y Comparator support for piston position checking Repeat the same operations to determine the thickness of the left cylinder gasket between cylinder and head also for the right cylinder CYLINDER G...

Page 22: ...bearings and other points needing lubri cation NLGI 2 Neutral grease or petroleum jelly Battery poles AGIP BRAKE 4 BRAKE 5 1 Brake fluid As an alternative for recommended fluids use top branded fluids that meet or ex ceed the requirements of SAE J1703 NHTSA 116 DOT 4 ISO 4925 Synthetic fluid specifications AGIP BRAKE 4 BRAKE 5 1 Clutch fluid As an alternative for recommended fluids use top branded...

Page 23: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 24: ...tion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05 92 72 30 Timing system cover sealing ring punch 01 92 91 00 Wrench for removing the cover on sump and filter Special tools GRISO 8V 1200 S TOOLS 24 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 25: ...ntrol ignition timing 12 91 18 01 Tool to lock flywheel and start up crown gear 12 91 36 00 Tool to remove the flywheel side flange AP8140179 Support for valve fitting removal AP9100838 Tool for valve pressure plate GRISO 8V 1200 Special tools S TOOLS 25 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 26: ... er with sealing ring on the crankshaft 19 92 71 00 Tool to fit the sealing ring on the flywheel side flange 020673Y Graduated dial hub 020672Y Clutch spring centre and pusher 020674Y Piston ring clamp 020675Y Service shaft gear lock Special tools GRISO 8V 1200 S TOOLS 26 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 27: ...ing 05 91 26 30 Tool for tightening the fork pin ring nut clutch hub AP8140190 Tool for steering tightening 05 90 27 30 Gearbox support 05 90 27 31 Gearbox oil seal buffer 05 90 27 32 Buffer handgrip GRISO 8V 1200 Special tools S TOOLS 27 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 28: ...nion ring nut 05 90 27 35 Pinion oil seal buffer 05 90 27 36 Bevel gear pair support AP8140145 fitting tool for Ø 41 mm sealing rings AP8140146 Weight AP8140147 Spacer tool Special tools GRISO 8V 1200 S TOOLS 28 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 29: ...rating plate AP8140149 Protection for fitting operations AP8140150 Perforated rod for pumping member air bleed AP8140151 Complete tool kit for fork GRISO 8V 1200 Special tools S TOOLS 29 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 30: ...INDEX OF TOPICS MAINTENANCE MAIN Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 31: ...ssion oil Change Tyres Check and clean adjust grease or replace if necessary Tyre pressure Adjust Engine revs at idle speed Adjustment Valve clearance adjustment Adjust Wheels Check and clean adjust grease or replace if necessary Bolts nuts and screws tightening Check and clean adjust grease or replace if necessary Battery terminals tightening Check and clean adjust grease or replace if necessary ...

Page 32: ...e or replace if necessary Clutch wear Check and clean adjust grease or replace if necessary AFTER THE FIRST 10 000 KM 6 250 MILES AND THEN AFTER EVERY 20 000 KM 12 500 MILES Action Fork oil Change Fork oil seals Replace EVERY 20 000 KM 12 500 MI OR 24 MONTHS Action Alternator belt Adjust EVERY 50 000 km 31 050 mi Air filter Replace Fork Check and clean adjust and lubricate Brake fluid Change Suspe...

Page 33: ...d to the drainage plug 3 magnet Screw and tighten the drainage plug 3 Pour new oil through the fill opening 1 until it reaches the cap dipstick hole 1 CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Screw and tighten the caps 1 2 Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO N...

Page 34: ...if required Unscrew and remove the dipstick 1 Top up with engine oil until it goes above the minimum level marked MIN CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE OIL WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Place a container with 4000 cm 245 cu in capacity under the drai...

Page 35: ...oil Drain off the engine oil completely Unscrew and remove the engine oil fil ter from its seat NOTE NEVER REUSE A FILTER Spread a thin layer of oil on the sealing ring of the new engine oil filter Fit and screw the new oil filter in its seat See also Replacement Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTION ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WI...

Page 36: ...e a container with suitable capacity under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler cap 1 Drain the oil into the container allow several mi nutes for oil to drain out completely Check and replace if necessary the sealing washers of drainage plug 2 Remove any metal scrap attached to the drain age plug 2 magnet Screw and tighten the drainage plug 2 Pou...

Page 37: ...sensor connector Slide off and remove the main fuse box from its holder Undo and remove the six screws Lift the filter housing cover GRISO 8V 1200 Maintenance MAIN 37 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 38: ...SE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE Checking the valve clearance If the timing system is very noisy check the clearance between the valves and the rocking levers NOTE ADJUST WITH COLD ENGINE WITH PISTON AT TOP DEAD CENTRE TDC IN COMPRESSION STROKE VALVES CLOSED Disconnect both spark plug tubes Maintenance GRISO 8V 1200 MAIN 38 Revente Interdite Revendita Vietata Resaling Forbiden ...

Page 39: ...S SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURNOUT ETC Braking system Level check Brake fluid check Place the vehicle on the service stand For the front brake turn the handlebar fully to the right For the rear brake keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug Make sure that the fluid level in the reservoir is above the MIN reference mark MIN mi...

Page 40: ...O COMPLETE THE TOPPING UP PROCEDURE TO AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE TANK PARALLEL TO THE RESERVOIR EDGE IN HORIZONTAL POSITION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN DO NOT EXCEED THE MAX LEVEL MARK WHEN TOP PING UP TOP UP TO MAX LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW WHEN TOPPING UP DO NOT E...

Page 41: ...GRISO 8V 1200 Maintenance MAIN 41 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 42: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 43: ...Components arrangement Key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector GRISO 8V 1200 Electrical system ELE SYS 43 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 44: ...iary fuses Electrical system installation INTRODUCTION Scope and applicability The position of the cable harnesses how they are fixed to the motorcycle and potential problems are defined on the following sections in order to reach the objectives of vehicle reliability Vehicle sections The wiring distribution is subdivided in three es sential sections as indicated in the figure 1 Front section 2 Ce...

Page 45: ... but do not tauten it TABLE B SIDE STAND SENSOR Fasten the side stand sensor cable harness to the stand plate using two clamps TABLE B1 SIDE STAND SENSOR AND TIM ING SENSOR Fasten the side stand sensor cable harness and the timing sensor cable harness to the chassis using one clamp GRISO 8V 1200 Electrical system ELE SYS 45 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbot...

Page 46: ...ring diagram Key 1 Multiple connectors 2 Start up relay 3 Maintenance relay 4 Clutch switch Electrical system GRISO 8V 1200 ELE SYS 46 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 47: ...switch 21 ECU Diagnosis connector 22 Auxiliary fuses 23 Main fuses 24 Starter motor 25 Battery 26 27 Alternator 28 Main injection relay 29 Secondary injection relay 30 Oil pressure bulb 31 Gear in neutral switch 32 Lambda Probe 33 Side stand switch 34 Fuel reserve sensor 35 Fuel pump 36 Intake air temperature thermistor 37 Head temperature thermistor 38 Automatic air 39 Throttle sensor 40 41 Right...

Page 48: ...ont headlamp 57 Right front turn indicator Cable colour Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple Checks and inspections Dashboard Diagnosis Changing the CODE If you know the code just enter it and then a new code that will be automatically stored in the memory If the vehicle is new the user code is 00000 Electrical system GRISO 8V 1200 ...

Page 49: ...read ENTER THE SERVICE CODE This vehicle code is 12425 The functions in this menu are Exit ECU diagnosis Instrument Panel Errors Delete errors Reset Service Update Change Keys km Miles ECU ERRORS The instrument panel receives only the current errors from the control unit Description Error code Throttle Valve Error DC V DC ECU 10 Throttle Valve Error DC Gnd ECU 11 Engine Temperature Error DC V DC E...

Page 50: ...Immobilizer failure Key code read but not recognised Error code DSB 01 Description Immobilizer failure Key code not read Key not inserted or transponder broken Error code DSB 02 Description Immobilizer failure Aerial not working Open or short circuited Error code DSB 03 Description Immobilizer failure Internal controller failure Error code DSB 04 Description Error code DSB 05 Description Air tempe...

Page 51: ... 4 keys 3 should a new key lock be necessary and thus program the new set of keys In the first phase the user code must be entered and after confirming the inserted key key I has been programmed the other keys must be entered too The procedure finishes once the 4 keys have been programmed or after 20 seconds Should a new key lock be necessary the procedure is once the key is set to ON but the inst...

Page 52: ...fuel level equal to 22 5 litres 40 86 pt The low fuel warning light turns on with values over 230 Ohm In case there is anomaly on the fuel probe the low fuel warning light flashes on the instrument panel The alarm warning light on the instrument panel does not light up and the word Service is not displayed Lights list FRONT HEADLAMP Tail light 12V 5W Low beam light 12V 55W High beam light 12 V 60 ...

Page 53: ...ection relay coil start up relay coil speed sensor power supply ECU control unit power supply engine kill 15 A E Permanent positive ECU power supply 3A MAIN FUSES 1 From battery to voltage regulator 30 A 2 From battery to key and auxiliary fuses C D 30 A NOTE THERE IS ONE SPARE FUSE GRISO 8V 1200 Electrical system ELE SYS 53 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbo...

Page 54: ...r 10 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used 17 Stepper motor 18 Stepper motor 19 Stepper motor 20 5V power supply NTC sensors 21 Not used 22 Not used 23 Neutral sensor signal 24 Not used 25 Engine revolution sensor signal 26 Not used Electrical system GRISO 8V 1200 ELE SYS 54 Revente Interdite Revendita Vietata Resaling For...

Page 55: ...rol 2 Not used 3 Not used 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxiliary relay control 7 Immobilizer line 8 Pin 85 ignition relay control 9 Not used 10 Not used 11 Oxygen probe negative control 12 Not used 13 Not used 14 Not used 15 Not used 16 K line diagnosis 17 Power supply from main relay 18 Not used 19 Not used 20 CAN H line ccm instrument panel 21 Not used 22 Ox...

Page 56: ...ed 38 Side stand sensor signal Battery 12 V 18 Ampere hour Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed Operation Operating principle HALL effect sensor a square wave pulse is gen erated with voltage between 12 V and 0 3 0 4V approx Level in wiring diagram Speed sensor Location Electrical system GRISO 8V 1200 ELE SYS 56 Revente Interdite Revendita Vie...

Page 57: ...URE IS FOUND Check correct position of the sensor in its fitting Check voltage between PINS 1 3 of the sensor In case of null voltage check continuity between PIN 1 of the sensor and PIN 17 of the ECU BLUE connector Check PIN 17 of the blue connector Check continuity to ground of PIN 3 of the sensor Check continuity of the cable between PIN 2 of the sensor and PIN 24 of the ECU blue connector Chec...

Page 58: ...able AXONE PARAMETERS Target engine revs Example value 1100 100 rpm Parameter valid at idle setting depends especially on the engine temperature the ECU unit will try to keep the engine running at this revs acting on the ignition advance AXONE STATUSES Synchronisation Example value Synchronised Not synchronised Indicates if the control unit detects the revolution sensor signal correctly DIAGNOSIS ...

Page 59: ...nciple The throttle position sensor works as a variable resistance according to the throttle rotation Level in wiring diagram Throttle and idle motor Location sensor on the right cylinder throttle body connector on the potentiometer Electrical characteristics PINS A C throttle closed approx 2 5 kOhm throt tle open approx 1 5 kOhm PINS A B approx 1 1 kOhm Pin out A ground connection B supply voltag...

Page 60: ... it means the red cable is shorted to positive and the cable harness should be restored if shorted to negative disconnect the sensor connector and check the ground insulation of the red cable from throttle sensor connector or control unit connector if there is continuity to ground restore the cable harness if it is ground insulated the resistance between PIN A and PIN C is below 1 3 kOhm therefore...

Page 61: ...22 F 1 080 kOhm 11 Resistance at 60 C 140 F 0 750 kOhm 12 Resistance at 70 C 158 F 0 530 kOhm 13 Resistance at 80 C 176 F 0 380 kOhm 14 Resistance at 90 C 194 F 0 280 kOhm 15 Resistance at 100 C 212 F 0 204 kOhm 16 Resistance at 110 C 230 F 0 153 kOhm 17 Resistance at 120 C 257 F 0 102 kOhm Pin out PIN 1 Ground connection PIN 2 0 5 V signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECT...

Page 62: ...ound connection if there is not continuity restore the cable harness if there is continuity it means that the cause of the error is that the cable is shorted to positive and now the cable harness between the BROWN PIN 5 and PIN 2 of the sensor should be restored If the air temperature sensor error is displayed at the same time this means that the grey cable common for both sensors is shorted to po...

Page 63: ...Resistance at 40 C 104 F 1 600 kOhm 7 Resistance at 90 C 194 F 0 280 kOhm Pin out PIN 1 Ground connection PIN 2 0 5 V signal AXONE FUEL INJECTION SYSTEM AXONE PARAMETERS Air temperature In case of failure 25 C is set as temperature AXONE ELECTRICAL ERRORS Air temperature sensor P0110 Open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessi...

Page 64: ...e harness NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check through Axone if the temperature indicated is plausible in relation to the ambient temperature Check also that the sensor electrical characteristics are observed replace the sensor if not OK if it is OK check the sensor connector and the Marelli control ...

Page 65: ... the combustion as close as possible to the stoichiometric value AXONE ELECTRICAL ERRORS Lambda probe P0130 shorted to positive Error cause Excessive voltage battery voltage has been detected at PINS 32 and 22 of the BLUE connector Troubleshooting if shorted to positive with the key set to ON disconnect the sensor connector and measure voltage at PIN 1 on the cable harness side white yellow cable ...

Page 66: ... with the colour of the cables If there are also coil and injector errors check that relay and its excitation and power line if there is voltage at PIN 4 check the white cable ground insulation cable harness side PIN 3 if it is not OK restore the cable harness If OK check continuity of the white cable cable harness side between PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector a...

Page 67: ...le has continuity to the ground connection if there is continuity to ground re store the cable harness if there is not continuity replace the injector The circuit is open check the component correct electrical characteristic if it is not the cor rect one replace the component if it is correct check the connector on the component and the Marelli control unit connector If they are not OK restore If ...

Page 68: ...e component correct electrical characteristic if it is not the correct one replace the component if it is correct check the connector on the component and the Marelli control unit connector if they are not OK restore If OK check cable continuity be tween PIN 37 of the BROWN connector and the component PIN and restore the cable harness Coil Function It controls the ignition spark plug in order to g...

Page 69: ... 2 if there is voltage restore the cable harness if voltage 0 replace the coil If the circuit is open shorted to negative check the coil connector and the Marelli control unit connector If they are not OK restore if everything is OK check cable continuity be tween PIN 2 of the coil connector and PIN 38 of the BROWN connector If there is not continuity restore the cable harness if there is cable co...

Page 70: ...ity be tween PIN 2 of the coil connector and PIN 10 of the BROWN connector If there is not continuity restore the cable harness if there is cable continuity with the key set to KEY ON check the cable ground insulation from coil connector or control unit connector If this is not OK restore the cable harness Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pr...

Page 71: ... cable is ground insulated if there is continuity to ground restore the cable harness if it is ground insulated replace the switch It this error persists use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit in neutral or in gear Operation Operating principle for gear in neutral the circuit is closed to gr...

Page 72: ...ith gear in neutral Indication on the instrument panel always gear in neutral disconnect the terminals from the sensor and check if there is continuity with ground connection at PIN toward the sensor with gear engaged if there is continuity replace the sensor If it is ground insulated it means that the grey black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is shorted to ground ...

Page 73: ...there is continuity between the two PINS with clutch released if there is continuity replace the sensor If the circuit is open it means that the brown purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground restore the cable harness Side stand sensor Function It tells the side stand position to the control unit Operation Operating principle If the gear is engaged...

Page 74: ... sensor to PIN 38 of the BLUE connector is shorted to ground restore the cable harness Bank angle sensor Function it tells the vehicle position to the control unit Operation Operating principle When the sensor is inverted the circuit is closed to ground when the Marelli control unit detects this earthing it disables the fuel pump circuit and the engine start up circuit via the injection relay Leve...

Page 75: ...re the cable harness whose pink yellow cable will be shorted to ground Air temperature sensor instrument panel Function It tells the ambient air temperature to the instru ment panel Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in wiring diagram Temperature sensors Location Sensor under the instrument panel Connector under the instrument ...

Page 76: ...hort circuit to ground is detected at PIN 10 of the instrument panel connector the display will show a full scale temperature indication of 60 C Check the earth insulation of the sensor connector pink cable if there is a connection restore the cable harness if it is earth insulated check that sensor resistance is correct if it is not OK replace the sensor if it is OK replace the instrument panel R...

Page 77: ... no voltage restore the cable harness if there is check the ground insulation of the sky blue orange cable cable harness side if there is continuity to ground restore the cable harness if it is OK take the key to OFF and check that the BLUE connector is in good conditions and if there is continuity of the sky blue orange cable between the connector in question and PIN 27 of the BLUE connector if n...

Page 78: ...OPTIONAL The pin configuration of the black bodied connector is as follows PIN USE 21 BATTERY 22 LEFT FRONT TURN INDICATOR ACTIVATION 23 LEFT REAR TURN INDICATOR ACTIVATION 24 AERIAL 1 25 26 CAN H 27 28 LIGHTS RELAY ACTIVATION 29 30 SELECT 2 31 BATTERY 32 RIGHT FRONT TURN INDICATOR ACTIVATION 33 RIGHT REAR TURN INDICATOR ACTIVATION 34 AERIAL 2 35 36 CAN L 37 38 Electrical system GRISO 8V 1200 ELE ...

Page 79: ...39 40 SELECT 3 GRISO 8V 1200 Electrical system ELE SYS 79 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 80: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 81: ...d to the work bench Place the engine service stand under the oil sump Remove the exhaust system the fork with cardan shaft and the fuel tank Removing the engine from the vehicle Disconnect the spark plug tubes Working on both sides disconnect the injector connectors Disconnect the throttle cables GRISO 8V 1200 Engine from vehicle ENG VE 81 Revente Interdite Revendita Vietata Resaling Forbiden Wied...

Page 82: ...ector Disconnect the revolution sensor con nector Disconnect the alternator connectors Disconnect the neutral sensor connec tor Engine from vehicle GRISO 8V 1200 ENG VE 82 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 83: ...ound leads Disconnect the starter motor connec tors Undo and remove the three screws and remove the clutch control cylinder Lock the cylinder using a clamp to pre vent oil leaks Slide off the gearbox oil breather pipe GRISO 8V 1200 Engine from vehicle ENG VE 83 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 84: ...e the oil vapour union Disconnect the stand sensor connec tor and release it from the clamps Undo and remove the two screws and remove the control unit protection Undo and remove the two screws and move the control unit downwards Engine from vehicle GRISO 8V 1200 ENG VE 84 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 85: ...by tank from the two hooks on the chassis Working from both sides undo and re move the three inlet manifold screws Collect the gasket Remove both footrest holding plates Unscrew and remove the engine lower fixing nut and collect the washer Remove the lower bolt and collect the washer GRISO 8V 1200 Engine from vehicle ENG VE 85 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Ver...

Page 86: ...xing nut and collect the washer Remove the upper bolt and collect the washer Lower the engine partially Disconnect the oil pressure sensor connector Lower the engine completely Lift the rear part of the vehicle Release the front belts Hold the rear part of the vehicle re move the chassis from the engine See also Exhaust Removing Fuel tank Engine from vehicle GRISO 8V 1200 ENG VE 86 Revente Interdi...

Page 87: ...engine placing it in position Connect the oil pressure sensor con nector Working from the left side fit the en gine upper bolt with the washer From the opposite side fit the washer and screw the nut Working on both sides insert the washer and screw the screw without tighten it Place the plate and the cable guide and fix them using the two screws GRISO 8V 1200 Engine from vehicle ENG VE 87 Revente ...

Page 88: ...ighten the front screw to the prescribed torque Tighten the stud bolt Place the oil vapour recovery reservoir and tighten the screw Fit the control unit and tighten the two screws Fit the control unit cover and tighten the two screws Engine from vehicle GRISO 8V 1200 ENG VE 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 89: ...the three screws Connect the stand sensor connector and fix it to the chassis with new clamps Place the oil vapour union and tighten the two fixing screws Insert the oil breather pipe and fasten it with a new clamp GRISO 8V 1200 Engine from vehicle ENG VE 89 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 90: ...crews Connect the starter motor connectors Connect the ground cables and tighten the screw Fit the starter motor cover Place the two washers and tighten the two screws Engine from vehicle GRISO 8V 1200 ENG VE 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 91: ...nnect the alternator connectors Connect the revolution sensor connec tor Connect the engine temperature sen sor connector GRISO 8V 1200 Engine from vehicle ENG VE 91 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 92: ...ct the in jector connectors Working from both sides connect the spark plug tube Install the fuel tank Fit the saddle Working from both sides fit the fairing and tighten the three screws Install the complete exhaust Engine from vehicle GRISO 8V 1200 ENG VE 92 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 93: ...INDEX OF TOPICS ENGINE ENG Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 94: ...Gearbox Diagram Key 1 Ball bearing Engine GRISO 8V 1200 ENG 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 95: ...earing 19 Gear 20 Circlip 21 Clutch shaft 22 Ball bearing 23 Oil plug 24 Washer 25 Gearbox 26 Aluminium washer 27 Breather cap 28 Neutral sensor 29 Gasket 30 Sealing ring 31 Bushing 32 Gasket 33 Oil drainage plug 34 Sealing ring 35 Thrust bearing 36 Roller bearing 37 Spring 38 Complete pre selector 39 Bushing GRISO 8V 1200 Engine ENG 95 Revente Interdite Revendita Vietata Resaling Forbiden Wiederv...

Page 96: ...5th 1st 54 Fork shaft 55 Fork 3rd 4th 56 Fork 2nd 4th 57 Gear 58 Gear 59 Ball bearing 60 Transmission shaft 61 Gear 62 Spacer Gearbox Removing the gearbox Remove the starter motor Make sure the transmission is in idle Undo and remove the screw and re move the gearbox lever Engine GRISO 8V 1200 ENG 96 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 97: ...uitable capacity under it unscrew and remove the cap and then bleed all gearbox oil Loosen and turn the oil pipe fitting on the sump Undo and remove the three screws GRISO 8V 1200 Engine ENG 97 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 98: ...two screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts Engine GRISO 8V 1200 ENG 98 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 99: ...nd collect the abutment washer that is inside the gearbox From the outside slide off the thrust cylinder and collect the O Ring and the washer Remove the thrust bearing and the washer GRISO 8V 1200 Engine ENG 99 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 100: ...ws Place the gearbox on the specific gearbox support tool and on a vice Specific tooling 05 90 25 30 Gearbox support Undo and remove the nine internal screws Open the gearbox Engine GRISO 8V 1200 ENG 100 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 101: ...se rubber bands to tie down the trans mission shaft unit and extract it Once the transmission shaft unit is in on a bench remove the rubber bands being careful with the group Detach the shafts and label the forks before removal GRISO 8V 1200 Engine ENG 101 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 102: ... Remove the forks and collect the shaft Engine GRISO 8V 1200 ENG 102 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 103: ...t Remove the main shaft Operate on the main shaft from the second gear side Remove the gear of the second gear and collect the ball bearing cage Remove the gear of the sixth gear and collect the shoulder washer GRISO 8V 1200 Engine ENG 103 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 104: ...hird and fourth gears Remove the circlip and collect the shoulder washer Remove the gear of the fifth gear and collect the ball bearing cage Engine GRISO 8V 1200 ENG 104 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 105: ...shaft Remove the transmission shaft Operate on the shaft from the grooved side Remove the shoulder washer Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer GRISO 8V 1200 Engine ENG 105 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 106: ...the sixth gear Remove the circlip and collect the shoulder washer Remove the gear of the fourth gear and collect the ball bearing cage Engine GRISO 8V 1200 ENG 106 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 107: ...Remove the gear of the fifth gear Remove the circlip the shoulder wash er and remove the gear of the first gear collect the ball bearing cage Remove the bearing if necessary See also Disassembling the gearbox GRISO 8V 1200 Engine ENG 107 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 108: ... a centring device and re place it if not complying with specifications Characteristic Shaft coaxiality limit 0 08 mm 0 0031 in Check transmission gears for signs of pitting and wear and replace damaged gears if necessary Check the gear fitting teeth for cracks damage and wear and replace those damaged if necessary Check the transmission gears movement and if it is not regular replace the damaged ...

Page 109: ...e primary shaft NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER REMEMBER TO REPLACE ALL SEALING RINGS CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED See also Removing the primary shaft Fitting the secondary shaft NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER REMEMBER TO REPLACE ALL SEALING RINGS CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMO...

Page 110: ...ee picture According to the value found select the correct rod based on the following table Specific tooling 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc Quantity Protrusion 9 8 11 2 mm 0 386 0 441 in Clutch control rod length code 976593 183 mm 7 205 in Protrusion 8 3 9 7 mm 0 327 0 382 in Clutch control rod length code 976594 184 5 mm 7 264 in Protrusion 6...

Page 111: ...2 Spacer 3 Screw 4 Screw 5 Nut 6 Belt 7 Generator control pulley 8 Nut 9 Washer 10 Magneto flywheel cotter 11 Screw 12 Nut GRISO 8V 1200 Engine ENG 111 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 112: ... seat Disconnect the alternator connectors Undo and remove the five screws and collect the bushings Remove the cover Unscrew the nut and collect the screw Loosen the screw Engine GRISO 8V 1200 ENG 112 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 113: ...ly loosen and remove the screw Remove the belt and the alternator with pulley Using a compressed air gun unscrew and remove the nut and collect the spacer Remove the lower pulley GRISO 8V 1200 Engine ENG 113 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 114: ... Undo and remove the eight screws Undo and remove the two screws Undo and remove the two screws Engine GRISO 8V 1200 ENG 114 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 115: ... manifold Remove the control unit Undo and remove the fixing screw of the engine oil scavenge reservoir Unscrew and remove the spacer Undo and remove the five fixing screws of the timing system cover Remove the timing system cover Loosen the set screw lock nut GRISO 8V 1200 Engine ENG 115 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 116: ...Y Alternator belt tensioner Installing the generator If the sealing ring has been previously removed replace it using the punch of the timing system cover sealing ring Specific tooling 05 92 72 30 Timing system cover sealing ring punch Engine GRISO 8V 1200 ENG 116 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 117: ...emove the insertion cone afterwards Specific tooling 05 91 17 30 Front cover insertion cone Tighten the two screws Tighten the eight lower screws Operating diagonally and in stages tighten the ten fixing screws on the al ternator fitting GRISO 8V 1200 Engine ENG 117 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 118: ...n the lower pulley and the spacer Tighten the nut to the prescribed tor que Position the alternator and the timing system belt Position the screw and pre tighten it Engine GRISO 8V 1200 ENG 118 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 119: ...que and tighten the set screw Remove the belt tensioning tool Lock the set screw in position by screwing the lock nut Specific tooling 020677Y Alternator belt tensioner Tighten the alternator fixing screws GRISO 8V 1200 Engine ENG 119 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 120: ...ng in oblique direction and in stages Starter motor Removing the starter motor Undo and remove the two screws and collect the washers Slide off the starter motor Engine GRISO 8V 1200 ENG 120 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 121: ...Clutch disc 6 Crown 7 TCEI screw 8 Clutch pressure plate 9 Ring 10 TE flanged screw 11 Conical washer 12 Bushing 13 Rod 14 Bushing 15 Intermediate body 16 Thrust bearing 17 Clutch control bowl GRISO 8V 1200 Engine ENG 121 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 122: ...plete gearbox Undo and remove the six screws Remove the start up crown gear Remove the clutch bell and the friction disc Remove the Seeger ring Remove the clutch pressure plate Engine GRISO 8V 1200 ENG 122 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 123: ...e as follows Fit the new clutch on the crankshaft Fit the clutch control bowl in the gear box Fit the gearbox on the engine block Fit the tool in the gearbox to determine the clutch control rod length Measure rod protrusion using a depth gauge see picture According to the value found select the correct rod based on the following table Specific tooling GRISO 8V 1200 Engine ENG 123 Revente Interdite...

Page 124: ... 0 209 0 264 in Clutch control rod length code 976596 187 5 mm 7 382 in Assembling the clutch Lock crankshaft rotation with the crankpin facing upwards Place the clutch disc with the reference facing upwards Fasten the clutch disc on the crank shaft with the six screws Loctite 243 and the belleville springs Place the clutch pressure plate Fit the tool to centre and compress the plate Fully tighten...

Page 125: ...lace the friction disc centre it Place the clutch bell with the reference facing upwards Place the start up crown gear with the reference facing upwards Tighten the six screws to the prescri bed torque operating diagonally and in stages GRISO 8V 1200 Engine ENG 125 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 126: ... Right exhaust left intake rocking lever 9 Left exhaust right intake rocking lever 10 Set screw 11 Nut 12 Rocking lever rod 13 Tappet bowl 14 Flanged screw 15 Spacer 16 Camshaft 17 Pin 18 Timing system gear 19 Breather plate Engine GRISO 8V 1200 ENG 126 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 127: ...st left intake rocking lever 37 Left exhaust right intake rocking lever 38 Set screw 39 Nut 40 Rocking lever rod 41 Tappet bowl 42 Flanged screw 43 Spacer 44 Camshaft 45 Pin 46 Timing system gear 47 Breather plate 48 TE flanged screw 49 O ring 50 Complete breather cover 51 TBEI screw 52 Timing system chain 53 Chain guide slider 54 Chain tensioner pad 55 Chain tensioner screw 56 Left chain tensione...

Page 128: ...e sealing O rings Remove the head cover together with the gasket Removing the cylinder head CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the head cover Undo and remove the two screws Remove the cap Engine GRISO 8V 1200 ENG 128 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverk...

Page 129: ... Unscrew and remove the chain ten sioner cap Remove the right chain tensioner For the left head Undo and remove the screw and the washer Relief oil pressure from the left chain tensioner GRISO 8V 1200 Engine ENG 129 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 130: ...ud bolts Remove the complete cam cap Undo and remove the two screws Remove the head Fit the timing system upper gear back to the chain Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft Engine GRISO 8V 1200 ENG 130 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 131: ...UTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the two rocking levers from the cam cap Remove the two rods Undo and remove the four screws Remove the U bolt GRISO 8V 1200 Engine ENG 131 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 132: ...ving the rocker arms CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the cam cap from the stud bolts Undo and remove the two screws Remove the U bolt Engine GRISO 8V 1200 ENG 132 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 133: ...d where the upper cap works with a mallet so that the two cotters 1 get detached from the upper cap 2 Once the two cotters 1 are detached screw these cotters until they can be slid off the valve seats unscrew the tool and remove it from the head Slide off the upper cap 2 Remove the spring 3 Remove the lower cap 5 and the valve guide oil seal 4 if necessary Remove the valve 6 from inside the head C...

Page 134: ...nside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 972 4 987 mm 0 19574 0 19633 in Fitting clearance 0 013 0 040 mm 0 00051 0 00157 in VALVE GUIDE COUPLING VALVES OUTLET Specification Desc Quantity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 960 4 975 mm 0 19527 0 19587 in Fitting clearance 0 025 0 052 mm 0 00098 0 00205 in Checking the cylin...

Page 135: ...Y TO BOTH HEADS Place the valve guide oil seal 4 in the head Place the lower cap 5 Place the valve 6 inside the head Place the spring 3 Fit the upper cap 2 Place the two cotters 1 on the seats in the valves By compressing the spring 3 with the special tool fit the valve cotters Specific tooling 10 90 72 00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate Remove the spec...

Page 136: ... Place the U bolt on the rocking levers making sure the two reference pins match the seats on the cam cap Tighten the two screws operating diag onally and in stages See also Installing the overhead camshaft Engine GRISO 8V 1200 ENG 136 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 137: ...e them Place the camshaft with the gear seat on the dowel side Place the U bolt on the camshaft mak ing sure the two reference pins match the seats on the cam cap Tighten the four screws operating di agonally and in stages Timing GRISO 8V 1200 Engine ENG 137 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 138: ...e timing sensor and any shim washers Remove the tone wheel Remove the cotter and shim washer from the service shaft See also Removing the generator Service shaft removal Remove the tone wheel Remove both cylinders Undo and remove the two screws Remove the service shaft closing cap Engine GRISO 8V 1200 ENG 138 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 139: ...ankcase Fix it to the seat with the lock washer and screw Fit the timing chains according to the references marked at the removal phase Lubricate the service shaft Insert the service shaft in its crankcase seat by sliding it through the two chains Fit each chain to the corresponding service shaft gear Fit the roller cage and a new O ring on the service shaft closing cap GRISO 8V 1200 Engine ENG 13...

Page 140: ...n the cap with the two original TBEI screws Installing sliders Fit the crankshaft and the service shaft on the crankcase Fit the fixed chain sliders and tighten the fixing screws Tighten the chain caps with O rings The operations related to the movable chain sliders are described in the cyl inder fitting section See also Installing the crankshaft Installing the service shaft Engine GRISO 8V 1200 E...

Page 141: ...side facing the crankcase on the serv ice shaft Lock crankshaft rotation Unscrew and remove the nut fixing the crankshaft gear Remove the oil pump control gear Specific tooling 12 91 18 01 Tool to lock flywheel and start up crown gear Fit the timing system gear and align the reference with that on the crankshaft gear Turn the crankshaft to align the two gears GRISO 8V 1200 Engine ENG 141 Revente I...

Page 142: ...gear fixing nut of the service shaft Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump Place the driving pin on the oil pump shaft Engine GRISO 8V 1200 ENG 142 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 143: ...ign its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Tighten the screw with the washer to the prescribed torque See also Installing the crankshaft Installing the service shaft Measuring air gap GRISO 8V 1200 Engine ENG 143 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 144: ...clearance between the fixing plate and the crankcase with a thickness gauge Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel Remove the washer and fit the sensor after applying adequate sealing paste on the fixing plate then tighten the screws to the prescribed torque Engine GRISO 8V 1200 ENG 144 Revente Interdite Revendita Vietata...

Page 145: ...er piston ring 7 Pin 8 Snap ring 9 Cylinder base gasket 10 Stud bolt 11 Pin 12 Cylinder head gasket 13 Left cylinder 14 Washer 15 Chain tensioner cap 16 Washer 17 Left chain tensioner 18 Right chain tensioner GRISO 8V 1200 Engine ENG 145 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 146: ...pins on the stud bolts Remove the two gaskets between the crankcase and the cylinder Cover the crankcase opening with a clean cloth See also Removing the cylinder head Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Remove the cylinder Cover the crankcase opening with a clean cloth Disengage the pin clip Remove the pin Engine GRI...

Page 147: ...mooth ring in the intermediate slot the less thick smooth ring in the upper slot The piston rings must be offset at 120 one from the other Fit one of the two pin snap rings on the piston Lock crankshaft rotation Specific tooling 12 91 18 01 Tool to lock flywheel and start up crown gear Fit the piston NOTE CHECK THE PISTON DIRECTION ACCORDING TO THE REFERENCES MARKED ON THE PISTON CROWN DO NOT ASSE...

Page 148: ...new metal gasket between the crankcase and the cylinder Place the two dowel pins on the stud bolts Lu bricate the piston and the cylinder Lock connecting rod motion with the fork tool Using the suitable piston ring clamp tool place the cylinder and fit the chain in the timing system plate CAUTION DURING THIS OPERATION PAY ATTENTION NOT TO DAMAGE THE PISTON Specific tooling 020674Y Piston ring clam...

Page 149: ...aut on the service shaft LEFT CYLINDER Fit the piston Remove the cloth used to prevent for eign bodies from getting into the crank case Turn the rings so that the coupling ends are 120 degrees from each other Place a new metal gasket between the crankcase and the cylinder Place the two dowel pins on the stud bolts Undo the screw which will be used to time the upper gear GRISO 8V 1200 Engine ENG 14...

Page 150: ... motion with the fork tool Using the suitable piston ring clamp tool place the cylinder and fit the chain in the timing system plate CAUTION DURING THIS OPERATION PAY ATTENTION NOT TO DAMAGE THE PISTON Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking Fit the movable chain slider Fit the upper gear Fit the chain tensioner cap temporarily and keep the chain taut on the servi...

Page 151: ...and the cylinder as described in the section Shimming system Place the two dowel pins Fit the gasket with the correct thick ness between the head and the cylin der Fit the left cylinder head Fit a new O ring in the spark plug hole Fit the complete cam cap Fix the cam cap with the four nuts on the stud bolts GRISO 8V 1200 Engine ENG 151 Revente Interdite Revendita Vietata Resaling Forbiden Wiederve...

Page 152: ... the left camshaft pin fit the hole marked with the letter L of the timing system gear Block the left chain tensioner hole with screw and washer Rotate the crankshaft by 90 so that the right cylinder piston reaches the TDC lock crankshaft rotation Also determine the thickness of the gasket for the right cylinder to be fitted between the head and the cylinder as described in the section Shimming sy...

Page 153: ...ed with the letter R of the timing system gear Screw the cap of the right chain ten sioner Undo and remove the screws used to place the gear on the camshaft Place the bulkhead and align the holes with the timing system gear Fix the bulkhead on the timing system gear using a screw with Loctite on the thread Tighten the screw to the prescribed tor que Also place the bulkhead of the other head GRISO ...

Page 154: ...cking the valve clearance Installing the head cover Replace the gasket and install the head cover Place the plastic half cover Replace the four rubber rings Tighten the four screws to the prescri bed torque Place the spark plug tube Engine GRISO 8V 1200 ENG 154 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 155: ...ing rods Undo and remove the eight fixing screws and collect the washers Hold the crankshaft during flange re moval Using the suitable special tool remove the crankshaft flange Remove the sealing ring from the flange if necessary Specific tooling 12 91 36 00 Tool to remove the flywheel side flange GRISO 8V 1200 Engine ENG 155 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verb...

Page 156: ...g rod Remove both heads Remove the cylinders and the pistons Remove the oil sump Undo the coupling screws A inside the crankcase and remove the con necting rods B See also Removing the flywheel Disassembling the piston Removing the cylinder Removing the cylinder head Engine GRISO 8V 1200 ENG 156 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 157: ...ication Desc Quantity Blue bushing half shell regular production 44 008 44 014 mm 1 73259 1 73283 in Red bushing half shell regular production 44 014 44 020 mm 1 73283 1 73307 in BALANCING SELECTION COLOURS 2 Specification Desc Quantity Crankshaft selection colour 2 brown Type 1 to be used with brown connecting rods Balance with a 1558 g 54 96 oz 0 25 weight fitted on the crankpin B Maximum imbala...

Page 158: ... 0 10 mm 0 00393 inch CONNECTING ROD BEARING THICKNESS Specification Desc Quantity Regular Blue connecting rod bearing production 1 539 1 544 mm 0 06059 0 06079 in Regular Red connecting rod bearing production 1 535 1 540 mm 0 06043 0 06063 in CRANKPIN DIAMETER B Specification Desc Quantity Blue bushing half shell regular production 44 008 44 014 mm 1 73259 1 73283 in Red bushing half shell regula...

Page 159: ...g rods the two pins must be facing the crankcase internal side Place the connecting rods and the caps B on the crankshaft and fasten them with new screws A Remember these recommendations The screws fixing the connecting rods to the crankshaft must be replaced with new ones at the following refitting as they are subject to high loads and stress The fitting clearance between bearing and connecting r...

Page 160: ...he sealing ring on the flange Specific tooling 19 92 71 00 Tool to fit the sealing ring on the flywheel side flange Fit a new gasket between the crankcase and the crankshaft flange flywheel side Fit the crankshaft on the crankcase flywheel side Mark the crankshaft on the flywheel side with the crankpin facing upwards Place the suitable sealing ring centring tool on the crankshaft Specific tooling ...

Page 161: ...ent oil leaks Screw the eight flange screws on the flywheel side proceeding diagonally Remove the sealing ring centring tool from the crankshaft Specific tooling 12 91 20 00 Tool to fit the flywheel side flange together with sealing ring on the crankshaft To avoid that the shim washer inside the crankcase moves out of its seat fit the two gears and the nut on the crank shaft on the generator side ...

Page 162: ...th two new of the same type Check that the O ring is fitted on the jets Do not interchange them upon refitting because they have a different length Lubrication Conceptual diagrams Key Engine GRISO 8V 1200 ENG 162 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 163: ...m the sump through the filter 12 the oil is sent to the radiator 1 through the hoses 3 Oil passes through the radiator 1 dispersing part of the heat and reaches the heads through the hoses 2 Oil goes down to the sump again and joins the oil used for lubrication Lubrication The rotor 6 takes in oil from the sump through the filter 11 the oil is sent through special ducts in the crankcase to all the...

Page 164: ...in upon refitting Unscrew and remove the nut on the crankshaft Remove the oil pump control gear Screw the nut again so that the internal shim washer does not fall in the crank shaft crankcase Unscrew and remove the driven gear nut Collect the washer Remove the oil pump driven gear Remove the driving pin Engine GRISO 8V 1200 ENG 164 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkau...

Page 165: ...d the oil pump See also Replacement Removing the generator Installing Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump GRISO 8V 1200 Engine ENG 165 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 166: ...hten the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Engine GRISO 8V 1200 ENG 166 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 167: ...UITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL If necessary the filter can be removed with the suitable special tool Specific tooling 01 92 91 00 Wrench for removing the cover on sump and filter Unscrew and remove the oil level plug and collect the O Ring GRISO 8V 1200 Engine ENG 167 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 168: ...he fourteen screws fixing the oil sump to the engine crank case Undo and remove the four screws Remove the flange Engine GRISO 8V 1200 ENG 168 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 169: ...crew and remove the plug Remove the thermostatic valve Unscrew and remove the pressure re lief valve plug Remove the pressure relief valve com ponents GRISO 8V 1200 Engine ENG 169 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 170: ...alve compo nents correctly Screw the pressure relief valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Engine GRISO 8V 1200 ENG 170 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 171: ...a new gasket between the crank case and the flange Fit the flange Fix the flange with the four screws Fit the lubrication oil intake filter GRISO 8V 1200 Engine ENG 171 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 172: ...Fix both filters and tighten the two screws to the prescribed torque Fit a new oil filter and tighten it to the prescribed torque Place a new gasket between the flange and the sump Engine GRISO 8V 1200 ENG 172 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 173: ...for the fastening clamps of the pipes on the blow by tank Both blow by and clutch pipes should be laid in the front part of the chassis underneath the main cable harness Fuel pipes in the area underneath the fuel tank should be laid over the grey blow by pipes GRISO 8V 1200 Engine ENG 173 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 174: ...pes laying on the right hand size of the vehicle Blow by pipes laying on the left hand size of the vehicle Engine GRISO 8V 1200 ENG 174 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 175: ...INDEX OF TOPICS POWER SUPPLY P SUPP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 176: ...3 Fuel pipe 4 Pipe 5 Screw FUEL PIPES LAYING The fuel pipes should be laid in the innermost po sition compared to the electrical connections Power supply GRISO 8V 1200 P SUPP 176 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 177: ...ttle bodies should be placed on the right Fuel pipes in the area underneath the fuel tank should be laid over the grey blow by pipes Injection GRISO 8V 1200 Power supply P SUPP 177 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 178: ...6 Instrument panel 7 Air temperature sensor 8 Throttle valve position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor 12 Side stand Power supply GRISO 8V 1200 P SUPP 178 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 179: ...e bodies should be placed on the right Cylinders synchronisation With engine off connect the Axone 2000 tool to the diagnosis connector and to the vehicle battery Turn on the scanner Screw the joints connecting the vacu ometer pipes on the inlet pipe holes Connect the vacuometer pipes to the relative joints Set the key to ON GRISO 8V 1200 Power supply P SUPP 179 Revente Interdite Revendita Vietata...

Page 180: ... 2 If the value is incorrect replace the control unit and repeat the procedure from the start Completely close the two by pass screws on the throttle bodies Start the engine Take the engine to the prescribe tem perature 60 C 140 F Make the engine rev at 2000 3000 rpm and with the vacuometer check that the difference between the two pressures is 1 cm Hg 1 33 kPa maximum If this condition is detecte...

Page 181: ...e following sensors is interrupted the control unit determines some values to keep the engine running or it uses a different parameter The instrument panel and the Axone also signal the problem RECOVERY FUNCTION Specification Desc Quantity air temperature 25 C 77 F engine temperature 30 C 86 F with linear increase from the air temperature at ignition barometric pressure 1010 hPa throttle valve pot...

Page 182: ...er casing This is not the temperature indicated by the instrument panel Engine temperature C Battery voltage V Throttle Value corresponding to the throttle when closed approximate value between 4 5 and 4 9 left throttle supported by the end of stroke screw If a different value is read it is necessary to activate the parameter Throttle positioner autodetection and obtain this value Atmospheric pres...

Page 183: ...ehicle systems for example lambda probe functioning status DEVICE STATUS Specification Desc Quantity Engine status ON run power latch stopped operation conditions Throttle position Released pressed indicates if the throttle potentiometer is open or closed Stand Retracted expanded indicates the position of the side stand only with gear engaged IGNITION Enabled disabled indicates if the control unit...

Page 184: ...in the control unit MEM and it is possible to check error deletion STO ERRORS DISPLAY Specification Desc Quantity Pressure sensor Possible short circuit in the earth lead battery or open circuit recovery function noticeable for customer Careful with the air pressure sensor in the instrument panel Air temperature Possible short circuit in the earth lead battery or open circuit recovery function har...

Page 185: ...ead battery or lambda probe heating circuit open SPEED SENSOR Possible short circuit in the earth lead battery or speed sensor circuit open also possible lack of supply from the control unit CAN line diagnosis Possible error on the CAN line short circuit or line break or no signal or plausibility error detected RAM memory Possible internal control unit error Also check the control unit supply and ...

Page 186: ...INDEX OF TOPICS SUSPENSIONS SUSP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 187: ...t part of the vehicle Unscrew and remove the nut fixing the wheel bolt and collect the sealing ring Working from both sides loosen the screws on the wheel bolt clamps Hit the wheel pin slightly with a rubber hammer so that the hole on the oppo site side is exposed GRISO 8V 1200 Suspensions SUSP 187 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 188: ...n the bolt holes Upon extracting the wheel hold it and then remove it Collect the spacer from the front wheel right side Front fork Diagram Key Suspensions GRISO 8V 1200 SUSP 188 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 189: ... washer 27 screws M10x1 5 Adjustment The standard front fork setting is adjusted to suit most low and high speed riding conditions wheth er the vehicle is partially or fully loaded This set ting can also be customised based on vehicle use CAUTION SPORTS SETTING MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE REL...

Page 190: ... for sports use screw 2 Open 0 5 1 turn from fully closed Spring preloading nut 3 Open 4 5 protrusion notches from fully closed Stems A protrusion from top plate excluding cover standard adjustment 4 protrusion notches Take your vehicle only to a Moto Guzzi Official Dealer for this type of adjustment Stems A protrusion from top plate excluding cover sports use adjustment 5 protrusion notches Take ...

Page 191: ...ading Specific tooling AP8140149 Protection for fitting operations Unscrew the sleeve upper cap Lock the fork end in a vice paying at tention not to damage it Fit the tool on the spring joint Specific tooling AP8140147 Spacer tool GRISO 8V 1200 Suspensions SUSP 191 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 192: ...40148 Spacer pumping element separat ing plate Loosen the cap acting on the wrench slot and making the lock nut turn Remove the whole cap Detach the spacer and the washer Press down the spring and slide off the spacer Suspensions GRISO 8V 1200 SUSP 192 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 193: ...r and re move the spring Disassembling the fork After emptying the oil fasten the fork stem end in a vice Take out the washer and the lower spacer GRISO 8V 1200 Suspensions SUSP 193 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 194: ...ntring bushing Slide off the dust scraper from the sleeve using a screwdriver as a lever Do not damage the sleeve edge while doing this Remove the snap ring Suspensions GRISO 8V 1200 SUSP 194 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 195: ...s ing the stem as a hammer puller From the stem remove the fixed fitted bushing the movable bushing the ring and the oil seal GRISO 8V 1200 Suspensions SUSP 195 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 196: ...ENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check that the spring is in good conditions Check that the spring length is within the limit value Replace the spring if its length does not fall withi...

Page 197: ...or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SUR FACE Replace the following components with new ones gasket dust guard gasket the two O rings on the regulator GRISO 8V 1200 Suspensions SUSP 197 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 198: ...ape Lubricate the sliding edges with fork oil or with seal grease Fit the dust scraper the snap ring and the sealing ring on the slider The sealing ring must be placed with the stamped part facing the dust guard Suspensions GRISO 8V 1200 SUSP 198 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 199: ...ol fit the oil seal into posi tion Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in holes 8140145 Fitting tool for Ø 41 mm 1 61 in seal ing ring 8140146 Weight to be applied to the tool 8140145 and 8140189 GRISO 8V 1200 Suspensions SUSP 199 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 200: ...or Ø 41 mm 1 61 in seal ing ring 8140146 Weight to be applied to the tool 8140145 and 8140189 Fit the centring bushing on the car tridge and insert the whole assembly in the fork Tighten the screw fixing the pumping element on the fork end to the prescri bed torque Suspensions GRISO 8V 1200 SUSP 200 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 201: ...oil left Pump out oil a few times Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT FOR A CORRECT OIL LEVEL MEASUREMENT THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Characteristic Fork oil 520 2 5 cm 31 7 0 15 in for each stem Oil level from sleeve rim without the spring and preloading pipe 110 mm 4 33 in GRISO 8V 1200 Suspensions SUSP 201 Revente Interdite...

Page 202: ...ou pling so that the cartridge stem is locked in position Specific tooling 8140147 Spacer tool 8140148 Spacer pumping member separating plate Position the spacer and the washer Suspensions GRISO 8V 1200 SUSP 202 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 203: ...he vice using the specified tool Screw the upper cap to the prescribed torque Specific tooling AP8140149 Protection for fitting operations Steering bearing GRISO 8V 1200 Suspensions SUSP 203 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 204: ...o and remove the screws and col lect the U bolts holding the handlebar Move the handlebar forward without tilting the clutch and the front brake flu id reservoirs Undo and remove the screw Collect the right handlebar support Suspensions GRISO 8V 1200 SUSP 204 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 205: ...upper plate fixing screw on the fork stems Lift the fork upper plate sliding it off from the stems Rivet the safety washer on the head stock UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE GRISO 8V 1200 Suspensions SUSP 205 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 206: ...teering tightening Remove the safety washer Using the suitable special tool set the preloading of the steering bearings Specific tooling AP8140190 Tool for steering tightening Fit a new safety washer Suspensions GRISO 8V 1200 SUSP 206 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 207: ...ing AP8140190 Tool for steering tightening Rivet the tongues of the new safety washer Fit the fork upper plate on the stems Rear Removing the rear wheel Support the vehicle from the rear with an adequate stand Remove the cover GRISO 8V 1200 Suspensions SUSP 207 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 208: ...e system To set vehicle suspension the shock absorber has a set screw 1 to adjust the hydraulic rebound damping a set screw 2 to adjust the hydraulic compres sion damping a ring nut 3 to adjust spring preloading and a locking ring nut 4 Standard rear shock absorber setting is adjusted to suit most high and low speed riding conditions to transport the rider plus luggage Suspensions GRISO 8V 1200 SU...

Page 209: ... rebound damping Turn the screw 2 to adjust the shock absorber hydraulic compression damping CAUTION SET THE SPRING PRELOADING AND THE REBOUND DAMPING OF THE SHOCK ABSORBERS ACCORDING TO THE VEHICLE USE CONDITIONS IF THE SPRING PRELOADING IS IN CREASED IT IS NECESSARY TO INCREASE THE REBOUND DAMPING ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING IF NECESSARY CONTACT AN OFFICIAL Moto Guzzi DEALER TR...

Page 210: ...the front with a suitable stand Unscrew and remove the fixing nut Take out the screw tapping lightly with a rubber hammer and follow as the as sembly slides out of its position Suspensions GRISO 8V 1200 SUSP 210 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 211: ... Undo and remove the suspension low er screw Undo and remove the suspension up per screw GRISO 8V 1200 Suspensions SUSP 211 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 212: ...INDEX OF TOPICS CHASSIS CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 213: ...brake pipe Remove the cover Engage first gear Undo and remove the four screws col lect the spacers and the dust protec tion ring Remove the rear wheel Unscrew and remove the nut fixing the reaction rod Remove the screw Fasten the reaction rod to the chassis with a clamp GRISO 8V 1200 Chassis CHAS 213 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 214: ...crew and remove the fixing nut of the connecting rod assembly and col lect the screw Disconnect the speed sensor connec tor and release the cable from the clamp on the chassis Chassis GRISO 8V 1200 CHAS 214 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 215: ...e not deformed or damaged otherwise replace the joint Check that the rubber bellows are not cut or pierced otherwise replace it Check that the fork pin threads and the fork fixing nuts are not damaged de formed or flattened otherwise replace them Check that the sleeve grooves are not damaged deformed or deteriorated otherwise replace the sleeve Check that the sleeve outer toothing and grooves are ...

Page 216: ...cts table Block the fork insert the universal joint align the holes and at the same time helped by a second operator insert the pin completely Tighten the fork pin Use the suitable box spanner to tight en the ring nut Specific tooling 05 91 26 30 Tool for tightening the fork pin ring nut clutch hub Tighten the two fork terminal screws Chassis GRISO 8V 1200 CHAS 216 Revente Interdite Revendita Viet...

Page 217: ...ew the nut fixing the reaction rod Place the connecting rod assembly on the fork Insert the screw Tighten the fixing nut of the connecting rod assembly Connect the speed sensor connector and fix the cable to the chassis with clamps GRISO 8V 1200 Chassis CHAS 217 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 218: ...e pipe on the fork See also Recommended products chart Bevel gears Removing To remove the gearbox first remove the exhaust silencer and the rear wheel Unscrew and remove the nut fixing the reaction rod Remove the screw Fasten the reaction rod to the chassis with a clamp Chassis GRISO 8V 1200 CHAS 218 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 219: ...move the four screws Remove the transmission casing slid ing off the universal joint Checking Support unit GRISO 8V 1200 Chassis CHAS 219 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 220: ...move the stop rings 3 and 6 from the support 5 with suitable pliers NOTE THIS OPERATION DESTROYS THE SEALING RING Remove the ball joint 4 with a suitable buffer and a rubber hammer FITTING Fit the stop ring 6 in the support 5 with suitable pliers Chassis GRISO 8V 1200 CHAS 220 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 221: ...ort 5 with suitable pliers Manually assemble the new sealing rings 2 and 7 Assemble the bushing 1 Drive the bushing 1 in with a plastic hammer Turn the support 5 over and assemble the other bushing 8 Pinion unit GRISO 8V 1200 Chassis CHAS 221 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 222: ...the ring nut 2 and remove the sealing ring from the ring nut NOTE THIS OPERATION DESTROYS THE SEALING RING Assemble the sealing ring 3 to the ring nut 2 with the buffer CA715855 see Fig 1 and a ham mer Chassis GRISO 8V 1200 CHAS 222 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 223: ...2 Tighten the ring nut 2 with the special spanner s4 to the prescribe torque Insert the stop ring 1 in the ring nut 2 in the in dicated direction GRISO 8V 1200 Chassis CHAS 223 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 224: ...asing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer Assemble the casing to the special fastening tool Clean the casing faying surfaces carefully Chassis GRISO 8V 1200 CHAS 224 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 225: ...Insert the support group in the casing Assemble the cap and the ring Fit the cap on the support Fit the clamp GRISO 8V 1200 Chassis CHAS 225 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 226: ...g Fit a new sealing ring using the buffer Lubricate the sealing ring Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture Chassis GRISO 8V 1200 CHAS 226 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 227: ...ws 7 Tighten the screws 7 to the prescribed torque Remove excessive sealant Assemble the ring to the casing Tighten the fixing screws to the prescribed torque GRISO 8V 1200 Chassis CHAS 227 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 228: ...r Screw the breather to the prescribed torque Fill the transmission with the prescribed oil Fit the cap with the washer Screw the cap to the prescribed torque Assemble the cap with the clamps Chassis GRISO 8V 1200 CHAS 228 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 229: ...the wheel axle with a suitable extractor Turn the unit over Remove the bearing from the wheel axle with a suitable extractor FITTING Heat the bearings to 100 C 212 F GRISO 8V 1200 Chassis CHAS 229 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 230: ... bearings to the wheel axle Turn the unit over Assemble the bearings to the wheel axle Casing unit removal Chassis GRISO 8V 1200 CHAS 230 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 231: ...ove the plug 3 to drain out the oil Lift the cap 10 Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 GRISO 8V 1200 Chassis CHAS 231 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 232: ...llect the ring 15 Remove the screws 7 Remove the casing 4 Remove the clamp 12 Remove the cap 14 Chassis GRISO 8V 1200 CHAS 232 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 233: ...ten to the correct torque 2 Replace the sealing ring 3 Tighten the plug to the correct torque 1 Damaged cap 2 Retaining clamps or closing cover slacken 3 Fitting error of the radial seal or seal damaged 4 Sliding surface of the wheel spacer seal spoiled or damaged 1 Replace the cap 2 Screw the clamp with suitable pliers 3 Replace the sealing ring and fit it correctly with the suitable tool 4 Repla...

Page 234: ...e operating diagonally Place the reaction rod into its seat Insert the screw Screw the nut fixing the reaction rod Place the dust protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit Chassis GRISO 8V 1200 CHAS 234 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 235: ... the cover Place the rear brake calliper on the disc and the brake pipe on the fork Exhaust Key 1 Right exhaust pipe 2 Left exhaust pipe 3 Gasket 4 Nut 5 Washer 6 Washer 7 Washer 8 Washer 9 Gasket 10 Clamp GRISO 8V 1200 Chassis CHAS 235 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 236: ...Silencer fixing bushing 22 Nut 23 Silent block 24 Screw 25 Screw 26 Washer 27 Nut Removing the tail pipe Loosen the sealing clamp between the exhaust and the central manifold Undo and remove the front screw fas tening the exhaust to the chassis Chassis GRISO 8V 1200 CHAS 236 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 237: ... probe connector Unscrew and remove the nut and re move the fixing screw Remove the manifold exhaust end coupling together with the lambda probe See also Removing the exhaust manifold Removing the tail pipe Removing the exhaust manifold 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 handli...

Page 238: ...st clamps Remove the protection Unscrew and remove the two nuts on the head exhaust stud bolts Collect the washers Loosen the clamp Remove the exhaust manifold Chassis GRISO 8V 1200 CHAS 238 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 239: ...s 4 T shaped bushing 5 Screw 6 Radiator grille 7 Air deflector 8 Screw 9 Washer 10 Bushing 11 Spacer 12 Rubber ring 13 Cover 14 Spacer 15 Screw 16 Washer 17 Screw 18 Washer GRISO 8V 1200 Chassis CHAS 239 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 240: ... the pipes and the four washers Undo and remove the rear screw col lect the washer Undo and remove the two screws col lect the washers Undo and remove the screw collect the washer Remove the oil radiator Chassis GRISO 8V 1200 CHAS 240 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 241: ...the min imum level marked MIN on the dip stick 1 Screw the dipstick 1 Start the vehicle and let the engine run for a few minutes so that the oil circu lates and fills the radiator internal ducts Stop the engine and check the oil level with the dipstick 1 Fill with engine oil as required GRISO 8V 1200 Chassis CHAS 241 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 242: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 243: ... Screw 3 Pads 4 Pin calliper split pin 5 Spring 6 Gasket 7 Screw 8 Air bleed 9 Air bleed cap 10 Rear brake pipe 11 Oil pipe screw GRISO 8V 1200 Braking system BRAK SYS 243 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 244: ... Front left brake calliper 3 Pads 4 Air bleed 5 Air bleed cap 6 Pins Calliper springs 7 Spring 8 Aluminium gasket 9 Screw Front brake pads Braking system GRISO 8V 1200 BRAK SYS 244 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 245: ...e Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS GRISO 8V 1200 Braking system BRAK SYS 245 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 246: ...POSITIONED INSIDE THE CALLIPER Position the anti vibration plate Insert both pins Position both split pins Abut the plungers against the pads acting on the brake pump lever several times Check the brake fluid level in the res ervoir Rear brake pads Braking system GRISO 8V 1200 BRAK SYS 246 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 247: ...amps Undo and remove the two screws Remove the brake calliper from the disc Turn the pin and remove the split pin Remove the split pin Remove the pin GRISO 8V 1200 Braking system BRAK SYS 247 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 248: ...hat the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Insert the pin Position the split pin Abut the plungers against the pads acting on the brake pump pedal sever al times Check the brake fluid level in the res ervoir Braking system GRISO 8V 1200 BRAK SYS 248 Revente Interdite Revendita Vietata Resaling ...

Page 249: ...THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con...

Page 250: ...e brake control and poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHEC...

Page 251: ...HE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleed valve and remove the pipe Top up the reservoir until the right brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber protection cover GRISO 8V 1200 Braking system BRAK SYS 251 Revente ...

Page 252: ...INDEX OF TOPICS CLUTCH SYSTEM CLU SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 253: ...n the front part of the chassis underneath the main cable harness Clutch system pipes laying on the right hand size of the vehicle GRISO 8V 1200 Clutch system CLU SYS 253 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 254: ...INDEX OF TOPICS BODYWORK BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 255: ...emove the rear brake calliper from the disc Undo and remove the rear upper screw and collect the nut Undo and remove the front upper screw Remove the air filter housing Disconnect the connector of the rear brake lever switch and release it from the clamps GRISO 8V 1200 Bodywork BODYW 255 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 256: ... Remove the exhaust silencer Undo and remove the screw and col lect the nut and the spacer Undo and remove the rear upper screw and collect the nut Undo and remove the front upper screw Bodywork GRISO 8V 1200 BODYW 256 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 257: ...Air box Remove the fuel tank Disconnect the connector from the air temperature sensor Slide off and remove the main fuse box from its holder Undo and remove the four screws GRISO 8V 1200 Bodywork BODYW 257 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 258: ... holder Undo and remove the two screws Disconnect the low pressure pipe Disconnect the blow by tank breather pipe Free the pipes from the clamps Bodywork GRISO 8V 1200 BODYW 258 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 259: ...de fairings and the sad dle Undo and remove the two front screws fixing the tank Undo and remove the two rear screws fixing the tank and collect the two T spacers Remove the battery Lift the front and then the rear of the fuel tank leaning its lower part onto the support rubber pad of the brackets wel ded to the chassis Disconnect the quick release coupling GRISO 8V 1200 Bodywork BODYW 259 Revente...

Page 260: ... Disconnect the connector Remove the fuel tank Bodywork GRISO 8V 1200 BODYW 260 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 261: ...INDEX OF TOPICS PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 262: ...ain switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Electric start up Engine st...

Page 263: ...H WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OU...

Page 264: ...braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRE...

Page 265: ... 33 70 239 F Fork 188 190 193 198 Forks 109 Fuel 86 115 259 Fuses 53 G Gearbox oil 35 I Identification 10 Instrument panel 75 M Maintenance 8 31 O Oil filter 35 R Recommended products 22 218 S Shock absorber Shock absorbers 208 Stand 73 Start up 52 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 266: ...T Tank 86 115 259 Transmission 12 32 Tyres 14 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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