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MOTO GUZZI NORGE GT 8V, Service Station Manual

The MOTO GUZZI NORGE GT 8V is a powerful and elegant touring motorcycle built for adventure. To ensure its optimal performance and maintenance, it is crucial to have the Service Station Manual. Easily download this comprehensive manual for free from manualshive.com to enhance your riding experience and keep your motorcycle in top shape.

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020716Y

 

Connecting rod locking

•

Remove the piston ring clamp tool and

finish positioning the cylinder.

Specific tooling

020674Y

 

Piston ring clamp

•

Fit the movable chain slider.

•

Fit the upper gear.

•

Fit the chain tensioner and the chain

tensioner cap temporarily and keep the

chain taut 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.

Norge GT 8v

Engine

ENG - 209

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten 

Summary of Contents for NORGE GT 8V

Page 1: ...SERVICE STATION MANUAL 897237 Norge GT 8v ...

Page 2: ...ights regarding electronic data storage total or partial reproduction or adaptation of this manual by any means are reserved for all Countries Third party products or services referred to in this manual should be considered only informative and are not binding Moto Guzzi s p a shall not be liable for any functions or use of these products Revente Interdite Revendita Vietata Resaling Forbiden Wiede...

Page 3: ...nicated 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 ve...

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

Page 5: ...NTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK 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: ... MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled dow...

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

Page 9: ... guard rims and gaskets before refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble oil guards and bearings with the brand or lot number facing outward visible side ELECTRIC CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness Press t...

Page 10: ...MPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUN IN PERIOD Follow the guidelines detailed below Do not twist the throttle grip abruptly and completely when the engine is working at a low revs either during or after run in During the first 100 Km 62 miles use ...

Page 11: ... WEIGHT AND DIMENSIONS Specification Desc Quantity Max length 2195 mm 86 4 in Max width 880 mm 34 6 in Max height to the windshield 1430 1480 mm 56 3 58 3 in Saddle height 810 mm 31 9 in Minimum ground clearance 185 mm 72 8 in Wheelbase 1495 mm 58 8 in Kerb weight 257 Kg 566 6 lb Engine ENGINE Specification Desc Quantity Type traverse mounted twin cylinder four stroke V 90 No of cylinders 2 Cylind...

Page 12: ...Gear ratios 5th gear 31 29 1 0 9355 Gear ratios 6th gear 30 24 1 0 8 Final drive with U joint Ratio 12 44 1 3 6667 Capacities CAPACITIES Specification Desc Quantity Engine oil Oil and oil filter change 3400 cm 207 48 cu in Gearbox oil 500 cm 30 5 cu in Transmission oil 380 cm 23 2 cu in Fuel reserve included 23 litres 5 06 UK gal Fuel reserve 4 litres 0 88 UK gal Seats 2 Maximum weight limit 349 K...

Page 13: ...th adjustable spring preload Front wheel travel 120 mm 4 7 in Rear single sided swingarm with progressive linkage and mono shock absorber with adjustable rebound and with ergonomic hand grip for preloading adjustment Rear wheel travel 140 mm 5 5 in SIZES A AND B Specification Desc Quantity Size A 758 9 1 mm 29 88 0 04 in Size B 345 5 mm 13 60 in Brakes BRAKES Specification Desc Quantity Front Dual...

Page 14: ...ssenger 2 5 bar 250 kPa 36 26 PSI Rear tyre size 180 55 ZR 17 Rear tyre pressure 2 8 bar 280 kPa 40 61 PSI Rear tyre pressure with passenger 2 8 bar 280 kPa 40 61 PSI Supply FUEL SYSTEM Specification Desc Quantity Fuel system Electronic injection Weber Marelli with stepper motor Diffuser diameter 50 mm 1 97 in Fuel Premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM Tightening Torque...

Page 15: ...NT PANEL pos Description Type Quantity Torque Notes 1 Instrument panel fixing screw SWP M5x14 3 3 Nm 2 21 lbf ft 2 Ignition lock fixing screw M8x30 1 25 Nm 18 44 lbf ft 3 Ignition lock shear head fixing screw M8x28 1 At the point of fail ure Norge GT 8v Characteristics CHAR 15 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 16: ... ft 2 Piston fixing screw to the sleeve M10x35 2 50 Nm 36 87 lbf ft 3 Fork cap 2 20 Nm 14 75 lbf ft WINDSHIELD pos Description Type Quantity Torque Notes 1 Top fairing fixing screw M5x9 8 4 Nm 2 95 lbf ft Characteristics Norge GT 8v CHAR 16 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 17: ...x16 2 4 Nm 2 95 lbf ft FRONT BRAKE LEVER pos Description Type Quantity Torque Notes 1 Front brake pump U bolt fixing screw M6 2 10 Nm 7 37 lbf ft Sequence 1 2 1 Norge GT 8v Characteristics CHAR 17 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 18: ...ar lower fixing screw on the up per steering yoke M8x25 2 25 Nm 18 44 lbf ft 2 Half handlebar upper fixing screw on the up per steering yoke M8x25 STAIN LESS STEEL 4 20 Nm 14 75 lbf ft Loctite 243 3 Handlebar pipe fixing screw on the half han dlebar M8x30 2 18 Nm 13 27 lbf ft Loctite 243 4 Counterweight fixing screw M6x70 2 10 Nm 7 37 lbf ft Loctite 243 Characteristics Norge GT 8v CHAR 18 Revente ...

Page 19: ...t fixing screw M5 4 4 Nm 2 95 lbf ft 3 Engine guide lock to frame upper fixing screw M6 2 10 Nm 7 37 lbf ft 4 Engine guide lock to frame lower fixing screw M6 2 10 Nm 7 37 lbf ft 5 Windshield support fixing screw M6 4 10 Nm 7 37 lbf ft Norge GT 8v Characteristics CHAR 19 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 20: ... Nm 18 44 lbf ft 2 Fork stanchion fixing screw on the lower plate M8x25 4 25 Nm 18 44 lbf ft 3 Upper yoke fixing cap M29 1 100 Nm 73 76 lbf ft 4 Headstock ring nut M35 1 40 Nm 29 50 lbf ft 5 Headstock counter lock ring M35 1 Manually screw 6 Pipe stop plate fixing screw to the steering base M6x18 1 10 Nm 7 37 lbf ft Characteristics Norge GT 8v CHAR 20 Revente Interdite Revendita Vietata Resaling F...

Page 21: ...pos Description Type Quantity Torque Notes 1 Front wheel spindle nut M25 1 80 Nm 59 00 lbf ft 2 Front brake disc fixing screw M8x20 12 25 Nm 18 44 lbf ft Loctite 243 3 Front tone wheel fixing screw 5 4 Nm 2 95 lbf ft Loctite 243 Norge GT 8v Characteristics CHAR 21 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 22: ...g screw M6 1 10 Nm 7 37 lbf ft FRONT FRAME pos Description Type Quantity Torque Notes 1 Frame to chassis fixing screw M8x40 2 10 Nm 7 37 lbf ft Central part Characteristics Norge GT 8v CHAR 22 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 23: ... 11 lbf ft Loctite 243 7 Oil temperature sensor 1 12 Nm 8 85 lbf ft Kluber Wolfacoat Grease 8 Spark plug 2 15 Nm 11 06 lbf ft CENTRE AND SIDE STAND pos Description Type Quantity Torque Notes 1 Centre stand on the plate fixing screw M10x30 2 10 Nm 7 37 lbf ft Loctite 243 2 Side stand plate to chassis fixing screw M12x35 2 80 Nm 59 lbf ft 3 Side stand retainer pin M10 1 10 Nm 7 37 lbf ft Loctite 270...

Page 24: ...0 Nm 7 37 lbf ft 2 Peg to lever locking screw M6x16 1 10 Nm 7 37 lbf ft 3 Rod fixing nut M6 2 10 Nm 7 37 lbf ft 4 Transmission lever on the gear locking screw M6x20 1 10 Nm 7 37 lbf ft Characteristics Norge GT 8v CHAR 24 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 25: ...21 lbf ft 7 Peg to lever fixing screw M6x16 1 10 Nm 7 37 lbf ft EXHAUST SYSTEM pos Description Type Quantity Torque Notes 1 Exhaust pipe fixing nut to the engine M8 4 25 Nm 18 44 lbf ft 2 Exhaust pipe fixing clamp screw to the com pensator M6 2 20 Nm 14 75 lbf ft Clamp 3 Compensator fixing screw to the plate M10 2 25 Nm 18 44 lbf ft 4 Compensator fixing clamp screw to the muffler M8 1 20 Nm 14 75 ...

Page 26: ...mp M10 2 25 Nm 18 44 lbf ft 2 Joint with brake pipes retainer bleeding on the calliper M10 3 25 Nm 18 44 lbf ft 3 Brake pipes joint on the ABS hydraulic unit 4 25 Nm 18 44 lbf ft Characteristics Norge GT 8v CHAR 26 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 27: ... Footrest plate to chassis front upper fixing screw M8x30 4 20 Nm 14 75 lbf ft Loctite 243 2 Footrest plate to chassis rear upper fixing screw M8x25 4 25 Nm 18 44 lbf ft Loctite 243 3 Right footrest plate to chassis lower fixing screw M8x40 2 25 Nm 18 44 lbf ft 4 Left footrest plate to chassis lower fixing screw M8x55 2 25 Nm 18 44 lbf ft Norge GT 8v Characteristics CHAR 27 Revente Interdite Reven...

Page 28: ...M8 2 25 Nm 18 44 lbf ft 2 Tank to chassis rear fixing screw M8 1 25 Nm 18 44 lbf ft 3 Tank breather joint M6 2 6 Nm 4 42 lbf ft 4 Filler to tank fixing screw M5 4 4 Nm 2 95 lbf ft Characteristics Norge GT 8v CHAR 28 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 29: ...ssis lower fixing pin M12x270 1 80 Nm 59 lbf ft Back side TAIL Tail pos Description Type Quantity Torque Notes 1 Handgrip to chassis fixing screw M8x25 5 25 Nm 18 44ft 2 Tail to handgrip and to rear fairings fixing screw M5x9 10 4 Nm 2 95 lbf ft 3 Hooks and tail fairing to chassis fixing screw M8 4 20 Nm 14 75 lbf ft Norge GT 8v Characteristics CHAR 29 Revente Interdite Revendita Vietata Resaling ...

Page 30: ... rod fixing screw M10x55 2 50 Nm 36 87 lbf ft REAR SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm clamp fixing screw on the bushing M6x25 2 10 Nm 7 37 lbf ft Characteristics Norge GT 8v CHAR 30 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 31: ... Nm 44 25 lbf ft 4 Preloading bushing to the swingarm pin M25 1 10 Nm 7 37 lbf ft REAR LIGHTS pos Description Type Quantity Torque Notes 1 Handgrip taillight fixing screw M5x16 4 4 Nm 2 95 lbf ft 2 Rear turn indicator fixing screw M6 2 2 Nm 1 47 lbf ft Norge GT 8v Characteristics CHAR 31 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 32: ...1 lbf ft 3 Retroreflector support fixing screw to the li cense plate M5x10 2 4 Nm 2 95 lbf ft 4 Retroreflector fixing nut retainer to the support M5 1 4 Nm 2 95 lbf ft REAR BRAKE CALLIPER pos Description Type Quantity Torque Notes 1 Rear brake calliper fixing screw M10 2 50 Nm 36 87 lbf ft Characteristics Norge GT 8v CHAR 32 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbo...

Page 33: ...f ft 2 Rear brake disc fixing screw M8 6 25 Nm 18 44 lbf ft Loctite 243 3 Rear tone wheel fixing screw M5x12 6 4 Nm 2 95 lbf ft Loctite 243 4 Rear ABS sensor fixing screw M6 1 10 Nm 7 37 lbf ft Norge GT 8v Characteristics CHAR 33 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 34: ...ty Torque Notes 1 Pump outlet oil pipe nipple M14x1 5 1 40 Nm 29 50 lbf ft 2 Slot screw for oil pipe on the cylinder head M14x1 5 2 20 Nm 14 75 lbf ft 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 lbf ft Apply vaseline oil 4 Oil delivery pipe to radiator slot screw M14x1 5 1 35 Nm 25 81 lbf ft 5 Jets fixing screw 3 Using a T spanner close by hand Loctite 243 6 Cover on the flange...

Page 35: ...ley locking nut M16 1 80 Nm 59 00 lbf ft Loctite 243 2 Generator upper fixing screw M8 1 22 Nm 16 23 lbf ft 3 Generator lower fixing screw M10x60 1 30 Nm 22 13 lbf ft Norge GT 8v Characteristics CHAR 35 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 36: ... 37 lbf ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 lbf ft 8 Oil sump fixing screw M6 14 10 Nm 7 37 lbf ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 lbf ft 10 Magnetic oil drainage cap 1 20 Nm 14 75 lbf ft 11 Gear to engine fixing nut M8 5 20 Nm 14 75 lbf ft 12 Gear to engine fixing screw 1 20 Nm 14 75 lbf ft Loctite 542 GEAR INTERNAL CONTROLS pos Description Type Qu...

Page 37: ...nt 1 10 Nm 7 37 lbf ft Loctite 243 3 Oil sump pipe 1 20 Nm 14 75 lbf ft Loctite 648 4 Oil filter 1 15 Nm 11 06 lbf ft Engine oil 5 Rose pipe fixing screw M6 10 Nm 7 37 lbf ft 6 Maximum pressure valve cover M18 1 40 Nm 29 50 lbf ft Norge GT 8v Characteristics CHAR 37 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 38: ...OVER pos Description Type Quantity Torque Notes 1 Timing system cover cap fixing screw M6x20 2 10 Nm 7 37 lbf ft Loctite 243 2 Timing system cover fixing screw M8x55 4 25 Nm 18 44 lbf ft 3 Timing system cover fixing screw M6x30 9 12 Nm 8 85 lbf ft 4 Generator cover fixing screw M6x16 5 12 Nm 8 85 lbf ft Characteristics Norge GT 8v CHAR 38 Revente Interdite Revendita Vietata Resaling Forbiden Wiede...

Page 39: ...ver fixing screw SWP 5x20 7 3 Nm 2 21 lbf ft 2 Air temperature sensor fixing screw SWP 2 9x12 2 2 Nm 1 47 lbf ft 3 Air filter box front fixing screw M6x20 2 4 Nm 2 95 lbf ft Norge GT 8v Characteristics CHAR 39 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 40: ...utch to crankshaft fixing screw 6 42 Nm 30 98 lbf ft Tighten with cross sequence 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 lbf ft Loctite 243 3 Start up crown fixing screw on flywheel 6 10 Nm 7 37 lbf ft Loctite 243 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 lbf ft Loctite 243 Characteristics Norge GT 8v CHAR 40 Revente Interdite Revendita Vietata Resaling Forb...

Page 41: ...243 2 Connecting rod screws 4 40 Nm 29 50 lbf ft Pre tightening 2 Connecting rod screws 4 80 Nm 59 00 lbf ft Final tightening 3 Right hydraulic tensioner cover 1 42 Nm 30 98 lbf ft 4 Left hydraulic tensioner cover 1 30 Nm 22 13 lbf ft Norge GT 8v Characteristics CHAR 41 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 42: ...ank M5x16 4 6 Nm 4 42 lbf ft BLOW BY SYSTEM pos Description Type Quantity Torque Notes 1 Blow By tank fixing screw SWP M5x14 2 3 Nm 2 21 lbf ft 2 Reduction joint for oil return pipe 1 20 Nm 14 75 lbf ft 3 Oil return pipe on sump 1 20 Nm 14 75 lbf ft Vaseline oil Characteristics Norge GT 8v CHAR 42 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 43: ...s 1 Starter motor fixing screw 2 25 Nm 18 44 lbf ft 2 Stud bolt 1 10 Nm 7 37 lbf ft 3 Starter motor cover fixing screw M6x10 2 8 Nm 5 90 lbf ft Norge GT 8v Characteristics CHAR 43 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 44: ... pressure valve cap 1 40 Nm 29 50 lbf ft OIL RADIATOR pos Description Type Quantity Torque Notes 1 Solenoid valve to radiator fixing screw M5x60 3 4 Nm 2 95 lbf ft 2 Radiator fixing pin on the grille M5 1 4 Nm 2 95 lbf ft 3 Radiator to grille fixing screw M5 1 4 Nm 2 95 lbf ft Characteristics Norge GT 8v CHAR 44 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 45: ...ng nut M10x1 25 4 42 Nm 30 98 lbf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 lbf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 lbf ft Loctite 243 5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 lbf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 lbf ft Norge GT 8v Characteristics CHAR 45 Revente Interdite Revendita Vietata Resali...

Page 46: ...cylinder head M5x10 2 8 Nm 5 90 lbf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 lbf ft TIMING SYSTEM CONTROL pos Description Type Quantity Torque Notes 1 Control timing system shaft support flange fixing screw M6x14 2 8 Nm 5 90 lbf ft 2 Bearing fixing screw M6x16 1 10 Nm 7 37 lbf ft Loctite 243 3 Driving gears locking nut on the crankshaft M25 1 200 Nm 147 51 lbf ft Loctite 601 4 Timing syste...

Page 47: ...ns on the selected diameter if it exceeds the value speci fied it is necessary to replace cylinders and pistons The pistons of an engine must be balanced a weight difference of up to 1 5 g 0 0033 lb is allowed PISTON CYLINDER SELECTION TYPES Specification Desc Quantity Piston 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 ...

Page 48: ...t the coupling ends are 120 degrees from each other CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON Specification Desc Quantity Top ring 0 030 0 065 mm 0 00118 0 00256 in Middle ring 0 020 0 055 mm 0 00079 0 00216 in Oil scraper ring 0 010 0 045 mm 0 00039 0 00177 in Gap between the end of the piston rings inserted in the cylinder Top and middle piston ring 0 40 0 65 mm 0 00158 0 00255 in Oil s...

Page 49: ...flange 54 019 54 0 mm 2 12673 2 12598 in Clearance between bushing and main journal clutch side 0 030 0 058 mm 0 00118 0 00228 in Slot packing system Fit both pistons on the connecting rods Working from both sides fit the gasket between the crankcase and the cylin der on the crankcase Fit both cylinders Take the left cylinder piston to TDC and lock crankshaft rotation Specific tooling 020675Y Serv...

Page 50: ...mm 0 0075 0 in gasket thickness 1 05 mm 0 0413 in Recommended products chart RECOMMENDED PRODUCTS Product Description Specifications AGIP RACING 4T 10W 60 Engine oil SAE 10W 60 As an alternative for rec ommended oils use top branded oils that meet or exceed the requirements of CCMC G metricconverter productid 4 A w st on 4 A metricconverter PI SG specifications AGIP GEAR SAE 80 W 90 Transmission o...

Page 51: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 52: ...over insertion 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 Norge GT 8v S TOOLS 52 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 53: ...and the starting ring gear 12 91 36 00 Tool to remove the flywheel side flange AP8140179 Support for valve fitting removal AP9100838 Tool for valve pressure plate 14 92 71 00 Tool to fit the sealing ring on the flywheel side flange Norge GT 8v Special tools S TOOLS 53 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 54: ...it the seal 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 020676Y Comparator support for piston position checking Special tools Norge GT 8v S TOOLS 54 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 55: ...r for fixing ring nut of the clutch shaft internal body CICLISTICA Stores code Description 020884Y 46 mm wrench for steering ring nut BEVEL GEAR SET Stores code Description 05 90 27 30 Gearbox support Norge GT 8v Special tools S TOOLS 55 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 56: ...all joint sealing buffer 05 90 27 34 Wrench for pinion ring nut 05 90 27 35 Pinion oil seal buffer FORCELLA ANTERIORE Stores code Description 9100903 Marzocchi fork oil seal ø 45 mm 1 77 in Special tools Norge GT 8v S TOOLS 56 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 57: ...Stores code Description AP8140146 Weight AP8140149 Protection for fitting operations Norge GT 8v Special tools S TOOLS 57 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 58: ...INDEX OF TOPICS MAINTENANCE MAIN Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 59: ...O I I I I I I I I Throttle body C C C C Transmission cables and controls I I I I I I I I I Alternator belt A A R A A Steering bearings and steering clearance I I I I I I I I I Wheel bearings I I I I I I I I Brake discs I I I I I I I I I Air filter I R I R I R I R Engine oil filter 5 R R R R R R R R R Fork I I I I I Vehicle general operation I I I I I I I I I Braking systems I I I I I I I I I Light...

Page 60: ...LUID WHEN USING A FUNNEL OR ANY OTHER EL EMENT MAKE SURE IT IS PERFECTLY CLEAN Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN NOTE RIDE SOME km miles TO WARM UP ENGINE OIL Place a container with 400 cm 25 cu in capacity under the drainage plug 3 Unscrew and remove the drainage plug 3 Unscrew and remove the breather...

Page 61: ...LL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER A TRIP OR AFTER TRAVELLING APPROXIMATELY 15 km 10 mi OUT OF TOWN ENOUGH TO WARM UP ENGINE OIL TO OPERATING TEMPERATURE Switch off the engine and wait at least five minutes to allow the lubricant to drain back into the sump Keep the vehicle upright with both wheels on the ground Remove the oil leve...

Page 62: ...rew and remove the drainage plug Remove the oil level inspection cover on the left fairing Remove the dipstick for checking the oil level 1 Drain the oil into the container allow several minutes for oil to drain out com pletely Check and if necessary replace the sealing washers of drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Screw and tighten the drainage plug 2 Po...

Page 63: ...at 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 WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM 10 miles Stop the engine Keep the vehicle upright with the two wheels on the ground Remov...

Page 64: ...tainer 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 Pour in new oil until it reaches the dipstick open ing 1 Tighten the filler cap 1 CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID WHEN USING A FUNNEL ...

Page 65: ... so that no foreign bodies could get into NOTE DO NOT START THE ENGINE WITHOUT THE AIR FILTER TO CLEAN THE FILTERING ELEMENT USE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE Checking the valve clearance Remove the fuel tank Remove the side fairing by unscrew ing the three screws Norge GT 8v Maintenance MAIN 65 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 66: ...plug boots Unscrew and remove the four head cover fixing screws and collect the sealing O rings Remove the head cover together with the gasket Loosen the nut 1 Use a screwdriver to act on set screw 2 until the following clearances are obtained Technical specifications Values valid with control clearance between rockers and valve Inlet valve 0 15 mm 0 0059 in Exhaust valve 0 20 mm 0 0079 in Mainten...

Page 67: ... the same level with the plug Make sure that the fluid level in the reservoir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN reference mark Check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid Top up Front brake Unscrew the two screws 1 of the brake fluid reservoir 2 using a Phillips ...

Page 68: ...ERVOIR 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 EXCEED THE MAX LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS CHEC...

Page 69: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 70: ...4 10 Nm 7 37 lbf ft 4 Coil fixing screw to the support plate M4x25 8 2 Nm 1 47 lbf ft 5 Timing sensor fixing screw M5x12 2 6 Nm 4 42 lbf ft 6 Oil temperature sensor support fixing screw M10x20 1 11 Nm 8 11 lbf ft Loctite 243 7 Oil temperature sensor 1 12 Nm 8 85 lbf ft Kluber Wolfacoat Grease 8 Spark plug 2 15 Nm 11 06 lbf ft Electrical system Norge GT 8v ELE SYS 70 Revente Interdite Revendita Vie...

Page 71: ...arrangement Key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve potentiometer Norge GT 8v Electrical system ELE SYS 71 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 72: ...ture sensor Electrical system installation INTRODUCTION Scope and applicability The purpose of this document is to define how cable harnesses are laid and fixed to the motorcycle and foresee potential problems special checks on connections and layouts in order to attain the vehicle reliability objectives Materials used and corresponding quantities The electrical system consists of the following ca...

Page 73: ... 2 Relay support rubber ring No 1 Horn No 1 Fall sensor No 1 Fall sensor rubber ring No 1 External air temperature sensor No 1 Locks kit No 1 Front stop switch No 1 Rear stop switch No 1 Clutch switch No 1 Plug Socket No 1 Fuel pump and reserve sensor No 1 YTX20 BS battery No 1 Battery Cover No 1 Oil T Fan No 1 Thermometric switch No 1 Left Device No 1 Right Device No 1 Left Bracelet No 1 Right Br...

Page 74: ...t ABS sensor No 1 Rear ABS sensor Small parts and mountings No 3 large clamps 7 6x380 No 22 medium clamps 3 6X20 6 No 1 small clamps 2 4x92 No 2 Clips 2 different types No 1 Bracket No 2 Bushings No 2 TE FL M6x35 screws No 7 Rubber rings 3 different types No 6 T Bushings 2 different types No 1 FL M6 self locking nut No 1 TE FL M6x12 screw No 2 TE FL M6x20 screw No 8 TCEI M4x25 screw No 8 4 3X8X0 5...

Page 75: ...operator in charge of assemble must verify the correct connection and tightening of any Secondary Lock and uncheck the connector with a mark of indelible ink Instrument Panel Connector Immobilizer connector Pick up connector Side Stand Switch Connector Right Cylinder and Left Cylinder Coil Connectors Right and Left Injector Connectors Stepper Connector and Throttle Sensor Starter Command Connector...

Page 76: ... areas are followed meticulously in order to guarantee functionality and reliability Front side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION FRONT SECTION TABLE A DRIVING CABLE HARNESS PREP...

Page 77: ...dshield button stop switch right heated hand grip e throttle grip 2 Clamps FRONT SECTION TABLE B1 RIGHT LIGHT SWITCH 1 Connect the faston of the brake switch taking care not to bend it 2 Right heated hand grip cable Norge GT 8v Electrical system ELE SYS 77 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 78: ...s FRONT SECTION TABLE C1 LEFT LIGHT SWITCH 1 Clutch switch wired 2 UP button connector to be connect to N A but ton FRONT SECTION TABLE C2 LEFT LIGHT SWITCH 1 The cable coming from the right half handlebar pass through the forks present on the chassis Electrical system Norge GT 8v ELE SYS 78 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 79: ...mmobilizer connector 4 Left light switch connectors 5 Windshield driving engine connector 6 Clip Connectors 3 4 5 must pass through clip 6 FRONT SECTION TABLE D2 FRONT MAIN CABLE HARNESS 1 Main cable harness connection driving cable harness 2 Insert the clip on the cable harness lowest hole 3 Clamp 4 Instrument panel air temperature connector 5 Instrument panel air temperature sensor wired 6 Low b...

Page 80: ... D5 FRONT MAIN CABLE HARNESS 1 Right headlamp connector 2 Left headlamp connector The connectors of the left and right front headlamp can be connected interchangeably without causing malfunctions and must be located behind the main cable harness branch Electrical system Norge GT 8v ELE SYS 80 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 81: ... Brake pipe fixing plate 2 Chassis fork 3 Front ABS sensor cable FRONT SECTION TABLE F TURN INDICATORS 1 Cable guide 2 Right turn indicator connector 3 Left turn indicator connector Norge GT 8v Electrical system ELE SYS 81 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 82: ...C TRICAL SYSTEM INSTALLATION SECTION CENTRAL SECTION TABLE A ELECTRIC FAN CABLE HARNESS PREPARATION 1 Electric fan connector 2 Clamps 3 Clip TABLE A1 ELECTRIC FAN CABLE HARNESS PREPARATION 1 Electric fan connector TABLE A2 ELECTRIC FAN CABLE HARNESS PREPARATION 1 Electric fan connector 2 Electric fan cable harness Electrical system Norge GT 8v ELE SYS 82 Revente Interdite Revendita Vietata Resalin...

Page 83: ...le harness with the pipe TABLE B1 MAIN CABLE HARNESS ON THE CHASSIS 1 Horn 2 Clamp 3 Faston Horn x2 TABLE B2 MAIN CABLE HARNESS ON THE CHASSIS 1 Clamp 2 The main cable harness in the central area of the motorbike passes inside the chassis Norge GT 8v Electrical system ELE SYS 83 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 84: ...E CHASSIS 1 Arrange the connectors of the right light switch device to the connection 2 The instrument panel branch must be passed through the upper triangle of the chassis 3 The lambda sensor branch front turn indicator and coil must be passed through the lower triangle of the chassis TABLE C COILS 1 Left coil 2 Right coil 2 Coil connectors 3 Ground terminals Electrical system Norge GT 8v ELE SYS...

Page 85: ...ct the sub branch with three connectors of which one blue engine cylinder head temperature and direct it towards the right side of the motorbike Spread the injection branch inside the V of the en gine so that the grey belt is positioned at the height of the two bolts TABLE E ENGINE CYLINDER HEAD TEMPER ATURE 1 Engine cylinder head connector Norge GT 8v Electrical system ELE SYS 85 Revente Interdit...

Page 86: ...ABLE G 1 Pick up 2 Front ABS sensor connector TABLE H OIL PRESSURE SENSOR 1 Oil pressure sensor 2 Grey sheathing of the oil pressure sensor cable harness reference TABLE I INJECTORS 1 Right injector connector 2 Left injector connector Electrical system Norge GT 8v ELE SYS 86 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 87: ...lectric fan cable harness connector 5 Clamp TABLE L 1 Alternator eyelet 2 Generator connector 3 Alternator 4 Right device connectors 5 Alternator eyelet hood After having tightened the eyelet fit the alternator hood Norge GT 8v Electrical system ELE SYS 87 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 88: ...on relay 1 4 Start up relay 5 Maintenance relay TABLE N 1 Fuel pump connector 2 Rear ABS sensor connector 3 Rear stop switch connector Electrical system Norge GT 8v ELE SYS 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 89: ...motor 2 Clamp 3 Battery ground cable harness path engine ground TABLE Q 1 Starter motor connector 2 Starter motor eyelet 3 Clamp 4 ABS ECU connector The hood of the ABS ECU connector must be bent toward the front of motorcycle TABLE R 1 Neutral switch connector faston Norge GT 8v Electrical system ELE SYS 89 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 90: ... lambda connector 3 Clamps 4 Clamp with which the electric fan cable harness must be held 5 Right lambda sensor 6 Left lambda sensor Each lambda cable must be connected with two clamps Electrical system Norge GT 8v ELE SYS 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 91: ...nnector and the ABS control unit must be 7 5 mm 0 29 in TABLE U2 WRONG ASSEMBLY If the initial position of the connector and the pulling level is not as the one previously shown the connector will not hook correctly and the distance measured will be higher than approxi mately 12 mm 0 47 in In this case repeat the connection operations Back side TABLE A 1 Clamp 2 Plug socket 3 Fit the hood carefull...

Page 92: ...tor connectors TABLE D 1 Battery 2 Positive pole red heat shrinking 3 Negative pole TABLE E 1 Secondary fuse box ECU diagnosis connectors and instrument panel diagnosis Electrical system Norge GT 8v ELE SYS 92 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 93: ...EAR ABS SENSOR 1 Cable grommets TABLE G1 REAR ABS SENSOR 1 Rear brake switch cable harness 2 Clamp 3 Rear ABS sensor cable harness Norge GT 8v Electrical system ELE SYS 93 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 94: ...ultiple connectors 2 Clutch switch 3 Start up relay 4 Start up maintenance relay 5 High low beam Relay lights Electrical system Norge GT 8v ELE SYS 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 95: ...unit 23 Front wheel speed sensor 24 Rear wheel speed sensor 25 Secondary fuses 26 Starter motor 27 Main fuses 2 28 Main fuses 1 29 Battery 30 12 V Plug socket 31 Alternator 32 Main injection relay 33 Secondary injection relay 34 Oil pressure sensor 35 Neutral sensor 36 Lambda sensor 1 SX 37 Side stand switch 38 Fuel level sensor 39 Fuel pump 40 Water Temperature Sensor 41 Electric fan 42 Intake ai...

Page 96: ...ndicator 56 Complete front headlamp 57 Tail light bulb 58 Low beam bulb 59 High beam bulb 60 Front right turn indicator 61 62 Instrument panel diagnosis 63 ECU Diagnosis 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 Ro pink Checks and inspections Electrical system Norge GT 8v ELE SYS 96 Revente Interdite Revendita Vietata Resali...

Page 97: ...ODE Once the operation is finished the instrument panel goes back to the SET UP menu DIAGNOSIS Access to this menu diagnosis functions for the technical service only after requesting a service code It will read ENTER THE SERVICE CODE This vehicle code is 10695 The functions in this menu are Exit ECU diagnosis Instrument Panel Errors Error Clearing Reset Service Update Change Keys km Miles ECU ERRO...

Page 98: ...MENT PANEL ERRORS In this mode a chart is displayed showing potential errors in the immobilizer and its sensors This is the error decoding chart Description 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 ...

Page 99: ...GE FUNCTION This function can be used 1 if one key is lost the dealer can disable this key 2 to activate up to 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 ...

Page 100: ... 300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11 25 litres 20 43 pt 10 20 Ohm with 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 Servi...

Page 101: ...ted 2 b 15A fuse Daylight running lights number plate light starter motor electric fan starter relay 3 c 15A fuse Fuel pump coils injectors 4 d 10A fuse Oxygen sensor 1 and 2 heater secondary injection relay 5 e 3A fuse Permanent positive ECU power supply ignition relay coil 6 f 10A fuse Key on positive ABS ECU activation instrument panel activation 7 3A 10A 15A Spare fuses Norge GT 8v Electrical ...

Page 102: ...orcycle fuse 3 I 20A fuse Low beam high beam fuse 4 J 20A fuse Main ABS fuse 5 20A QUANTITY 2 30A 40A Spare fuses Control unit Model Magneti Marelli IAW 5 AM2 Battery 12 V 18 Ampere hour Electrical system Norge GT 8v ELE SYS 102 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 103: ...nector If it is not OK restore the connectors if it is OK check continuity of the cable between sensor PIN 2 on the cable harness side and PIN 14 ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor on the cable harness side with the sensor disconnected and key set to ON must have 12V voltage approximately if there is no voltage check PIN 2 for continui...

Page 104: ...ion Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it ...

Page 105: ...le harness If it is OK replace the sensor LOGIC ERRORS Speed sensor 5DA1 the signal works irregularly faulty sensor or signal interference Troubleshooting Check speed sensor retainer If it is not OK restore it If it is OK check if the tone wheel is dirty deformed or wrongly fixed If any of this happens replace the tone wheel Otherwise replace the speed sensor 5DA2 the signal decreases periodically...

Page 106: ...re not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK check that the tyre size is the correct one If it is not OK replace it If it is OK check that the tyre pressure is the correct one If it is not O...

Page 107: ...if there is continuity check the interruption on the sensor and replace it WARNING If the electric circuit is short circuited no error is displayed Check the sensor electrical specifications If they are not correct replace the sensor If correct check supply insulation and ground connection insulation of both cables Perform the tests from the sensor connector towards the sensor If they are not OK r...

Page 108: ... AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER NAVIGATOR FUEL INJECTION SYSTEM NAVIGATOR PARAMETERS Throttle Example value 4 9 NAVIGATOR STATUSES Throttle position Example value Released Pressed Full load Indicates if the throttle potentiometer is open or closed in the released position NAVIGATOR ERRORS Throttle actuator position sensor P0120 Example value open circuit shorted to positive s...

Page 109: ...t operation to be carried out after the throttle body is cleaned or in the case a new engine a new lambda probe or a new injector is fitted or the correct operation of the injection system or the valves is restored NAVIGATOR RESET PROCEDURE Once the throttle body or the injection control unit is replaced it is necessary to connect to the diagnosis instrument selecting FUEL INJECTION and carry out ...

Page 110: ...R PARAMETERS Engine temperature In case of recovery this value is set by the control unit NAVIGATOR ERRORS engine temperature sensor P0115 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 5 of connector A BROWN If shorted to negative voltage equal to zero has been detected at PIN 5 of the BROWN co...

Page 111: ... control unit connector Air temperature sensor Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti mise the petrol quantity necessary for correct com bustion Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in electrical circuit diagram Temperature sensors Location sensor on filte...

Page 112: ...ection 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 14 and PIN 2 of the sensor should be restored If the engine temperature sensor error is displayed at the same time this means that the grey cable common for both sensors is shorted to positiv...

Page 113: ...al grey wire 3 Heater ground connection white 4 Heater power supply white NAVIGATOR PARAMETERS Lambda sensor example value 0 1000 mV If there is a short circuit at 5 V or above the value read is approx 5 000 mV If there is a short circuit to ground instead the value read is equal to 0 mV and the Lambda Sensor Correction parameter shows 25 no error is displayed though Lambda sensor correction examp...

Page 114: ...unit connector If not OK restore If OK and with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if not ok check the red black cable cable harness side between the probe connector and the auxiliary injection relay No 33 in the wiring diagram located under the saddle left rear relay in the relay group attached to the fall sensor CHECK however the identifica...

Page 115: ... replace the sensor if not OK if it is OK restore the cable harness circuit is open shorted to negative check the continuity from probe connector PIN 3 and 4 towards the probe if not OK replace the probe if it is correct check the sensor connector and the Marelli control unit connector If not OK restore If OK and with key set to ON and sensor connector disconnected check if there is battery voltag...

Page 116: ...n the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C Pin out Supply Ground connection NAVIGATOR FUEL INJECTION SYSTEM NAVIGATOR PARAMETERS Injection time NAVIGATOR ACTIVATION Left injector operation for 4 ms 5 times The auxiliary injection relay no 33 in the wiring diagram placed under the saddle left rear relay in the relay group attached to the fall sensor CH...

Page 117: ...re not OK restore If OK check cable continuity between PIN 28 of the BROWN connector and PIN 2 of the component and restore the cable harness NAVIGATOR ACTIVATION Right injector Operation for 4 ms 5 times The auxiliary injection relay no 33 in the wiring diagram placed under the saddle left rear relay in the relay group attached to the fall sensor CHECK however the identification of the relay with...

Page 118: ...ontrol unit connector If they are not OK restore If OK check cable continuity between PIN 33 of the BROWN connector and PIN 2 of the component and restore the cable harness Coil Function It controls the ignition spark plug in order to gen erate the fuel ignition spark Operation Operating principle Inductive discharge system Level in electrical circuit diagram Coils and in jectors Location In front...

Page 119: ...n 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 continuity with the key set to KEY ON check the cable ground insulation from coil connector or control...

Page 120: ...y 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 pressure 0 35 0 15 bar 5 1 2 18 PSI in the engine Operation Operating principle normally closed switch With oil pressure above 0 35 0 15 bar 5 1 2 18 PSI open circuit Lev...

Page 121: ...ear position to the control unit in neutral or in gear Operation Operating principle for gear in neutral the circuit is closed to ground connection then via CAN the control unit sends the signal to the instrument panel which turns on the neutral speed warning light Level in electrical circuit diagram start up enabling switches Location Sensor rear upper side of the gearbox Connector on the sensor ...

Page 122: ... 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 restore the cable harness Clutch lever sensor Function It tells the clutch lever position to the control unit Operation Operating principle If the gear is engaged ...

Page 123: ... 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 and the side stand is unfolded and therefore the circuit is open the control unit does not enable vehicle start up or shuts off the engine if it is rotating Level in electrical cir...

Page 124: ... fuel pump circuit and the engine start up circuit via the injection relay Level in electrical circuit diagram Start up ena bling switches Location Sensor under the saddle right side Connector near the sensor Electrical characteristics Sensor in vertical position open circuit resistance 62 kOhm Sensor inverted closed circuit resist ance below 0 5 kOhm Pin out 1 Voltage 12V 2 Ground connection NAVI...

Page 125: ... sensor resistance sensor inversely variable with temperature Level in electrical circuit diagram Temperature sensors Location Sensor under the instrument panel Connector under the instrument panel Electrical characteristics Resistance at 0 C 32 F 32 5 kOhm 5 Resistance at 25 C 77 F 10 0 kOhm 5 Pin out 1 Voltage 5V 2 Ground connection Instrument panel Air temperature sensor failure DSB 06 Error ca...

Page 126: ...strument panel connector the display will show a full scale air temperature indication of 60 C 140 F Check the ground 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 RUN STOP switch Function It tells the contro...

Page 127: ...und 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 not OK restore the cable harness if OK replace the Marelli control unit Indication on Navigator always RUN disconnect the connector and with the switch set ...

Page 128: ...trol 29 Ignition potentiometer negative 30 Not used 31 Not used 32 Ignition potentiometer power supply 33 Not used 34 Revolution sensor anti jamming cable 35 Engine revolution sensor signal 36 Not used 37 Right cylinder injector control 38 Left cylinder coil control BLUE connector pin configuration Pin Use 1 Oxygen probe negative control 2 right 2 Not used 3 Not used 4 Power supply protected from ...

Page 129: ...22 Lambda sensor 1 input left 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 Engine stop signal input 28 Ignition signal input 29 CAN L line ccm instrument panel 30 Not used 31 Lambda sensor 2 input right 32 Lambda sensor 1 input left 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal Norge GT 8v Electrical system ELE...

Page 130: ... PIN USE 1 KEY 2 RIGHT TURN INDICATOR CONTROL 3 OIL PRESSURE SENSOR 4 HIGH BEAM LIGHT INPUT Electrical system Norge GT 8v ELE SYS 130 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 131: ... 21 BATTERY 22 BATTERY 23 LOW BEAM LIGHT RELAY ACTIVATION 24 25 HEATED HANDGRIP CONTROL 26 CAN L 27 CAN H 28 K LINE 29 ABS INPUT 30 AERIAL 1 31 32 33 34 RIGHT REAR TURN INDICATOR ACTIVATION 35 RIGHT FRONT TURN INDICATOR ACTIVATION 36 LEFT REAR TURN INDICATOR ACTIVATION 37 LEFT FRONT TURN INDICATOR ACTIVATION 38 LEFT HEATED HANDGRIP ACTIVATION 39 RIGHT HEATED HANDGRIP ACTIVATION 40 AERIAL 2 Norge G...

Page 132: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 133: ...block proceed as follows From the back secure the vehicle with belts attached to a hoist From the front secure the vehicle with belts attached to the handlebar and fixed to the work bench Place the engine service stand under the oil sump Disconnect the battery Remove the upper fairings and the fairing lug Remove the exhaust system the swingarm with cardan shaft and the fuel tank Remove the air fil...

Page 134: ... Working on both sides disconnect the injector connectors Undo and remove the cable guide screw on the generator cover Disconnect the throttle cables Engine from vehicle Norge GT 8v ENG VE 134 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 135: ...or Disconnect the revolution sensor con nector Disconnect the alternator connectors Disconnect the gear in neutral sensor connector Norge GT 8v Engine from vehicle ENG VE 135 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 136: ...rt er motor Unscrew 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 Engine from vehicle Norge GT 8v ENG VE 136 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 137: ... Disconnect the oil pressure sensor connector Disconnect the oil temperature sensor connector Working from both sides loosen the intake manifold clamps Norge GT 8v Engine from vehicle ENG VE 137 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 138: ...ERATIONS BELOW AIDED BY A SEC OND OPERATOR Working on both sides unscrew and remove the front screw and collect the washer Unscrew and remove the upper nut fix ing the engine and collect the washer Remove the upper pin and collect the washer Engine from vehicle Norge GT 8v ENG VE 138 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 139: ... hoist From the front secure the vehicle with belts attached to the handlebar and fixed to the work bench Lift the engine placing it in position AT LEAST UNTIL THE LOWER ENGINE BOLT IS TIGHTENED PERFORM THE OPERATIONS DESCRIBED AIDED BY A SECOND OPERATOR 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 Norge GT 8v Engine ...

Page 140: ...t with the washer From the opposite side fit the washer and tighten the nut Working on both sides tighten the front screw to the prescribed torque Fit the throttle body onto the intake manifolds Tighten the clamps on both sides to the specified torque Engine from vehicle Norge GT 8v ENG VE 140 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 141: ...o the engine with new clamps Connect the oil pressure sensor Connect the oil temperature sensor Fit the gearbox oil breather pipe Norge GT 8v Engine from vehicle ENG VE 141 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 142: ... screws Connect the starter motor connectors Connect the ground leads and tighten the stud bolt Connect the neutral sensor connector Engine from vehicle Norge GT 8v ENG VE 142 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 143: ...evolution sensor connec tor Connect the engine temperature sen sor connector Connect and adjust the throttle grip ca ble clearance Norge GT 8v Engine from vehicle ENG VE 143 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 144: ...s Working from both sides connect the spark plug tube Install the fuel tank Position the upper fairings and the fair ing lug Install the complete exhaust Re connect the battery Fit the saddle Engine from vehicle Norge GT 8v ENG VE 144 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 145: ...INDEX OF TOPICS ENGINE ENG Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 146: ...Gearbox Diagram Key 1 Ball bearing Engine Norge GT 8v ENG 146 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 147: ...bearing 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 Norge GT 8v Engine ENG 147 Revente Interdite Revendita Vietata Resaling Forbiden Wiederv...

Page 148: ...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 Norge GT 8v ENG 148 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 149: ... suitable capacity under it unscrew and remove the cap and then bleed all gearbox oil Loosen and turn the oil pipe joint on the sump Undo and remove the three screws Norge GT 8v Engine ENG 149 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 150: ...two screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts Engine Norge GT 8v ENG 150 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 151: ...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 Norge GT 8v Engine ENG 151 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 152: ...fic 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 using the specific tool Specific tooling 05 91 25 30 Gearbox opening Engine Norge GT 8v ENG 152 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 153: ...lease the spring Pressing the selector slide off the whole transmission lever Use rubber bands to tie down the trans mission shaft unit and extract it Norge GT 8v Engine ENG 153 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 154: ...h remove the rubber bands being careful with the group Detach the shafts and label the forks before removal Remove the forks and collect the shaft Engine Norge GT 8v ENG 154 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 155: ... gearbox Removing the primary shaft 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 Norge GT 8v Engine ENG 155 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 156: ...lect the shoulder washer Remove the circlip Remove the gear of the third and fourth gears Remove the circlip and collect the shoulder washer Engine Norge GT 8v ENG 156 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 157: ...a specific heater and remove the helical transmission gear Removing the secondary shaft Remove the transmission shaft Operate on the shaft from the grooved side Remove the shoulder washer Norge GT 8v Engine ENG 157 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 158: ...e ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the sixth gear Remove the circlip and collect the shoulder washer Engine Norge GT 8v ENG 158 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 159: ...earing cage Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the fifth gear Norge GT 8v Engine ENG 159 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 160: ...ar and replace those damaged if necessary Check the transmission gears movement and if it is not regular replace the damaged part Checking the secondary shaft Measure the coaxiality of the transmission shaft with a dial gauge and 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 pitti...

Page 161: ...ssion fork cam roller 1 and the transmission fork tooth 2 for damage deformation and wear Replace the transmission fork if nec essary Check the transmission fork move ment and if it is not regular replace the transmission forks See also Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER REMEMBER TO REPLACE ALL SEALING ...

Page 162: ...t 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 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 con...

Page 163: ... selector GEAR INTERNAL CONTROLS pos Description Type Quantity Torque Notes 1 Spring guide pin 1 24 Nm 17 70 lbf ft Loctite 243 Norge GT 8v Engine ENG 163 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 164: ... 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 Engine Norge GT 8v ENG 164 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 165: ... upper fixing screw M8 1 22 Nm 16 23 lbf ft 3 Generator lower fixing screw M10x60 1 30 Nm 22 13 lbf ft GENERATOR COVER pos Description Type Quantity Torque Notes 1 Timing system cover cap fixing screw M6x20 2 10 Nm 7 37 lbf ft Loctite 243 Norge GT 8v Engine ENG 165 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 166: ...cover fixing screw M6x16 5 12 Nm 8 85 lbf ft Removing the generator Remove the fuel tank Remove the control unit from its 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 Engine Norge GT 8v ENG 166 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 167: ...do the set screw so that the alternator slides down Completely loosen and remove the screw Remove the belt and the alternator with pulley Norge GT 8v Engine ENG 167 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 168: ...w and remove the nut and collect the spacer Remove the lower pulley Undo and remove the eight screws Undo and remove the two screws Engine Norge GT 8v ENG 168 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 169: ...Collect the spacers Undo and remove the five screws fixing the alternator belt cover Remove the oil radiator lower support bracket and the alternator belt cover Locking torques N m Alternator belt cover screw radiator bracket retainer TCEI M6x40 2 10 Nm 7 38 lbf ft Alter nator belt cover screw TCEI M6x16 4 10 Nm 7 38 lbf ft Norge GT 8v Engine ENG 169 Revente Interdite Revendita Vietata Resaling Fo...

Page 170: ... the belt tensioning tool tension the belt to the prescribed torque Screw the set screw Tighten the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning Locking torques N m Belt tension 50 Nm 36 88 lbf ft See also Engine oil cooler Engine Norge GT 8v ENG 170 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 171: ...cover sealing ring punch Place the bolt and the pin in the gen erator cover Replace the gasket and place the al ternator frame using the front cover in sertion cone Remove the insertion cone afterwards Specific tooling 05 91 17 30 Front cover insertion cone Tighten the two screws Norge GT 8v Engine ENG 171 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 172: ...nator fitting Tighten the four screws operating di agonally and in stages Position the lower pulley and the spacer Tighten the nut to the prescribed tor que Position the alternator and the timing system belt Engine Norge GT 8v ENG 172 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 173: ...belt to the prescribed torque and tighten the set screw Remove the belt tensioning tool Lock the set screw in position by screwing the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning Norge GT 8v Engine ENG 173 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 174: ...cover Tighten the five screws operating diag onally and in stages Starter motor Removing the starter motor Undo and remove the two screws and collect the washers Engine Norge GT 8v ENG 174 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 175: ...sassembling the clutch Key 1 Complete clutch 2 Clutch 3 Clutch bell 4 TCEI screw 5 Clutch plate 6 Sprocket 7 TCEI screw 8 Clutch thrust plate Norge GT 8v Engine ENG 175 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 176: ...ty Torque Notes 1 Clutch to crankshaft fixing screw 6 42 Nm 30 98 lbf ft Tighten with cross sequence 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 lbf ft Loctite 243 3 Start up crown fixing screw on flywheel 6 10 Nm 7 37 lbf ft Loctite 243 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 lbf ft Loctite 243 Engine Norge GT 8v ENG 176 Revente Interdite Revendita Vietata Re...

Page 177: ...he six screws Remove the start up crown gear Remove the clutch bell and the friction disc Remove the retainer ring Remove the clutch pressure plate Norge GT 8v Engine ENG 177 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 178: ...ure 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 Engine Norge GT 8v ENG 178 Revente Interdite...

Page 179: ...m 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 tighte...

Page 180: ...Place 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 Engine Norge GT 8v ENG 180 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 181: ... Torque Notes 1 Special cylinder head fixing screw 8 8 Nm 5 90 lbf ft Locked with cross sequence 2 Spark plug cover fixing screw M5x10 2 8 Nm 5 90 lbf ft Norge GT 8v Engine ENG 181 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 182: ...support fixing screw 6 18 Nm 13 28 lbf ft LEFT CYLINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 lbf ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 lbf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 lbf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 lbf ft 4 P...

Page 183: ...take 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 20 TE flanged screw 21 O ring Norge GT 8v Engine ENG 183 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 184: ... 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 tensioner 57 Spacer En...

Page 185: ...he 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 Unscrew and remove the two screws Remove the cap Norge GT 8v Engine ENG 185 Revente Interdite Revendita Vietata Resaling Forbiden Wiederve...

Page 186: ...d Unscrew and remove the chain ten sioner cap Remove the right chain tensioner For the left head Unscrew and remove the screw and the washer Relief oil pressure from the left chain tensioner Engine Norge GT 8v ENG 186 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 187: ...d bolts Remove the complete cam cap Unscrew 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 Norge GT 8v Engine ENG 187 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 188: ...AUTION 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 Engine Norge GT 8v ENG 188 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 189: ...oving 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 Norge GT 8v Engine ENG 189 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 190: ...rew until fitted and then hit the tool head 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...

Page 191: ... Specification Desc Quantity Valve guide inside 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 05...

Page 192: ...LY 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 spe...

Page 193: ...EVER Place the two rocking levers in the cam tower seats Place the U bolt on the rocking levers making sure the two reference pins match the seats on the cam tower Tighten the two screws operating diag onally and in stages See also Norge GT 8v Engine ENG 193 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 194: ...ful not to interchange 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 tower Tighten the four screws operating di agonally and in stages Engine Norge GT 8v ENG 194 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 195: ...Nm 147 51 lbf ft Loctite 601 4 Timing system driven gear locking nut M18 1 25 Nm 18 44 lbf ft Pre tightening 4 Timing system driven gear locking nut M18 1 150 Nm 110 63 lbf ft Final tightening Removing the phonic wheel Remove the generator and the timing system cover Unscrew and remove the nut and col lect the washer Remove the timing system gear on the service shaft Norge GT 8v Engine ENG 195 Rev...

Page 196: ...he tone wheel Remove both cylinders Undo and remove the two screws Remove the service shaft closing cap Mark the timing chains so as not to in vert the direction of rotation upon fit ting Slide off the service shaft from the chains Remove both chains See also Removing the phonic wheel Engine Norge GT 8v ENG 196 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 197: ...ough 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 Partially fit the service shaft closing cap To screw the cap until it stops use two M6 flanged screws larger than the orig inal screws Tighten the two M6 flanged screws op erating in stages until the cap stops against the crankcase Undo and remove the two...

Page 198: ...hain 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 Norge GT 8v ENG 198 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 199: ...e 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 the flywheel and the starting ring gear Fit the timing system gear and align the reference with that on the crankshaft gear Turn the crankshaft to align the two gears Norge GT 8v Engine ENG 199 Revente...

Page 200: ... 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 Norge GT 8v ENG 200 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 201: ...lign 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 Norge GT 8v Engine ENG 201 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 202: ... 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 Norge GT 8v ENG 202 Revente Interdite Revendita Vietata ...

Page 203: ...r piston ring 7 Pin 8 Retainer 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 Norge GT 8v Engine ENG 203 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 204: ...tite 243 2 Connecting rod screws 4 40 Nm 29 50 lbf ft Pre tightening 2 Connecting rod screws 4 80 Nm 59 00 lbf ft Final tightening 3 Right hydraulic tensioner cover 1 42 Nm 30 98 lbf ft 4 Left hydraulic tensioner cover 1 30 Nm 22 13 lbf ft Engine Norge GT 8v ENG 204 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 205: ...LINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 lbf ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 lbf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 lbf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 lbf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 ...

Page 206: ...he 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 ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Remove the cylinder Cover the crankcase opening with a clean cloth Release the snap ring Remove the pin Engine Norge GT 8v ENG 206 Revente Interdite Revendita Vietata Res...

Page 207: ...ooth 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 the flywheel and the starting ring gear Fit the piston NOTE CHECK THE PISTON DIRECTION ACCORDING TO THE REFERENCES MARKED ON THE PISTON CROWN DO NO...

Page 208: ... 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 cla...

Page 209: ...taut 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 Norge GT 8v Engine ENG 209...

Page 210: ...d 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 serv...

Page 211: ... 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 Norge GT 8v Engine ENG 211 Revente Interdite Revendita Vietata Resaling Forbiden Wiederver...

Page 212: ...ng system chain Place the gear in the chain On 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 cy...

Page 213: ...in On the right camshaft pin fit the hole marked 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 Al...

Page 214: ...ecking 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 Norge GT 8v ENG 214 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 215: ...ting 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 Norge GT 8v Engine ENG 215 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbo...

Page 216: ...ng 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 Norge GT 8v ENG 216 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 217: ...fication 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 imbal...

Page 218: ...e 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 regul...

Page 219: ...ng 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 ...

Page 220: ...it the sealing ring on the flange Specific tooling 19 92 71 00 Tool to fit the seal 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 221: ... vent 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 seal 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 N...

Page 222: ...pe on the cylinder head M14x1 5 2 20 Nm 14 75 lbf ft 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 lbf ft Apply vaseline oil 4 Oil delivery pipe to radiator slot screw M14x1 5 1 35 Nm 25 81 lbf ft 5 Jets fixing screw 3 Using a T spanner close by hand Loctite 243 6 Cover on the flange under the crankcase 1 20 Nm 14 75 lbf ft 7 Thermal switch 1 20 Nm 14 75 lbf ft 8 Minimum oil pres...

Page 223: ...lve to radiator fixing screw M5x60 3 4 Nm 2 95 lbf ft 2 Radiator fixing pin on the grille M5 1 4 Nm 2 95 lbf ft 3 Radiator to grille fixing screw M5 1 4 Nm 2 95 lbf ft Norge GT 8v Engine ENG 223 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 224: ... 18 lbf ft 4 Oil cap on the crankcase 2 25 Nm 18 44 lbf ft 5 Flange fixing screw under the crankcase M6x60 2 10 Nm 7 37 lbf ft 6 Flange fixing screw under the crankcase 2 10 Nm 7 37 lbf ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 lbf ft 8 Oil sump fixing screw M6 14 10 Nm 7 37 lbf ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 lbf ft 10 Magnetic oil drainage cap 1 20 N...

Page 225: ...r joint 1 10 Nm 7 37 lbf ft Loctite 243 3 Oil sump pipe 1 20 Nm 14 75 lbf ft Loctite 648 4 Oil filter 1 15 Nm 11 06 lbf ft Engine oil 5 Rose pipe fixing screw M6 10 Nm 7 37 lbf ft 6 Maximum pressure valve cover M18 1 40 Nm 29 50 lbf ft Norge GT 8v Engine ENG 225 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 226: ... 4 Oil pump body 5 Oil pump gasket 6 Rotor for lubrication 7 Rotor for cooling 8 Rotor control shaft 9 Oil pump cover 10 Oil pump control gear 11 Lubrication oil intake filter 12 Cooling oil intake filter Engine Norge GT 8v ENG 226 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 227: ...hes 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 parts to be lubricated Oil goes down to the sump again and joins the oil used for cooling Oil pump Removing Drain off the engine oil Remove the generator an...

Page 228: ...t 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 Undo and remove the three screws Remove the oil pump Engine Norge GT 8v ENG 228 Revente Interdite Revendita Vietata Resaling Forbiden Wied...

Page 229: ...ator 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 Place the driving pin on the oil pump shaft Norge GT 8v Engine ENG 229 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 230: ...lace 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 Insert the joint in the oil pump Engine Norge GT 8v ENG 230 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 231: ...RAIN 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 Undo and remove the fourteen screws fixing the oil sump to the engine crank case Norge GT 8v Engine ENG 231 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkau...

Page 232: ...ndo and remove the four screws Remove the flange Undo and remove the two screws Remove both filters Engine Norge GT 8v ENG 232 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 233: ... Remove the thermostatic valve Unscrew and remove the pressure re lief valve plug Remove the pressure relief valve com ponents Norge GT 8v Engine ENG 233 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 234: ...correctly Screw the pressure relief valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Tighten the thermostatic valve plug Engine Norge GT 8v ENG 234 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 235: ...flange Fix the flange with the four screws Fit the lubrication oil intake filter Check that the O rings are fitted on the oil pump Fit the cooling oil intake filter Norge GT 8v Engine ENG 235 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 236: ...hten it to the prescribed torque Place a new gasket between the flange and the sump Place the oil sump Tighten the fourteen screws to the pre scribed torque Add engine oil up to the correct level Engine Norge GT 8v ENG 236 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 237: ...INDEX OF TOPICS POWER SUPPLY P SUPP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 238: ...p support fixing screw to the tank M5x16 4 6 Nm 4 42 lbf ft THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake pipe fixing screw 6 10 Nm 7 37 lbf ft 2 Flange fixing screw on the throttle body M5x12 2 6 Nm 4 42 lbf ft Power supply Norge GT 8v P SUPP 238 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 239: ...iagram Key 1 Full fuel tank 2 Fuel pipe 3 Throttle body 4 Joint 5 Three way joint 6 Pipe Injection Norge GT 8v Power supply P SUPP 239 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 240: ...5 Coils 6 Instrument panel 7 Air temperature sensor 8 Throttle valve position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor Power supply Norge GT 8v P SUPP 240 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 241: ...serted in the air filter casing The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right Cylinders synchronisation With engine off connect the Navigator tool to the diagnosis connector and to the vehicle battery Norge GT 8v Power supply P SUPP 241 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 242: ...ent on the adjust ments screen page Autodetect the throttle position Turn the key to OFF and leave it for at least 30 seconds Turn the key back to ON and restore the instrument session Check that the Throttle value reading is 4 7 0 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 en...

Page 243: ...tween the two cylinders Otherwise open only the screw with higher depression using the by pass screws to compensate Recovery function If the signal of the 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 Navigator also signal the problem RECOVERY FUNCTION Specification Desc Quantity air...

Page 244: ...emperature of the air taken in by the engine measured by the sensor in the filter 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 par...

Page 245: ...tatus usually ON OFF of the vehicle devices or the operation con dition of some vehicle systems for example lamb da probe functioning status STATUSES 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 extended indicates the position of the side stand o...

Page 246: ...SA For 4 advancement command of 32 steps for the next 4 retrocession command of 32 steps and so on for 30 ERRORS screen page This screen page shows potential errors detected in the vehicle ATT or stored in the control unit MEM and it allows to check error clearing STO ERRORS Specification Desc Quantity Pressure sensor Possible short circuit in the earth lead battery or open circuit recovery functi...

Page 247: ...rcuit in the earth lead battery or open circuit Engine revolution sensor Possible open circuit Lambda heater Possible short circuit in the earth lead battery or lambda probe heating circuit open SPEED SENSOR CAN line diagnosis span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA Possible ...

Page 248: ...INDEX OF TOPICS SUSPENSIONS SUSP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 249: ...bf ft Loctite 243 3 Front tone wheel fixing screw 5 4 Nm 2 95 lbf ft Loctite 243 4 Front ABS sensor fixing screw M6 1 10 Nm 7 37 lbf ft Removing the front wheel Unscrew the speed sensor screw re lease the cable harness from the clamps Remove the speed sensor Norge GT 8v Suspensions SUSP 249 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 250: ...rt of the vehicle Remove the nut fixing the wheel pin Collect the sealing washer Loosen the screws on the wheel pin terminals Remove the wheel pin by inserting a screwdriver in the holes on the pin Suspensions Norge GT 8v SUSP 250 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 251: ... right side Installing the front wheel Position the wheel together with the right side spacer Insert the pin Screw the screws of the clamp nut side to lock the rotation of the wheel axle Norge GT 8v Suspensions SUSP 251 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 252: ...e wheel pin to the prescribed torque Fit the brake callipers tightening the fix ing screws to the prescribed torque CAUTION AFTER FITTING THE BRAKE CALLIPERS OPERATE THE FRONT BRAKE LEVER SEVERAL TIMES Fit the speed sensor Tighten the speed sensor screw Secure the speed sensor cable har ness with clamps Suspensions Norge GT 8v SUSP 252 Revente Interdite Revendita Vietata Resaling Forbiden Wiederve...

Page 253: ...ft 2 Half handlebar upper fixing screw on the up per steering yoke M8x25 STAIN LESS STEEL 4 20 Nm 14 75 lbf ft Loctite 243 3 Handlebar pipe fixing screw on the half han dlebar M8x30 2 18 Nm 13 27 lbf ft Loctite 243 4 Counterweight fixing screw M6x70 2 10 Nm 7 37 lbf ft Loctite 243 Norge GT 8v Suspensions SUSP 253 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 254: ...Wheel axle locking screw on the fork leg M6 4 10 Nm 7 37 lbf ft 2 Piston fixing screw to the sleeve M10x35 2 50 Nm 36 87 lbf ft 3 Fork cap 2 20 Nm 14 75 lbf ft Suspensions Norge GT 8v SUSP 254 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 255: ... Nm 73 76 lbf ft 4 Headstock ring nut M35 1 40 Nm 29 50 lbf ft 5 Headstock counter lock ring M35 1 Manually screw 6 Pipe stop plate fixing screw to the steering base M6x18 1 10 Nm 7 37 lbf ft Diagram KEY 1 Screw 2 Right sleeve 3 Left sleeve 4 Upper bushing 5 Cap 6 Sealing ring 7 Locking ring 8 Dust guard 9 Buffer 10 Washer 11 Screw Norge GT 8v Suspensions SUSP 255 Revente Interdite Revendita Vieta...

Page 256: ...body 27 O Ring 28 Rigging pin Removing the fork legs Undo the screws fixing the front mud guard and remove it Hold the motorcycle front section Remove the front wheel Unscrew the speed sensor screw re lease the cable harness from the clamps Remove the speed sensor See also Removing the Suspensions Norge GT 8v SUSP 256 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 257: ...emove them from their seats Support the stanchion and loosen the screws on the upper and then the lower plate See also Removing the front wheel Remove the fork stem Norge GT 8v Suspensions SUSP 257 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 258: ...careful not damage the O Ring during extrac tion Press the stem inside the wheel holder sleeve Remove the spring Be careful not damage the O Ring during extrac tion Press the stem inside the wheel holder sleeve Remove the spring Drain out all the oil inside the stem Collect the preload tube Suspensions Norge GT 8v SUSP 258 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbote...

Page 259: ... refill the stem otherwise replace the damaged elements Disassembling the fork Drain out all the oil in the stem Block the wheel holder sleeve with a vice Unscrew the bottom screw and remove it together with its gasket Remove the dust scraper using a screwdriver as a lever CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND THE DUST SCRAPER Norge GT 8v Suspensions SUSP 259 Revente Interdite Revend...

Page 260: ...ng sealing ring cap upper bushing and the entire pumping member NOTE WHEN REMOVING THE STEM FROM THE WHEEL HOLD ER SLEEVE SOME PARTS MAY REMAIN INSIDE THE SLEEVE IF THIS OCCURS THESE PARTS MUST BE RE MOVED AFTERWARDS BEING CAREFUL NOT TO DAM AGE THE SLEEVE RIM AND THE UPPER BUSHING SEAT Suspensions Norge GT 8v SUSP 260 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 261: ...RAIGHTENED 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 the spring is in good conditions Check that the following components are in good conditions upper bushing lower bushing piston If there are signs of excessive wear or damag...

Page 262: ...wing components with new ones seal ring dust gaiter O Ring on the cap Reassembling the fork CAUTION ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE FORE REFITTING Suspensions Norge GT 8v SUSP 262 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 263: ...e bushing is fitted on the wheel holder fork leg Insert the lower sliding bushing in the seat on the stem Refit the stem in the wheel holder fork leg pressing it until it stops Screw the bottom screw and tighten it to the prescribed torque Norge GT 8v Suspensions SUSP 263 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 264: ...ng in the stem Use a suitable inserting tool to push the sealing ring in the fork leg until it stops Fit the locking ring Fit the dust scraper Suspensions Norge GT 8v SUSP 264 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 265: ... gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Characteristic Quantity of single stanchion oil 540 2 cm 32 9 0 1 cu in Oil level from sleeve rim without the spring and preloading pipe 110 2 mm 4 33 0 08 in Insert the preload tube and the spring Norge GT 8v Suspensions SUSP 265 Revent...

Page 266: ...torque Installing the fork legs Insert the stanchion in position Insert the wheel pin so that the stems are aligned Tighten the screws on the fork plates to the prescribed torque Slide off the wheel axle Suspensions Norge GT 8v SUSP 266 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 267: ... on the lower plate M8x25 4 25 Nm 18 44 lbf ft 3 Upper yoke fixing cap M29 1 100 Nm 73 76 lbf ft 4 Headstock ring nut M35 1 40 Nm 29 50 lbf ft 5 Headstock counter lock ring M35 1 Manually screw 6 Pipe stop plate fixing screw to the steering base M6x18 1 10 Nm 7 37 lbf ft Norge GT 8v Suspensions SUSP 267 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 268: ...screw the screws on the cable re tainer plate Operating on both half handlebars re move the lower fixing screw to the fork plate Remove the upper plate closing cap Unscrew and remove the fixing screws on both sides of the upper plate Suspensions Norge GT 8v SUSP 268 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 269: ... the shim washer Unscrew and remove the four fixing screws of the half handlebar to the plate Remove both half handlebars leaving them tied to the cables Norge GT 8v Suspensions SUSP 269 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 270: ...IT SLIGHTLY UNTIL THE NOTCHES ARE ALIGNED WITH THE RING NUTS Specific tooling 020884Y 46 mm wrench for steering ring nut Remove the safety washer Adjust the steering bearing preload with the special tool NOTE GET THE ADEQUATE SPECIAL TOOL Specific tooling 020884Y 46 mm wrench for steering ring nut Suspensions Norge GT 8v SUSP 270 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf ...

Page 271: ... lbf ft 5 Screw fastening single linkage to chassis M10x85 1 50 Nm 36 87 lbf ft Adjusting The rear suspension consists of a spring shock absorber unit linked to the frame via Silent block and to the rear fork via a linkage system To set vehicle suspension the shock absorber has a set screw 1 to adjust the hydraulic rebound damping a set knob 2 to adjust spring 3 preloading To access the adjustment...

Page 272: ...SARY CONTACT AN Official Moto Guzzi Dealer TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED SHOCK ABSORBER SETTING TABLE Regular load adjustments are the standard settings by manufacturer REAR SHOCK ABSORBER ADJUSTMENT Specification Desc Quantity Preload regular load conditions 25 clicks from fully unloaded Preload half load conditions 35 clicks from fully unloaded Pre...

Page 273: ...ading knob until reaching the end of the stroke Remove the preloading knob by un screwing the central screw See also Bodywork Unscrew the connecting rod screws and remove the pin Norge GT 8v Suspensions SUSP 273 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 274: ... SIN GLE SHOCK ABSORBER HOLT THE SWINGARM WHEEL UNIT Remove the upper screw of the single shock absorber Remove the single shock absorber being careful not to damage the mo torbike components Suspensions Norge GT 8v SUSP 274 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 275: ...INDEX OF TOPICS CHASSIS CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 276: ...t 3 Swingarm pin on the swingarm M12 1 60 Nm 44 25 lbf ft 4 Preloading bushing to the swingarm pin M25 1 10 Nm 7 37 lbf ft Removing To remove the swingarm first remove both footrest supporting plates and the exhaust silencer Slide off the rear brake calliper from the disc and release the brake pipe Remove the cover Chassis Norge GT 8v CHAS 276 Revente Interdite Revendita Vietata Resaling Forbiden ...

Page 277: ... tection ring Remove the rear wheel Unscrew and remove the nut fixing the reaction rod Remove the screw Fix the reaction rod to the chassis with a clamp Remove the clamp from the dust guard cap Norge GT 8v Chassis CHAS 277 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 278: ...he screw Disconnect the speed sensor connec tor and release the cable from the clamps on the chassis Loosen the ring nut Specific tooling 14 91 26 03 Hook spanner for fixing ring nut of the clutch shaft internal body Chassis Norge GT 8v CHAS 278 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 279: ...rwise replace it Check that the fork pin threads and the fork fixing nuts are not damaged deformed or flat tened otherwise replace them Check that the sleeve grooves are not damaged deformed or deteriorated otherwise re place the sleeve Check that the sleeve outer toothing and grooves are not damaged Installing Spread a thin layer of lubricating grease all along the swingarm pin Fit the ring nut i...

Page 280: ...or insert the pin completely Tighten the swingarm pin Use the suitable box spanner to tight en the ring nut Specific tooling 14 91 26 03 Hook spanner for fixing ring nut of the clutch shaft internal body Tighten the two screws of the swing arm clamp Fit the dust guard cap in the gearbox Lock the dust guard cap with a new clamp Chassis Norge GT 8v CHAS 280 Revente Interdite Revendita Vietata Resali...

Page 281: ... the connecting rod assembly Connect the speed sensor connector and fix the cable to the chassis with clamps See also Recommended products chart Place the dust protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit Norge GT 8v Chassis CHAS 281 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 282: ...rake pipe on the swingarm 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 Undo and remove the four screws Chassis Norge GT 8v CHAS 282 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 283: ...ing slid ing off the universal joint Checking Casing unit removal Remove the cover 20 Remove the plug 3 to drain out the oil Norge GT 8v Chassis CHAS 283 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 284: ...t the cap 10 Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 Collect the ring 15 Chassis Norge GT 8v CHAS 284 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 285: ...emove the screws 7 Remove the casing 4 Remove the clamp 12 Remove the cap 14 Collect the ring 13 Norge GT 8v Chassis CHAS 285 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 286: ...l pins to the casing with the buffer and a hammer Assemble the casing to the special fastening tool Clean the casing faying surfaces carefully Heat the casing Chassis Norge GT 8v CHAS 286 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 287: ... the casing Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers Norge GT 8v Chassis CHAS 287 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 288: ...r Lubricate the sealing ring Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture Fit the casing Remove the two dowel pins Chassis Norge GT 8v CHAS 288 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 289: ...move excessive sealant Assemble the ring to the casing Tighten the fixing screws to the prescribed torque Fit the cap with the washer Screw the cap to the prescribed torque Norge GT 8v Chassis CHAS 289 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 290: ...e 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 Fit the cap in its seat Chassis Norge GT 8v CHAS 290 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 291: ... 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 Assemble the bearings to the wheel axle Norge GT 8v Chassis CHAS 291 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 292: ... ring 1 from the ring nut Unscrew the ring nut 2 with the special spanner s4 Remove the ring nut 2 and remove the sealing ring from the ring nut NOTE THIS OPERATION DESTROYS THE SEALING RING Chassis Norge GT 8v CHAS 292 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 293: ...A715855 see Fig 1 and a ham mer Lubricate the sealing ring 3 Assemble the ring nut 2 Tighten the ring nut 2 with the special spanner s4 to the prescribe torque Norge GT 8v Chassis CHAS 293 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 294: ...e ring nut 2 in the in dicated direction Assembly position of the stop ring 1 CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT Chassis Norge GT 8v CHAS 294 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 295: ...he other bushing 8 Remove the sealing rings 2 and 7 with a screw driver Remove the stop rings 3 and 6 from the support 5 with suitable pliers NOTE THIS OPERATION DESTROYS THE SEALING RING Norge GT 8v Chassis CHAS 295 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 296: ...ng 6 in the support 5 with suitable pliers Turn the support 5 over Assemble the ball joint 4 with the buffer and a rubber hammer Fit the stop ring 3 in the support 5 with suitable pliers Chassis Norge GT 8v CHAS 296 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 297: ...g has been fitted 3 Plug not tightened to the prescribed torque 1 Clean and tighten to the correct torque 2 Replace the sealing ring 3 Tighten the plug to the correct torque 1 Cap damaged 2 Retaining clamp or closing cover loose 3 Fitting error of the radial seal or seal damaged 4 Sliding sur face of the wheel spacer spoiled or damaged 1 Replace the cap 2 Screw the clamp with suitable pliers 3 Rep...

Page 298: ...rque 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 Norge GT 8v CHAS 298 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 299: ...14 75 lbf ft Clamp 3 Compensator fixing screw to the plate M10 2 25 Nm 18 44 lbf ft 4 Compensator fixing clamp screw to the muffler M8 1 20 Nm 14 75 lbf ft Clamp 5 Muffler fixing screw to the support M8x45 1 25 Nm 18 44 lbf ft 6 Lambda sensor on the exhaust pipe M18 2 38 Nm 28 03 lbf ft Removing the tail pipe CAUTION THE ENGINE AND THE EXHAUST SYSTEM COMPONENTS CAN GET VERY HOT AND REMAIN SO FOR S...

Page 300: ...the exhaust end Removing the manifold tail pipe Remove both exhaust manifolds Remove the exhaust end Unscrew and remove the anti vibration rubber ring fixing screws on both sides With the assistance of a second oper ator hold the vehicle upright and with small movements remove the manifold end joint See also Removing the exhaust manifold Chassis Norge GT 8v CHAS 300 Revente Interdite Revendita Vie...

Page 301: ... GLOVES BEFORE HANDLING THESE PARTS OR WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM COOL DOWN NOTE THE FOLLOWING PROCEDURE IS VALID FOR BOTH MANIFOLDS Disconnect the Lambda sensor con nector Cut the clamp indicated Unscrew and remove the two nuts on the head exhaust stud bolts Retrieve the washers Norge GT 8v Chassis CHAS 301 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verb...

Page 302: ...ifold Removing the lambda sensor Unscrew and remove the lambda sensor Remove the exhaust manifold See also Removing the exhaust manifold Chassis Norge GT 8v CHAS 302 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 303: ... 95 lbf ft 2 Radiator fixing pin on the grille M5 1 4 Nm 2 95 lbf ft 3 Radiator to grille fixing screw M5 1 4 Nm 2 95 lbf ft Remove the right side fairing Operating from both sides of the lug unscrew the front and lower screws Norge GT 8v Chassis CHAS 303 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 304: ... Remove the right fairing lug and recov er the internal bushing Working on the left side unscrew and remove the left side fairing lower fixing screw Chassis Norge GT 8v CHAS 304 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 305: ...ixing screws of the oil radiator Collect the spacers Disconnect the fan motor connector and release the cables from the indi cated clamp Unscrew the joints of the oil pipe on the radiator Remove the radiator oil together with the fan and duct Norge GT 8v Chassis CHAS 305 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 306: ...See also Replacement Side fairings Chassis Norge GT 8v CHAS 306 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 307: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 308: ...Nm 18 44 lbf ft 2 Joint with brake pipes retainer bleeding on the calliper M10 3 25 Nm 18 44 lbf ft 3 Brake pipes joint on the ABS hydraulic unit 4 25 Nm 18 44 lbf ft Interventions rules Braking system Norge GT 8v BRAK SYS 308 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 309: ...S sensor 4 Battery 5 ECU 6 Instrument panel 7 K line diagnosis 8 Key 9 Right Light Switch ABS ECU control unit pin configuration PIN 1 GND Earth Norge GT 8v Braking system BRAK SYS 309 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 310: ...PIN 11 R_SIGN Rear ABS sensor signal PIN 12 R_GND Rear ABS sensor ground connection PIN 13 F_GND Front ABS sensor ground connection PIN 14 F_SIG Front ABS sensor signal PIN 15 PCC2 Vehicle identification ground PIN 16 ISO_K K line diagnosis PIN 18 KL30 Power supply Braking system Norge GT 8v BRAK SYS 310 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 311: ...functional diagram key 1 Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit Norge GT 8v Braking system BRAK SYS 311 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 312: ...potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coincides with danger recognition wheel sli...

Page 313: ...wheel 2 form ing an integral unit with the vehicle wheel reads the status of the vehicle wheel spotting any possi ble lock A control unit 1 signals this out and adjusts the pressure in the braking circuit accordingly CAUTION WHEN THE ABS STARTS WORKING A PULSING IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE VEHICLE...

Page 314: ...tivated Riding with a deactivated ABS system The warning light 5 turns on permanently the system was deactivated ABS device deactivation To deactivate the system proceed as follows Start the engine With the vehicle at a standstill press and hold the button After roughly three seconds the indicator light ABS 5 on the instrument panel 4 becomes steadily on Release the button immediately Now the ABS ...

Page 315: ... the key is ON if at least one current or stored error is detected the ABS warning light turns on permanently The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The diagnosis requires exceeding the 5 km h 3 1 mph Each time the key is ON if at least one current or stored error of the ABS system is not detected the ABS warning light flashes When ...

Page 316: ...BS FAULTS GUIDE TO THE DIAGNOSIS 1 ABS WARNING LIGHT ON 2 CONNECT NAVIGATOR DOES NAVIGATOR COMMUNICATE NO go to 3 YES go to 4 3 PERFORM THESE CHECKS A Ground connection PIN 1 B 12V at PIN 18 C 12V at PIN 4 with key ON 4 ARE THERE ANY ERRORS YES go to 5 NO go to 6 5 CONSULT THE ERRORS TABLE 6 ABS WARNING LIGHT ACTIVATION ACTIVE YES go to 7 NO go to 8 7 CONTACT TECHNICAL SERVICE 8 CHECK A Cable cont...

Page 317: ...hicle the possible indications are Norge Stel vio identified by ECU See the following table NOTE the X in the table identifies the connector pin is grounded ABS CONNECTOR IS GROUNDED Vehicle PIN 2 PIN 15 Stelvio 1200 4V ABS X Norge 1200 4V ABS X PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the cont...

Page 318: ...by the control unit Ambient parameter error reading 3 for example if it indicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Ambient parameter error reading 4 Operation cycles from the last reading a cycle is counted if the following occurs key ON and speed over 20 km h Ambient parameter error readi...

Page 319: ... or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Rear speed sensor 5DA4 no accel eration after pressure reduction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Rear speed sensor excessive meas ured speed 5DA5 Faulty sensor or tone wheel with wrong number of teeth or wrong tyre size Contr...

Page 320: ...e INFO ECU screen page in the line Vehicle code NOTE the X in the table identifies the connector pin is grounded ABS CONNECTOR IS GROUNDED Vehicle PIN 2 PIN 15 Stelvio 1200 4V ABS X Norge 1200 4V ABS X Modulator Remove the fuel tank With a felt tip pen mark a reference on the pipes and on the ABS control unit to avoid inverting them when refitting Protect with a clean cloth the plastic materials n...

Page 321: ...BS control unit con nector Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR Check the initial position of the lever that couples the connector Norge GT 8v Braking system BRAK SYS 321 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 322: ... create a template to check the correct connector insertion Fit the protection casing Component maintenance The vehicle is fitted with a two channel ABS sys tem i e it works on both the front and the rear wheel Check periodically and each time the wheels are refitted the tone wheel 2 or the sensor 1 re placed that the wheel distance is constant at each 360 Use a thickness gauge to check the distan...

Page 323: ... a cloth or metal brush Avoid using solvents abrasives and air or water jets directly on the tone wheel 2 TONE WHEEL SENSOR REPLACEMENT Disconnect the tone wheel sensor connector 1 from the main wire Unscrew and remove the screw and remove the tone wheel sensor 1 CAUTION BEFORE REFITTING MAKE SURE THAT THE FAYING SURFACES BETWEEN THE SENSOR 1 AND THE SEAT ITSELF DO NOT SHOW SIGNS OF DAMAGE AND ARE...

Page 324: ...PERS pos Description Type Quantity Torque Notes 1 Front brake calliper fixing screws M10 4 50 Nm 36 87 lbf ft Rear brake disc Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI FICATIONS OF THE SYSTEM Braking system Norge GT 8v BRAK SYS 324 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 325: ...HAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point of the disc is less than the minimu...

Page 326: ...N AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE RE VERSE ORDER Rear brake pads Braking system Norge GT 8v BRAK SYS 326 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 327: ...O NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Insert two new pads placing them so that the holes are aligned with the calliper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED IN SIDE THE CALLIPER Norge GT 8v Braking system BRAK SYS 327 Revente Interdite Revendita Vietata Resaling Forbiden Wiederv...

Page 328: ...AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Insert the pin Position the split pin Insert the brake calliper into the disc by screwing in the two screws 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 Norge GT 8v BRAK SYS 328 Revente Interdite Revendita Vietata Resaling Forbiden Wiederv...

Page 329: ...to the new brake pump Fill the reservoir with new brake fluid CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reservoir up to the reference MAX and refit the cap Check the stroke and the sensitivity of both the lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that there are no leaks in the braking...

Page 330: ...kes and also seal these unions with protective caps Install the new ABS control unit previ ously filled up So that the brake fluid remains in the ABS control unit first remove the pro tective caps of the braking circuit un ions and connect the respective pipes Once all the braking circuits have been con nected remove the protective caps from the braking pump unions and connect the braking pump pip...

Page 331: ...lowing out from the open system Close the bleed screws of the front cal liper and remove the bleed bottle Replace the damaged calliper with a new one Unlock the brake lever Remove the reservoir cap and fill it with new brake fluid up to the reference MAX CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reservoir up to the reference MAX and ...

Page 332: ...IBED AT THE END OF THE CHAPTER See also Front Rear Front Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper The presence of air is signalled by the sponginess of the brake control and poor braking efficiency CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER RE...

Page 333: ...OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and block the front brake oil reservoir cap Refit the rubber protection cover Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the ...

Page 334: ... flows into the con tainer This will release the tension on the brake lever and will make it reach the end of stroke Close the bleed valve before the lever reaches its end of stroke Repeat the operation until the fluid draining into the container is air bubble free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION ...

Page 335: ...pos Description Type Quantity Torque Notes 1 Front brake pump U bolt fixing screw M6 2 10 Nm 7 37 lbf ft Sequence 1 2 1 Norge GT 8v Braking system BRAK SYS 335 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 336: ...INDEX OF TOPICS BODYWORK BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 337: ... Nm 4 42 lbf ft 2 Horn fixing screw M6 1 10 Nm 7 37 lbf ft INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Instrument panel fixing screw SWP M5x14 3 3 Nm 2 21 lbf ft Norge GT 8v Bodywork BODYW 337 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 338: ...ear head fixing screw M8x28 1 At the point of fail ure WINDSHIELD pos Description Type Quantity Torque Notes 1 Top fairing fixing screw M5x9 8 4 Nm 2 95 lbf ft 2 Top fairing fixing screw M5x16 2 4 Nm 2 95 lbf ft Bodywork Norge GT 8v BODYW 338 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 339: ...ck to frame upper fixing screw M6 2 10 Nm 7 37 lbf ft 4 Engine guide lock to frame lower fixing screw M6 2 10 Nm 7 37 lbf ft 5 Windshield support fixing screw M6 4 10 Nm 7 37 lbf ft FRONT MUDGUARD pos Description Type Quantity Torque Notes 1 Front mudguard fixing screw M5x12 4 4 Nm 2 95 lbf ft Norge GT 8v Bodywork BODYW 339 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbot...

Page 340: ...crew M8x25 5 25 Nm 18 44ft 2 Tail to handgrip and to rear fairings fixing screw M5x9 10 4 Nm 2 95 lbf ft 3 Hooks and tail fairing to chassis fixing screw M8 4 20 Nm 14 75 lbf ft Bodywork Norge GT 8v BODYW 340 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 341: ...assis M6 6 10 Nm 7 37 lbf ft Loctite 243 2 ABS support fixing screw to the splash guard SWP M5x20 3 3 Nm 2 21 lbf ft 3 Retroreflector support fixing screw to the li cense plate M5x10 2 4 Nm 2 95 lbf ft 4 Retroreflector fixing nut retainer to the support M5 1 4 Nm 2 95 lbf ft Headlight fairing Undo and remove the four screws in dicated Remove the two locks Norge GT 8v Bodywork BODYW 341 Revente Int...

Page 342: ... three fixing screws Remove the head guard RIGHT SIDE FAIRING Remove the head guard Undo and remove the three screws in dicated Remove the front fitting of the fairing Bodywork Norge GT 8v BODYW 342 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 343: ...e the left fairing lug Remove the head guard Remove the fairing cover Undo and remove the two screws indi cated Unscrew and remove the lower screw Remove the left side fairing Norge GT 8v Bodywork BODYW 343 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 344: ...sensor Remove the oil breather pipe Unscrew and remove the two screws from the oil vapour recovery reservoir Unscrew and remove the tube guide screw on the air filter casing Bodywork Norge GT 8v BODYW 344 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 345: ...g from both sides loosen the clamp and slide off the sleeve from the throttle body Lift the air filter casing and slide off the fuel depression pipe Remove the air filter casing Lower cowl See also Engine oil cooler Norge GT 8v Bodywork BODYW 345 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 346: ...Operating from both sides lift the side fairing to remove it and slide it off the pin Working from both sides undo and re move the front screw Undo and remove the rear screw Bodywork Norge GT 8v BODYW 346 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 347: ...the pipes from the T joint Disconnect the connector Disconnect the fuel pipe Remove the fuel tank by sliding it off and back Norge GT 8v Bodywork BODYW 347 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 348: ...the upper front screw Lift the control panel together with the instrument panel Disconnect the air temperature sensor connector Disconnect the connector together with the instrument panel Remove the control panel together with the instrument panel See also Steering bearing Bodywork Norge GT 8v BODYW 348 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 349: ...unscrew and remove the two screws indicated If necessary remove the stud bolts from each side unscrewing it from the fairing Working from both sides undo and re move the internal screw Unscrew and remove the screw below the front headlamp Norge GT 8v Bodywork BODYW 349 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 350: ...ont headlight Remove the upper fairings together with the headlight See also Side fairings Fuel tank Adjustable windscreen Remove the upper fairings Undo and remove the two lower screws Bodywork Norge GT 8v BODYW 350 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 351: ...e connector Unscrew and remove the two fixing screws and detach the two windshield end of the strokes leaving them con nected to the system NOTE WHEN REFITTING FIT THE END OF STROKE DOWN WARDS WITH THE SHORTEST CABLE See also Instrument cluster cover Norge GT 8v Bodywork BODYW 351 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 352: ...INDEX OF TOPICS PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 353: ...witch 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 starter Engine stop via...

Page 354: ...H WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY 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 ...

Page 355: ... 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 PR...

Page 356: ...15 217 220 Cylinder 47 185 188 190 191 205 206 208 211 216 D Desmodromic drum 161 E ECU 127 244 317 Electrical system 12 70 72 353 Engine oil 61 170 303 345 Engine temperature sensor 109 Exhaust 299 302 Exhaust manifold 300 302 F Fairings 306 342 350 Fork 254 256 259 262 266 Forks 161 Front wheel 249 251 257 Fuel 169 321 346 350 Fuses 101 G Gearbox oil 63 H Handlebar 253 Head cover 185 188 214 Hea...

Page 357: ...ecommended products 50 281 Run Stop switch 126 S Secondary shaft 157 160 162 Shock absorber Shock absorbers 271 Side fairings 342 Side stand 123 Side stand sensor 123 Speed sensor 103 Stand 123 Start up 100 Starter motor 150 174 T Tank 169 321 346 350 Throttle body Transmission 12 60 Tyres 14 W Windshield Wiring diagram 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbote...

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