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MOTO GUZZI Griso V1100, Руководство по ремонту

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TRANSMISSION

 

8 - 30

Griso V1100

 

Remove the seal ring (

2

) and (

7

) with a screwdriver.

Nota: 

destructive operation for the seal ring.

Remove from the support (

5

) the lock rings (

3

) and (

6

) with a

suitable pliers.

Remove the spherical joint (

4

) with a suitable pad and a hammer.

ASSEMBLY

Insert into the support (

5

) the lock ring (

6

) with a suitable pliers.

 

Overturn the support (

5

).

Assemble the spherical joint (

4

) with the special tool and a

hammer.

5

5

5

6

5

Содержание Griso V1100

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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