Page 1 SERVICE STATION MANUAL 897237 Norge GT 8v...
Page 2 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.
Page 3 In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries.
Page 4 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 7: Safety Rules
Norge GT 8v Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 Norge GT 8v Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10: Vehicle Identification
That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
Page 11 Norge GT 8v Characteristics ENGINE NUMBER The engine number is stamped on the left side, close to the engine oil level check cap. This number consists of numbers and letters, as in the example shown below. ZGULPS010YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code;...
Page 12 Norge GT 8v Characteristics Specification Desc./Quantity Clutch hydraulically controlled single-plate dry clutch with incorpora- ted flexible coupling Lubrication system Pressure-fed, controlled by valves and trochoidal pump Air filter cartridge-type dry filter Cooling air and oil cooled with independent trochoidal pump and oil...
Page 13 Norge GT 8v Characteristics Specification Desc./Quantity Dashboard lighting Turn indicator warning light Neutral gear warning light Side stand down warning light Low fuel warning light High beam warning light ABS warning light Gear shift warning light Antitheft device warning light...
Page 14: Wheels And Tyres
Norge GT 8v Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Wheel rims - type hollow 3-spoke rim in chilled cast aluminium alloy Wheel rims - front 3.5 '' x 17'' Wheel rims - rear 5.5 '' x 17''...
Page 15 Norge GT 8v Characteristics RONT IGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw 6 Nm (4.42 lbf ft) Horn fixing screw 10 Nm (7.37 lbf ft) NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Instrument panel fixing screw 3 Nm (2.21 lbf ft)
Page 16 Norge GT 8v Characteristics RONT FORK pos. Description Type Quantity Torque Notes Wheel axle locking screw on the fork leg 10 Nm (7.37 lbf ft) Piston fixing screw to the sleeve M10x35 50 Nm (36.87 lbf ft) Fork cap 20 Nm (14.75 lbf ft) INDSHIELD pos.
Page 17 Norge GT 8v Characteristics pos. Description Type Quantity Torque Notes Top fairing fixing screw M5x16 4 Nm (2.95 lbf ft) RONT RAKE EVER pos. Description Type Quantity Torque Notes Front brake pump U-bolt fixing screw 10 Nm (7.37 lbf ft)
Page 18 Norge GT 8v Characteristics LUTCH CONTROL pos. Description Type Quantity Torque Notes Clutch pipe fixing slot screw 10 Nm (7.37 lbf ft) Clutch pump U-bolt fixing screw 10 Nm (7.37 lbf ft) Sequence 1-2-1 ANDLEBAR AND ONTROLS pos. Description Type...
Page 19 Norge GT 8v Characteristics INDSHIELD pos. Description Type Quantity Torque Notes Windshield link rod fixing screw on the frame M6x25 10 Nm (7.37 lbf ft) Aesthetic support fixing screw 4 Nm (2.95 lbf ft) Engine guide lock to frame upper fixing screw 10 Nm (7.37 lbf ft)
Page 20 Norge GT 8v Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screw M5x12 4 Nm (2.95 lbf ft) TEERING YOKE pos. Description Type Quantity Torque Notes Fork stanchion fixing screw on the upper plate M8x30 25 Nm (18.44 lbf ft)
Page 21 Norge GT 8v Characteristics RONT BRAKE CALLIPERS pos. Description Type Quantity Torque Notes Front brake calliper fixing screws 50 Nm (36.87 lbf ft) RONT HEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut 80 Nm (59.00 lbf ft)
Page 22 Norge GT 8v Characteristics pos. Description Type Quantity Torque Notes Front ABS sensor fixing screw 10 Nm (7.37 lbf ft) RONT RAME pos. Description Type Quantity Torque Notes Frame to chassis fixing screw M8x40 10 Nm (7.37 lbf ft) Central part...
Page 23 Norge GT 8v Characteristics ABLE ARNESS pos. Description Type Quantity Torque Notes Electronic control unit lower fixing screw M6x20 10 Nm (7.37 lbf ft) Electronic control unit upper fixing screw M6x35 10 Nm (7.37 lbf ft) Coil support plate fixing screw M6x20 10 Nm (7.37 lbf ft)
Page 24 Norge GT 8v Characteristics ONTROL pos. Description Type Quantity Torque Notes Gearbox lever fixing screws M6x20 10 Nm (7.37 lbf ft) Peg to lever locking screw M6x16 10 Nm (7.37 lbf ft) Rod fixing nut 10 Nm (7.37 lbf ft)
Page 25 Norge GT 8v Characteristics EAR BRAKE LEVER pos. Description Type Quantity Torque Notes Rear brake pump fixing screw M6x20 10 Nm (7.37 lbf ft) Loctite 243 Rear brake pedal fixing screw 15 Nm (11.06 lbf ft) Loctite 243 Spring on the brake pedal return fixing screw M5x16 6 Nm (4.42 lbf ft)
Page 26 Norge GT 8v Characteristics RAKE YSTEM pos. Description Type Quantity Torque Notes Brake pipe slot screw on the pump 25 Nm (18.44 lbf ft) Joint with brake pipes retainer bleeding on the 25 Nm (18.44 lbf ft) calliper Brake pipes joint on the ABS hydraulic unit 25 Nm (18.44 lbf ft)
Page 27 Norge GT 8v Characteristics OOTRESTS pos. Description Type Quantity Torque Notes Rubber footrest fixing screw 10 Nm (7.37 lbf ft) Loctite 243 Rider footrest friction pin 25 Nm (18.44 lbf ft) Loctite 243 OOTREST UPPORT LATE pos. Description Type Quantity...
Page 28 Norge GT 8v Characteristics UEL TANK pos. Description Type Quantity Torque Notes Tank to chassis front fixing screw 25 Nm (18.44 lbf ft) Tank to chassis rear fixing screw 25 Nm (18.44 lbf ft) Tank breather joint 6 Nm (4.42 lbf ft) Filler to tank fixing screw 4 Nm (2.95 lbf ft)
Page 29 Norge GT 8v Characteristics RAME pos. Description Type Quantity Torque Notes Plate to chassis fixing screw M12x50 50 Nm (36.87 lbf ft) Plate to engine fixing nut 80 Nm (59 lbf ft) Gear to chassis upper fixing pin 80 Nm (59 lbf ft)
Page 30 Norge GT 8v Characteristics RANSMISSION CONNECTION NGINE pos. Description Type Quantity Torque Notes Reaction rod fixing screw M10x55 50 Nm (36.87 lbf ft) EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp fixing screw on the bushing M6x25 10 Nm (7.37 lbf ft)
Page 31 Norge GT 8v Characteristics pos. Description Type Quantity Torque Notes 2 - Swingarm fixing screw on the transmission M10x35 50 Nm (36.87 lbf ft) housing Swingarm pin on the swingarm 60 Nm (44.25 lbf ft) Preloading bushing to the swingarm pin 10 Nm (7.37 lbf ft)
Page 32 Norge GT 8v Characteristics PLASH GUARD pos. Description Type Quantity Torque Notes Splash guard fixing screw to the chassis 10 Nm (7.37 lbf ft) Loctite 243 ABS support fixing screw to the splash guard 3 Nm (2.21 lbf ft) M5x20...
Page 33 Norge GT 8v Characteristics HEEL pos. Description Type Quantity Torque Notes Rear wheel fixing screw M12x65 110 Nm (81.13 lbf ft) Rear brake disc fixing screw 25 Nm (18.44 lbf ft) Loctite 243 Rear tone wheel fixing screw M5x12 4 Nm (2.95 lbf ft)
Page 34 Norge GT 8v Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Shock absorber to chassis fixing screw M10x80 50 Nm (36.87 lbf ft) Shock absorber to double connecting rod fix- M10x82 40 Nm (29.50 lbf ft) ing screw Shock absorber to single connecting rod fixing M10x95 50 Nm (36.87 lbf ft)
Page 35 Norge GT 8v Characteristics LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm (59.00 lbf ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lbf ft) Generator lower fixing screw M10x60 30 Nm (22.13 lbf ft)
Page 36 Norge GT 8v Characteristics RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lbf ft) Stud bolt M8x66 10 Nm (7.37 lbf ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lbf ft) Oil cap on the crankcase 25 Nm (18.44 lbf ft)
Page 37 Norge GT 8v Characteristics IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lbf ft) Oil filter joint 10 Nm (7.37 lbf ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lbf ft)
Page 38 Norge GT 8v Characteristics YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lbf ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lbf ft) ENERATOR OVER pos.
Page 39 Norge GT 8v Characteristics IR FILTER pos. Description Type Quantity Torque Notes Air filter box bracket and cover fixing screw SWP 5x20 3 Nm (2.21 lbf ft) Air temperature sensor fixing screw 2 Nm (1.47 lbf ft) 2.9x12 Air filter box front fixing screw M6x20 4 Nm (2.95 lbf ft)
Page 40 Norge GT 8v Characteristics HROTTLE BODY pos. Description Type Quantity Torque Notes Intake pipe fixing screw 10 Nm (7.37 lbf ft) Flange fixing screw on the throttle body M5x12 6 Nm (4.42 lbf ft) LUTCH pos. Description Type Quantity Torque...
Page 41 Norge GT 8v Characteristics ONNECTING ROD ASSEMBLY YLINDERS pos. Description Type Quantity Torque Notes Thermal group fixing stud bolt M10x1.25 5 Nm (3.69 lbf ft) Loctite 243 Connecting rod screws 40 Nm (29.50 lbf ft) Pre-tightening Connecting rod screws 80 Nm (59.00 lbf ft)
Page 42 Norge GT 8v Characteristics UPPLY YSTEM pos. Description Type Quantity Torque Notes Fuel pump support fixing screw to the tank M5x20 5 Nm (3.68 lbf ft) Fuel pump support fixing screw to the tank M5x16 6 Nm (4.42 lbf ft) YSTEM pos.
Page 43 Norge GT 8v Characteristics TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screw 25 Nm (18.44 lbf ft) Stud bolt 10 Nm (7.37 lbf ft) Starter motor cover fixing screw M6x10 8 Nm (5.90 lbf ft) CHAR - 43...
Page 44 Norge GT 8v Characteristics pos. Description Type Quantity Torque Notes Oil pump fixing screw M6x45 10 Nm (7.37 lbf ft) Loctite 243 Oil pump driven gear locking nut 8 Nm (5.90 lbf ft) Loctite 243 Oil pressure valve cap 40 Nm (29.50 lbf ft) ADIATOR pos.
Page 45 Norge GT 8v Characteristics IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
Page 46 Norge GT 8v Characteristics YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
Page 47 Norge GT 8v Characteristics EARBOX pos. Description Type Quantity Torque Notes Clutch housing to gearbox fixing screw M6x55 13 Nm (9.59 lbf ft) Neutral sensor 10 Nm (7.37 lbf ft) Breather stud bolt 8 Nm (5.90 lbf ft) Loctite 243 Gear oil magnetic drainage cap 24 Nm (17.70 lbf ft)
Page 48 Norge GT 8v Characteristics PIN - PISTON COUPLING Specification Desc./Quantity Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in) Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in) Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)
Page 49 Norge GT 8v Characteristics Crankcase - crankshaft - connecting rod CRANKSHAFT SEAT (TIMING SYSTEM SIDE) Specification Desc./Quantity Diameter of crankshaft main journal, timing system side 37.975 - 37.959 mm (1.49507 - 1.49444 in) Inside diameter of crankshaft bushing, timing system side 38.016 - 38.0 mm (1.49669 - 1.49606 in)
Page 50 Norge GT 8v Characteristics • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown. • Take note of the measurement and, according to the values found, consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head.
Page 51 INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 52 Norge GT 8v Special tools MOTORE Stores code Description 020677Y Generator belt tensioner, lever for belt tensioning 05.91.17.30 Front cover 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...
Page 53 Norge GT 8v Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange AP8140179 Support for valve fitting/removal...
Page 54 Norge GT 8v Special tools Stores code Description 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with seal ring on the crankshaft 19.92.71.00 Tool to fit the seal ring on the flywheel- side flange 020673Y Graduated dial hub 020672Y...
Page 55 Norge GT 8v Special tools Stores code Description 020678Y Tool for clutch rod checking 05.91.25.30 Gearbox opening 14.91.26.03 Hook spanner for fixing ring nut of the clutch shaft internal body CICLISTICA Stores code Description 020884Y 46 mm wrench for steering ring nut...
Page 56 Norge GT 8v Special tools Stores code Description 05.90.27.31 Gearbox oil seal buffer 05.90.27.32 Buffer handgrip 05.90.27.33 Ball 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)
Page 57 Norge GT 8v Special tools Stores code Description AP8140146 Weight AP8140149 Protection for fitting operations S-TOOLS - 57 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 58 INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 59: Maintenance Chart
Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. For this purpose, Moto Guzzi has formulated a series of checks and scheduled services (at the owner's expense), are summarised in the table given in the following page. We recommend having any minor faults resolved immediately by an Authorised Moto Guzzi Dealer, without waiting until the next sched- uled service interval.
Page 60: Transmission Fluid
Norge GT 8v Maintenance I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean and adjust or replace, if necessary, before every journey. (2) Replace every 2 years or 20000 Km (12427 mi).
Page 61: Engine Oil
Norge GT 8v Maintenance DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. • Screw and tighten the caps (1 - 2). Engine oil Check Check the engine oil level frequently.
Page 62 Norge GT 8v Maintenance • Pull the filler plug / oil level dipstick (1) straight out. • Wipe the oil level dipstick (1) clean and reinsert it. • Pull it out again and check the oil level. • The oil level is correct when it is close to the "MAX"...
Page 63: Engine Oil Filter
Norge GT 8v Maintenance DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DIS- POSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE. Engine oil filter Replace the engine oil filter each time you change the engine oil.
Page 64: Air Filter
Norge GT 8v Maintenance • Top-up with oil until it reaches the dip- stick opening (1). CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Page 65: Checking The Valve Clearance
Norge GT 8v Maintenance • Remove the oil breather pipe. • Unscrew and remove the five screws. • Lift the filter casing cover. • Remove the acoustic insulation panel. • Remove the air filter. • Cover the inlet duct with a clean cloth so that no foreign bodies could get into.
Page 66 Norge GT 8v Maintenance • Remove the Moto Guzzi logo using a screwdriver. • Remove the spark plug protection. If the timing system is very noisy, check the clearance between the valves and the rocking levers. NOTE ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION STROKE (VALVES CLOSED).
Page 67: Braking System
Norge GT 8v Maintenance • The measurement must be taken using a special thickness gauge. CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED, THE TAPPETS WILL BE NOISY. OTHERWISE, THE VALVES DO NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROB- LEMS SUCH AS: •...
Page 68 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 68...
Page 69 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 70 Norge GT 8v Electrical system ABLE ARNESS pos. Description Type Quantity Torque Notes Electronic control unit lower fixing screw M6x20 10 Nm (7.37 lbf ft) Electronic control unit upper fixing screw M6x35 10 Nm (7.37 lbf ft) Coil support plate fixing screw M6x20 10 Nm (7.37 lbf ft)
Page 71 Norge GT 8v Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve potentiometer ELE SYS - 71 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 72 Norge GT 8v Electrical system 6 Fall sensor 7 Rear light 8 Battery 9 Main fuses 10 Lambda sensor 11 Intake air temperature sensor 12 Engine revolution sensor 13 Auxiliary fuses 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor...
Page 73 Norge GT 8v Electrical system • No.1 ECU • No.2 Coils • No.2 Supports for coil • No.2 Coil tongues • No.2 Spark plug hoods together with H.V. cable • No.2 NGK PMR8B Spark Plugs • No.1 Oil pressure sensor •...
Page 74 Norge GT 8v Electrical system • No.1 Front left turn indicator • No.1 Rear right turn indicator • No.1 Rear left turn indicator • No.1 License plate lamp • No.1 Taillight • No.1 Front headlight • No.1 Flexible headlamp panel •...
Page 75 Norge GT 8v Electrical system • No. 1 Ix 6.4x12x0.5 Ond Flexible Washer • No. 1 EBFM IX M8X1.25 nut • No. 1 Anti-vibration washer • No. 2 Adhesive cable grommet • No. 6 Cable grommets • No. 1 M6x16 screw •...
Page 76 Norge GT 8v Electrical system • Fuel pump connector • Key Connector • Right Light Switch Connectors • Left Light Switch Connectors • ABS Control Unit Connector and correct positioning of the cap • Front and rear speed sensor connector •...
Page 77 Norge GT 8v Electrical system • Clamp where indicated. FRONT SECTION - TABLE B: RIGHT LIGHT SWITCH 1. Cable retainer plate, to stop the cable from: right device, down windshield button, stop switch, right heated hand grip e throttle grip.
Page 78 Norge GT 8v Electrical system FRONT SECTION - TABLE B2: RIGHT LIGHT SWITCH 1. Windshield right down button connection cable, recognisable by the white belt. FRONT SECTION - TABLE C: LEFT LIGHT SWITCH 1. Clamps FRONT SECTION - TABLE C1: LEFT LIGHT SWITCH 1.
Page 79 Norge GT 8v Electrical system FRONT SECTION - TABLE D: FRONT MAIN CA- BLE HARNESS 1. Lights relay cable harness. 2. Low-beam/high-beam light relay cable harness. 3. Instrument panel fixing clip. The connectors of the left device and of the im- mobilizer must be above the fixing clip of the in- strument panel.
Page 80 Norge GT 8v Electrical system FRONT SECTION - TABLE D3: FRONT MAIN CABLE HARNESS 1. Instrument panel connector. FRONT SECTION - TABLE D4: FRONT MAIN CABLE HARNESS 1. Immobilizer connector. FRONT SECTION - TABLE D5: FRONT MAIN CABLE HARNESS 1. Right headlamp connector.
Page 81 Norge GT 8v Electrical system FRONT SECTION - TABLE E: FRONT ABS SEN- 1. Cable grommets. FRONT SECTION - TABLE E1: FRONT ABS SENSOR 1. Brake pipe fixing plate. 2. Chassis fork. 3. Front ABS sensor cable. FRONT SECTION - TABLE F: TURN INDICATORS 1.
Page 82 Norge GT 8v Electrical system Central part 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"...
Page 83 Norge GT 8v Electrical system TABLE A3: ELECTRIC FAN CABLE HARNESS PREPARATION 1. Clamp. 2. Bracket. TABLE B: MAIN CABLE HARNESS ON THE CHASSIS 1. Clamps. 2. Align the grey belt on the main cable harness with the pipe. TABLE B1: MAIN CABLE HARNESS ON THE CHASSIS 1.
Page 84 Norge GT 8v Electrical system TABLE B3: MAIN CABLE HARNESS ON THE CHASSIS 1. ECU control unit. Connect the ECU connectors like in the figure, be- ing careful to attach the slides to the bottom. 2. ECU ground. TABLE B4: MAIN CABLE HARNESS ON THE CHASSIS 1.
Page 85 Norge GT 8v Electrical system TABLE C1: COILS 1. Laying of the H.V. cable Connect the spark plug hood to the other end of the H.V. cable and repeat the laying on the left side. TABLE D: MAIN CABLE HARNESS 1.
Page 86 Norge GT 8v Electrical system TABLE F: THROTTLE SENSOR 1. Connect the throttle sensor making sure that the hook of the connector anchors onto the rear lock present on the component. TABLE G 1. Pick up. 2. Front ABS sensor connector.
Page 87 Norge GT 8v Electrical system TABLE J: STEPPER MOTOR 1. Engine stepper connector. TABLE K 1. Key connector. 2. Clutch switch connector. 3. Heated hand grips connector. 4. Electric fan cable harness connector. 5. Clamp. TABLE L 1. Alternator eyelet.
Page 88 Norge GT 8v Electrical system TABLE M 1. Fall sensor. 2. Injection relay 2. 3. Injection 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.
Page 89 Norge GT 8v Electrical system TABLE O 1. Fixing stud bolt and anti-vibration washers. 2. Negative battery cable harness - ground. 3. Side stand switch connector. 4. Engine ground eyelet (main cable harness). TABLE P 1. Starter motor. 2. Clamp.
Page 90 Norge GT 8v Electrical system TABLE S 1. Air temperature connector (filter box). TABLE T: LAMBDA SENSOR 1. Right lambda connector. 2. Left lambda connector. 3. Clamps. 4. Clamp with which the electric fan cable harness must be held. 5. Right lambda sensor.
Page 91 Norge GT 8v Electrical system TABLE U: PROCEDURE FOR THE CORRECT INSERTION OF THE ABS CONTROL UNIT CONNECTOR • Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard.
Page 92 Norge GT 8v Electrical system TABLE B 1. Clamp. TABLE C 1. Clamp. 2. License plate lamp, taillight AND rear turn indi- cator 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.
Page 93 Norge GT 8v Electrical system TABLE F 1. Main fuses 1. 2. Main fuses 2. TABLE G: REAR ABS SENSOR 1. Cable grommets TABLE G1: REAR ABS SENSOR 1. Rear brake switch cable harness. 2. Clamp. 3. Rear ABS sensor cable harness.
Page 94 Norge GT 8v Electrical system General wiring diagram 1. Multiple connectors 2. Clutch switch 3. Start-up relay 4. Start-up maintenance relay 5. High-/low beam Relay lights ELE SYS - 94 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 95 Norge GT 8v Electrical system 6. Light logic relay 7. Right light switch 8. Power supply for GPS 9. Horn 10.Left light switch 11.Ambient air temperature sensor 12.Instrument panel 13.Immobilizer aerial 14.Ignition switch 15.Heated handgrips 16.Rear right turn indicator 17.Taillight (LED) 18.Left rear turn indicator...
Page 96 Norge GT 8v Electrical system 44.Idle motor 45.Throttle position sensor 46.Right cylinder coil 47.Left cylinder coil 48.Right spark plug 49.Left spark plug 50.Right cylinder injector 51.Left cylinder injector 52.Fall sensor 53.Pick-up 54.ECU. 55.Front left turn indicator 56.Complete front headlamp 57.Tail light bulb 58.Low beam bulb...
Page 97 Norge GT 8v Electrical system Dashboard Diagnosis Changing the CODE If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available;...
Page 98 Norge GT 8v Electrical system Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25...
Page 99 The white connector is placed under the saddle, beside the fuse box, close to the diagnosis con- nector for the injection system. Use the Ditech connector in the Navigator Aprilia- Moto Guzzi package to connect to the Navigator cable. KEY CHANGE FUNCTION This function can be used: 1) if one key is lost;...
Page 100 Norge GT 8v Electrical system Checking the stator Single-phase generator with regulated voltage Maximum load 40A (550W) Charging voltage 14.2 - 14.8 V (5000 rpm) Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and...
Page 101 Norge GT 8v Electrical system Lights list FRONT HEADLAMP Tail light: 12V - 5W Low beam light: 12V - 55W H3 High beam light: 12V - 65W H1 REAR LIGHT Fuses SECONDARY FUSES DISTRIBUTION Specification Desc./Quantity (a) 15A fuse Stop, horn, GPS, HAZARD button backlight, light relay coils, high beam flash, electric windshield motor (if fit- ted).
Page 102: Control Unit
Norge GT 8v Electrical system MAIN FUSES - DISTRIBUTION Specification Desc./Quantity (G) 40A fuse Battery recharge (H) 30A fuse Main motorcycle fuse (I) 20A fuse Low beam - high beam fuse (J) 20A fuse Main ABS fuse 20A (QUANTITY' 2) - 30A - 40A...
Page 103: Speed Sensor
Norge GT 8v Electrical system Speed sensor FRONT FUNCTION:To indicate the vehicle speed by read- ing the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magne- toresistive sensor: a square-wave pulse is gener- ated with voltage approx. between 11.55 V and 11.25 V...
Page 104 Norge GT 8v Electrical system 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.
Page 105 Norge GT 8v Electrical system LOCATION ON THE VEHICLE:Under the bevel gear set box, right side. CONNECTOR LOCATION (if available):Under the saddle, right side. PIN-OUT: • PIN1 - Ground • PIN2 - Signal NAVIGATOR Parameters: Speed (km/h) - Vehicle speed.
Page 106 Norge GT 8v Electrical system 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, replace the speed sensor. 5DA4 missing acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel.
Page 107 Norge GT 8v Electrical system 1. Engine revolution sensor positive signal. 2. Engine revolution sensor negative signal. 3. Revolution sensor anti-jamming cable. NAVIGATOR: PARAMETERS Target engine revs Example value:1100 +/- 100 rpm Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance.
Page 108 Norge GT 8v Electrical system Location: • sensor: on the right cylinder throttle body • connector: on the potentiometer Electrical characteristics: • PINS A-C: throttle closed approx. 2.5 kOhm; throttle open approx. 1.5 kOhm. • PINS A-B: approx. 1.1 kOhm Pin-out: •...
Page 109 Norge GT 8v Electrical system connector A (BROWN) and PIN C of the sensor (red cable): if there is not continuity, restore the cable harness; if there is continuity, check continuity of the sensor between PIN A and PIN C: if there is not continuity, replace the potentiometer; if there is continuity, check the resistance.
Page 110 Norge GT 8v Electrical system Specification Desc./Quantity Resistance at +10 °C (50 °F) 5.970 kOhm Resistance at +20 °C (68 °F) 3.750 kOhm Resistance at +30 °C (86 °F) 2.420 kOhm Resistance at +40 °C (104 °F) 1.600 kOhm Resistance at +50 °C (122 °F) 1.080 kOhm...
Page 111 Norge GT 8v Electrical system BROWN PIN 5 and PIN 2 of the sensor should be restored. If the air temperature sensor error is displayed at the same time, this means that the grey cable common for both sensors is shorted to positive.
Page 112 Norge GT 8v Electrical system Air temperature In case of failure, temperature is set at 25 °C (77 °F) NAVIGATOR: ERRORS air temperature sensor P0110 - 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 14 of the BROWN connector.
Page 113 Norge GT 8v Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 114 Norge GT 8v Electrical system Error cause • Excessive voltage (battery voltage) has been detected at PINS 32 and 22 of the BLUE connector. Troubleshooting • shorted to positive: with the key set to ON, disconnect the sensor connector and measure voltage at PIN 1 on the cable harness side (white/yellow cable): if there is voltage (5 or 12 V), restore the cable harness;...
Page 115 Norge GT 8v Electrical system and the Marelli control unit connector: If not OK, restore. If OK, check continuity between the BLUE connector PIN 22 and PIN 32 and restore the cable harness. ELECTRICAL ERRORS Right lambda sensor P0136 - Shorted to positive.
Page 116 Norge GT 8v Electrical system • An abnormal behaviour of the voltage at PIN 31 of the BLUE connector has been detected: the voltage, that should vary over time, keeps a constant value instead. Troubleshooting • check circuit continuity of the lambda sensor connector (PIN 1 PIN2) toward the probe: replace the lambda sensor if there is no continuity;...
Page 117 Norge GT 8v Electrical system Left injector P0201 - shorted to positive / shorted to negative / open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 28 of the BROWN con- nector. •...
Page 118 Norge GT 8v Electrical system • Shorted to positive: disconnect the injector connector, take the key to ON and check if there is voltage on the blue/red cable: if there is voltage, restore the cable harness. If there is no voltage, replace the injector •...
Page 119 Norge GT 8v Electrical system 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 the colour of the cables) is energised for 5 seconds and the green/orange cable of the coil is closed to ground for 2 ms per second.
Page 120 Norge GT 8v Electrical system • If shorted to positive: excessive voltage has been detected at PIN 10 of the BROWN con- nector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 10...
Page 121 Norge GT 8v Electrical system • Check the sensor connector and the instrument panel connector (PIN 3): if they are not OK, restore. If OK, check continuity of the purple cable between the sensor connector and the instrument panel connector PIN 3: if not OK, restore the cable harness; if OK, replace the sensor.
Page 122 Norge GT 8v Electrical system the connector and, with gear in neutral, check continuity to ground of the terminal, sensor side: if there is not continuity, replace the sensor (after checking cable harness continuity on the sensor side and the correct mechanical position); if there is, check cable continuity between the sensor connector and PIN 23 of the BROWN connector: if there is no continuity, restore the cable harness.
Page 123 Norge GT 8v Electrical system • Indication on Navigator always No: check the correct position of the cable terminals on the sensor and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness; if correct, disconnect the two terminals from the sensor and check continuity to ground of PIN 2 (cable harness side): if there is no continuity, restore the cable harness;...
Page 124: Bank Angle Sensor
Norge GT 8v Electrical system restore the cable harness; if there is, check continuity of the green/brown cable: if it is not OK, restore; if OK, replace the sensor. • Indication on Navigator always RETRACTED: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with stand down: if there is continuity, replace the sensor;...
Page 125 Norge GT 8v Electrical system continuity, restore the cable harness; if there is, with key set to KEY ON, check if there is 12V voltage at PIN 1. If there is not, check the Marelli control unit connector (PIN 35 of the BLUE connector) •...
Page 126 Norge GT 8v Electrical system check the correct sensor resistance: if it is not OK, replace the sensor; if it is OK, check continuity of the brown cable between the sensor connector and PIN 18 of the instrument panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument panel;...
Page 127 Norge GT 8v Electrical system • sky blue/orange cable: 0V if engine kill in STOP; 12V if engine kill in RUN • red/black cable: Voltage 12V NAVIGATOR: STATUSES Run / stop switch Example value:Run/Stop DIAGNOSIS • Indication on Navigator always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the switch of the green/blue (PIN 4) cables and the grey/sky blue (PIN 2) cable (sensor side): if there is not continuity, replace the sensor;...
Page 128 Norge GT 8v Electrical system 9 Stepper motor (+) 10 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used 17 Stepper motor (+) 18 Stepper motor (-)
Page 129 Norge GT 8v Electrical system 7 Immobilizer line 8 Not used 9 Not used 10 Not used 11 Oxygen probe negative control 1 (left) 12 Not used 13 Not used 14 Not used 15 Not used 16 K line (diagnosis)
Page 130 Norge GT 8v Electrical system Dashboard PIN USE 1 + KEY 2 RIGHT TURN INDICATOR CONTROL 3 OIL PRESSURE SENSOR 4 HIGH BEAM LIGHT INPUT ELE SYS - 130 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 131 Norge GT 8v Electrical system 6 SELECT 1 7 SELECT 2 8 FUEL LEVEL SENSOR 9 AIR TEMPERATURE SENSOR 10 - 11 + BATTERY 12 LEFT TURN INDICATOR CONTROL 13 RESET TURN INDICATORS 14 HAZARD 15 ANTITHEFT DEVICE LED (IF CONNECTED)
Page 132 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 133 Norge GT 8v Engine from vehicle RAME pos. Description Type Quantity Torque Notes Plate to chassis fixing screw M12x50 50 Nm (36.87 lbf ft) Plate to engine fixing nut 80 Nm (59 lbf ft) Gear to chassis upper fixing pin...
Page 134 Norge GT 8v Engine from vehicle Removing the engine from the vehicle • Disconnect the spark plug tubes. • Working on both sides disconnect the injector connectors. • Undo and remove the cable guide screw on the generator cover. •...
Page 135 Norge GT 8v Engine from vehicle • Disconnect the engine temperature sensor connector • Disconnect the revolution sensor con- nector. • Disconnect the alternator connectors. • Disconnect the gear in neutral sensor connector. ENG VE - 135 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 136 Norge GT 8v Engine from vehicle • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the connectors of the start- er motor. • Unscrew and remove the three screws and remove the clutch control cylinder.
Page 137 Norge GT 8v Engine from vehicle • Disconnect the stand sensor connec- tor and release it from the clamps. • Disconnect the oil pressure sensor connector. • Disconnect the oil temperature sensor connector. • Working from both sides, loosen the intake manifold clamps.
Page 138 Norge GT 8v Engine from vehicle • Unscrew and remove the lower nut fix- ing the engine and collect the washer. • Remove the lower pin and collect the washer. • Remove the plates. CAUTION PERFORM THE OPERATIONS BELOW AIDED BY A SEC- OND OPERATOR.
Page 139 Norge GT 8v Engine from vehicle • Lower the engine completely. • Lift the rear part of the vehicle. • Release the front belts. • Hold the rear part of the vehicle, remove the chassis from the engine. Installing the engine to the vehicle •...
Page 140 Norge GT 8v Engine from vehicle • Working on both sides, insert the washer and screw the screw without tighten it. • Working on both sides, place the plates • Working from the left side, fit the engine lower bolt with the washer.
Page 141 Norge GT 8v Engine from vehicle • Connect the stand sensor connector and fix it to the engine with new clamps. • Connect the oil pressure sensor. • Connect the oil temperature sensor. • Fit the gearbox oil breather pipe.
Page 142 Norge GT 8v Engine from vehicle • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors. • Connect the ground leads and tighten the stud bolt. • Connect the neutral sensor connector. ENG VE - 142...
Page 143 Norge GT 8v Engine from vehicle • Connect the alternator connectors. • Connect the revolution sensor connec- tor. • Connect the engine temperature sen- sor connector. • Connect and adjust the throttle grip ca- ble clearance. ENG VE - 143...
Page 144 Norge GT 8v Engine from vehicle • Place the swingarm with cardan shaft and the rear wheel. • Working on both sides, connect the in- jector connectors. • Working from both sides, connect the spark plug tube. • Install the fuel tank.
Page 145 INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 146 Norge GT 8v Engine Gearbox Diagram Key: 1. Ball bearing ENG - 146 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 147 Norge GT 8v Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Ball bearing cage 16.Gear 17.Sealing ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft...
Page 148 Norge GT 8v Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Ball bearing cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Main shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear 59.Ball bearing...
Page 149 Norge GT 8v Engine • Unscrew and remove the gearbox oil filler cap. • Place a container of 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.
Page 150 Norge GT 8v Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 150 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 151 Norge GT 8v Engine Disassembling the gearbox • Remove the gearbox. • Unscrew and slide off the odometer gear and 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.
Page 152 Norge GT 8v Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
Page 153 Norge GT 8v Engine • Remove the bearings from the gearbox if necessary. • Release 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.
Page 154 Norge GT 8v Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft.
Page 155 Norge GT 8v Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side.
Page 156 Norge GT 8v Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer.
Page 157 Norge GT 8v Engine • Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft.
Page 158 Norge GT 8v Engine • Remove the gear of the second gear and collect the 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.
Page 159 Norge GT 8v Engine • Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip.
Page 160 Norge GT 8v Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft...
Page 161 Norge GT 8v Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic if necessary. Check the desmodromic segment «3» for damage and wear and replace it if necessary. Check the desmodromic bearing «4» for damage and cracks and replace it if necessary.
Page 162 Norge GT 8v Engine primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also Removing the...
Page 163 Norge GT 8v Engine Disassembling the gearbox Gear selector NTERNAL ONTROLS pos. Description Type Quantity Torque Notes Spring guide pin 24 Nm (17.70 lbf ft) Loctite 243 ENG - 163 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 164 Norge GT 8v Engine Generator Key: 1. Alternator 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 ENG - 164 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 165 Norge GT 8v Engine LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm (59.00 lbf ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lbf ft) Generator lower fixing screw M10x60 30 Nm (22.13 lbf ft)
Page 166: Removing The Generator
Norge GT 8v Engine pos. Description Type Quantity Torque Notes Timing system cover fixing screw M8x55 25 Nm (18.44 lbf ft) Timing system cover fixing screw M6x30 12 Nm (8.85 lbf ft) Generator cover fixing screw M6x16 12 Nm (8.85 lbf ft) Removing the generator •...
Page 167 Norge GT 8v Engine • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. ENG - 167...
Page 168 Norge GT 8v Engine • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley. • Undo and remove the eight screws. • Undo and remove the two screws. ENG - 168...
Page 169 Norge GT 8v Engine • Undo and remove the two screws. • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Remove the left fairing lug. • Undo and remove the two front fixing screws of the oil radiator.
Page 170 Norge GT 8v Engine • Remove the generator belt cover by lightly loosening the oil radiator. • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Using the belt tensioning tool, tension the belt to the prescribed torque.
Page 171: Installing The Generator
Norge GT 8v Engine Installing the generator • If the sealing ring has been previously removed, replace it using the punch of the timing system cover sealing ring. Specific tooling 05.92.72.30 Timing system cover sealing ring punch • Place the bolt and the pin in the gen- erator cover.
Page 172 Norge GT 8v Engine • Tighten the eight lower screws. • Operating diagonally and in stages, tighten the ten fixing screws on the al- ternator fitting. • Tighten the four screws, operating di- agonally and in stages. • Position the lower pulley and the spacer.
Page 173 Norge GT 8v Engine • Position the screw and pre-tighten it. • Position the screw and tighten the nut. • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool.
Page 174 Norge GT 8v Engine • Tighten the alternator fixing screws. • Place the alternator belt 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.
Page 175 Norge GT 8v Engine • Slide off the starter motor. Clutch side Disassembling 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 ENG - 175...
Page 176 Norge GT 8v Engine 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing 17.Clutch control bowl 18.Thrust cylinder 19.Clutch control cylinder 20.TE flanged screw LUTCH pos. Description Type Quantity Torque Notes Clutch to crankshaft fixing screw 42 Nm (30.98 lbf ft)
Page 177 Norge GT 8v Engine • Remove the complete gearbox. • Unscrew and remove the 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.
Page 178 Norge GT 8v Engine • Undo and remove the six screws and collect the belleville springs. • Remove the clutch plate. See also Removing the gearbox Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.
Page 179 Norge GT 8v Engine 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc./Quantity Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in) Clutch control rod length (code 976593) = 183 mm (7.205 in) Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in) Clutch control rod length (code 976594) = 184.5 mm (7.264 in)
Page 180 Norge GT 8v Engine • Once the centring tool is fitted, lock the plate with the snap ring. • Undo and remove the two screws fixing the tool. • Remove the special tool. • Place the friction disc; centre it.
Page 181 Norge GT 8v Engine Heads YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lbf ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lbf ft) ENG - 181...
Page 182 Norge GT 8v Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
Page 183 Norge GT 8v Engine Key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw...
Page 184 Norge GT 8v Engine 22.Complete breather cover 23.TBEI screw 24.Timing system chain 25.Chain guide slider 26.Chain tensioner pad 27.Chain tensioner screw 28.Right chain tensioner 29.Left cylinder head 30.Stud bolt 31.Cylinder head gasket 32.Left rocking lever support 33.Screw 34.Pin 35.Nut 36.Right exhaust, left intake rocking lever 37.Left exhaust, right intake rocking lever...
Page 185: Removing The Cylinder Head
Norge GT 8v Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Disconnect the spark plug tube. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings.
Page 186 Norge GT 8v Engine • Unscrew and remove the screw. • Remove the timing system upper gear bulkhead. For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: •...
Page 187 Norge GT 8v Engine • Slide off the timing system gear from the chain to remove it from the cam- shaft. • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. • Unscrew and remove the two screws.
Page 188: Cylinder Head
Norge GT 8v Engine • Collect the two head dowel pins. • Collect the gasket between the head and the cylinder. See also Removing the head cover Cylinder head Removing the overhead camshaft 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.
Page 189 Norge GT 8v Engine • Remove the camshaft. • Remove the bowls from the cam cap, and mark their position so as not inter- change them when refitting. See also Removing the rocker arms Removing 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.
Page 190: Removing The Valves
Norge GT 8v Engine • Remove the two rocking levers from the cam cap. See also Removing the cylinder head Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed.
Page 191: Checking The Cylinder Head
Norge GT 8v Engine Checking the valve guides Use a punch to extract the valve guides from the heads. The valve guides should be replaced only if the clearance between them and the stem cannot be elim- inated by simply replacing the valves.
Page 192: Installing The Valves
Norge GT 8v Engine OUTLET VALVE SEAT DETAIL DRAWING - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45° milling cutter and then grind. - Replace the head in case of excessive wear or damage.
Page 193 Norge GT 8v Engine Installing the rocker arms • Fit the camshaft. • Fit the two rods. WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • Place the two rocking levers in the cam tower seats.
Page 194 Norge GT 8v Engine Installing the overhead camshaft Installing the overhead camshaft • Place the bowls in the cam tower, if those previously removed are refitted be careful not to interchange them. • Place the camshaft with the gear seat on the dowel side.
Page 195 Norge GT 8v Engine Timing IMING YSTEM ONTROL pos. Description Type Quantity Torque Notes Control, timing system, shaft support flange M6x14 8 Nm (5.90 lbf ft) fixing screw Bearing fixing screw M6x16 10 Nm (7.37 lbf ft) Loctite 243 Driving gears locking nut on the crankshaft 200 Nm (147.51 lbf ft)
Page 196 Norge GT 8v Engine • Remove the timing sensor and any shim washers. • Remove the tone wheel. • Remove the cotter and shim washer from the service shaft. See also Removing the generator Service shaft removal • Remove the tone wheel.
Page 197 Norge GT 8v Engine Installing the service shaft • Place the service shaft bearing (if pre- viously removed) on the crankcase. • Fix it to the seat with the lock washer and screw. • Fit the timing chains according to the references marked at the removal phase.
Page 198 Norge GT 8v Engine • Tighten the cap with the two original TBEI screws. Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws. • Tighten the chain caps with O-rings.
Page 199 Norge GT 8v Engine Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC). • Fit the cotter and the shim washer on the service shaft.
Page 200 Norge GT 8v Engine • After shimming the timing sensor prop- erly, proceed to fit it. • Fit the washer and tighten the timing system gear fixing nut of the service shaft. • Place a new gasket between the crank- case and the oil pump.
Page 201 Norge GT 8v Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
Page 202 Norge GT 8v Engine Measuring air gap • Undo and remove the two screws and remove the sensor. • Insert a suitable plain washer on the sensor and note its thickness. • Place the sensor on the crankcase and move it until it makes contact with the tone wheel.
Page 203 Norge GT 8v Engine Cylinder-piston assembly Key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder...
Page 204 Norge GT 8v Engine ONNECTING ROD ASSEMBLY YLINDERS pos. Description Type Quantity Torque Notes Thermal group fixing stud bolt M10x1.25 5 Nm (3.69 lbf ft) Loctite 243 Connecting rod screws 40 Nm (29.50 lbf ft) Pre-tightening Connecting rod screws 80 Nm (59.00 lbf ft)
Page 205 Norge GT 8v Engine YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
Page 206 Norge GT 8v Engine • Remove the head, the gasket between the head and the cylinder and the two dowel pins. • Slide off the movable chain slider. • Remove the cylinder from the stud bolts. • Remove the two dowel pins on the stud bolts.
Page 207 Norge GT 8v Engine • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 208 Norge GT 8v Engine • Insert the pin. • Insert the snap ring. Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case.
Page 209 Norge GT 8v Engine 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.
Page 210 Norge GT 8v Engine • Check that the oil in the left cylinder chain tensioner has been drained off by compressing it. If the operation is difficult, use a pin drive to push the central hole so that the oil is drained off from the circuit.
Page 211: Installing The Cylinder Head
Norge GT 8v Engine Installing the cylinder head • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system.
Page 212 Norge GT 8v Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pres- sure from the left cylinder chain ten- sioner.
Page 213 Norge GT 8v Engine • Fit the gasket with the correct thick- ness between the head and the cylin- der. • Fit the right cylinder head. • Unscrew and remove the right chain tensioner cap. • Screw two screws in the threaded holes of the timing system upper gear.
Page 214 Norge GT 8v Engine • Place the cap. • Tighten the two screws to the prescri- bed torque. • Also place the cap of the other head. • Adjust valve clearance. See also Checking the valve clearance Installing the head cover •...
Page 215 Norge GT 8v Engine Crankcase - crankshaft Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut. • Remove both gears.
Page 216 Norge GT 8v Engine • Remove the crankshaft afterwards. • Collect the shim washer from inside the crankcase. See also Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod • Remove both heads. • Remove the cylinders and the pistons.
Page 217 Norge GT 8v Engine Inspecting the crankshaft components Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the undersize charts), and replace the main bushing/ Reference (1) indicates the position where the col- oured reference is applied to select diameter (B).
Page 218 Norge GT 8v Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin. Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear al- lowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin (B) should be reamed.
Page 219 Norge GT 8v Engine The connecting rods have a marked area for weight selection. The weight indicated in the chart includes screws, dowels and the bushing. CONNECTING ROD WEIGHT SELECTION Specification Desc./Quantity Connecting rod - brown 0.588 - 0.598 mm (0.02074 - 0.02109 in) Connecting rod - green 0.598 - 0.608 mm (0.02109 - 0.02145 in)
Page 220 Norge GT 8v Engine PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE. Installing the crankshaft • Fit the shim washer inside the crank- case with the chamfered side facing the generator side.
Page 221 Norge GT 8v Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • When fitting the flange on the crank- case, make sure that the three dowel pins match the seats on the crankcase.
Page 222 Norge GT 8v Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
Page 223 Norge GT 8v Engine ADIATOR pos. Description Type Quantity Torque Notes Solenoid valve to radiator fixing screw M5x60 4 Nm (2.95 lbf ft) Radiator fixing pin on the grille 4 Nm (2.95 lbf ft) Radiator to grille fixing screw 4 Nm (2.95 lbf ft)
Page 224 Norge GT 8v Engine pos. Description Type Quantity Torque Notes Oil pump fixing screw M6x45 10 Nm (7.37 lbf ft) Loctite 243 Oil pump driven gear locking nut 8 Nm (5.90 lbf ft) Loctite 243 Oil pressure valve cap 40 Nm (29.50 lbf ft) RANKCASE AND pos.
Page 225 Norge GT 8v Engine IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lbf ft) Oil filter joint 10 Nm (7.37 lbf ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lbf ft)
Page 226 Norge GT 8v Engine Conceptual diagrams Key: 1. Oil cooling radiator 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9.
Page 227: Oil Pump
Norge GT 8v Engine The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft. The gear (10) is mounted on the shaft (8), on which two rotors are fitted: one for engine cooling (7) and another for lubrication (6).
Page 228 Norge GT 8v Engine • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump con- trol gear and another on the driven gear so as to place them correctly again upon refitting.
Page 229 Norge GT 8v Engine • Remove the gasket between the crankcase and the oil pump. See also Removing the generator Installing • Place a new gasket between the crank- case and the oil pump. • Place the oil pump. •...
Page 230 Norge GT 8v Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
Page 231 Norge GT 8v Engine • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
Page 232 Norge GT 8v Engine • Undo and remove the four screws. • Remove the flange. • Undo and remove the two screws. • Remove both filters. ENG - 232 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 233 Norge GT 8v Engine • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com- ponents ENG - 233 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 234 Norge GT 8v Engine Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED. •...
Page 235 Norge GT 8v Engine • Place a new gasket between the crank- case and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter. • Check that the O-rings are fitted on the oil pump.
Page 236 Norge GT 8v Engine • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque. • Place a new gasket between the flange and the sump.
Page 237 INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 238 Norge GT 8v Power supply UPPLY YSTEM pos. Description Type Quantity Torque Notes Fuel pump support fixing screw to the tank M5x20 5 Nm (3.68 lbf ft) Fuel pump support fixing screw to the tank M5x16 6 Nm (4.42 lbf ft) HROTTLE BODY pos.
Page 239 Norge GT 8v Power supply Circuit diagram Key: 1. Full fuel tank 2. Fuel pipe 3. Throttle body 4. Joint 5. Three-way joint 6. Pipe Injection P SUPP - 239 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 240 Norge GT 8v Power supply Diagram Key: 1. Control unit 2. Ignition switch 3. Battery 4. Fuel pump 5. Coils 6. Instrument panel 7. Air temperature sensor 8. Throttle valve position sensor 9. Injectors 10. Engine temperature sensor 11. Crankshaft position sensor...
Page 241 Norge GT 8v Power supply 12. Lambda probe 13. Side stand 14. Fall sensor THROTTLE BODY PIPES LAYING Pipes from the throttle body to the idle motor should be laid so that the shaped part is inserted in the air filter casing.
Page 242 Norge GT 8v Power supply • Turn on the scanner. • Screw the joints connecting the vacu- ometer pipes on the inlet pipe holes. • Connect the vacuometer pipes to the relative joints. • Set the key to ON. •...
Page 243 Norge GT 8v Power supply difference between the two pressures is 1 cm Hg (1.33 kPa) maximum. If this condition is detected: • take the engine back to idle and check the depression values so that they are aligned between the two cylinders.
Page 244: Injection System
Norge GT 8v Power supply Injection system ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Specification Desc./Quantity Mapping PARAMETERS screen page...
Page 245 Norge GT 8v Power supply Specification Desc./Quantity Lambda integrator When the control unit uses the lambda probe signal (see the 'Lambda' parameter on the 'Statuses' screen page) this value should be close to 0%. Vehicle speed - km/h Target engine revs...
Page 246 Norge GT 8v Power supply ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times Right coil operation for 2.5 m, 5 times...
Page 247 Norge GT 8v Power supply Specification Desc./Quantity Lambda probe Possible short circuit on the earth lead, battery or open circuit or plausibility: recovery function hardly noticeable for customer. Left injector Possible short circuit in the earth lead, battery or open circuit.
Page 248 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 249: Removing The Front Wheel
Norge GT 8v Suspensions Front RONT HEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut 80 Nm (59.00 lbf ft) Front brake disc fixing screw M8x20 25 Nm (18.44 lbf ft) Loctite 243 Front tone wheel fixing screw 4 Nm (2.95 lbf ft)
Page 250 Norge GT 8v Suspensions • Unscrew the screws fixing the front brake callipers and remove them from their seat. • Support the front part of the vehicle. • Remove the nut fixing the wheel pin. • Collect the sealing washer.
Page 251: Installing The Front Wheel
Norge GT 8v Suspensions • During extraction, support the wheel and then remove it. • Collect the spacer from the front wheel right side. Installing the front wheel • Position the wheel together with the right side spacer. • Insert the pin •...
Page 252 Norge GT 8v Suspensions • Insert the sealing washer onto the wheel axle. • Tighten the wheel axle fixing nut to the specified torque • Make sure that the stanchions are aligned by working with the fork. • Tighten the terminal screws that lock the wheel pin to the prescribed torque.
Page 253 Norge GT 8v Suspensions • Fit the front mud guard. Handlebar ANDLEBAR AND ONTROLS pos. Description Type Quantity Torque Notes Half-handlebar lower fixing screw on the up- M8x25 25 Nm (18.44 lbf ft) per steering yoke Half-handlebar upper fixing screw on the up- M8x25 20 Nm (14.75 lbf ft)
Page 254: Front Fork
Norge GT 8v Suspensions Front fork RONT FORK pos. Description Type Quantity Torque Notes Wheel axle locking screw on the fork leg 10 Nm (7.37 lbf ft) Piston fixing screw to the sleeve M10x35 50 Nm (36.87 lbf ft) Fork cap 20 Nm (14.75 lbf ft)
Page 255 Norge GT 8v Suspensions TEERING YOKE pos. Description Type Quantity Torque Notes Fork stanchion fixing screw on the upper plate M8x30 25 Nm (18.44 lbf ft) Fork stanchion fixing screw on the lower plate M8x25 25 Nm (18.44 lbf ft) Upper yoke fixing cap 100 Nm (73.76 lbf ft)
Page 256: Removing The Fork Legs
Norge GT 8v Suspensions 12. Pin 13. Complete cover 14. Counter spring 15. Complete pumping member 16. Ring 17. Lower bushing 18. Stem 19. Preload tube 20. Spring 21. Locking ring 22. Bushing 23. Nut 24. Fifth wheel 25. O-Ring 26.
Page 257 Norge GT 8v Suspensions front wheel • Unscrew the fixing screws of the front brakes callipers and remove them from their seats. • Support the stanchion and loosen the screws on the upper and then the lower plate. See also...
Page 258 Norge GT 8v Suspensions Draining oil To drain out the oil follow these operations: • Remove the fork. • Unscrew the complete upper closing cap. Pay attention to the possible thrust that the spring can cause to the loosened cap.
Page 259 Norge GT 8v Suspensions NOTE FOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPING MEMBER ROD, PRESS THE STEM IN THE WHEEL HOLD- ER SLEEVE TO PUMP OIL OUT. • Carefully check each part of the stem and make sure that there are no damaged elements.
Page 260 Norge GT 8v Suspensions • Remove the locking ring inside the sleeve using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM. • Slide off the stem from the wheel hold- er sleeve together with the lower bush- ing, sealing ring, cap, upper bushing and the entire pumping member.
Page 261 Norge GT 8v Suspensions Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
Page 262 Norge GT 8v Suspensions REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR- FACE. Replace the following 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.
Page 263 Norge GT 8v Suspensions • Carry out any necessary service oper- ation. • On the stem, fit the entire pumping unit together with counter spring and ring. • Check that the upper guide bushing is fitted on the wheel holder fork leg.
Page 264 Norge GT 8v Suspensions • Insert the cap and the well lubricated sealing ring in the stem. • Use a suitable inserting tool to push the sealing ring in the fork leg until it stops. • Fit the locking ring.
Page 265 Norge GT 8v Suspensions Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stanchion. • Pour part of the fork oil into the sleeve. • Wait some minutes until the oil fills all the ducts.
Page 266: Installing The Fork Legs
Norge GT 8v Suspensions • Place the cap on the bearing tube tak- ing care not to damage the O-ring. • Then, tighten the cap to the prescribed torque. Installing the fork legs • Insert the stanchion in position. •...
Page 267 Norge GT 8v Suspensions Steering bearing TEERING YOKE pos. Description Type Quantity Torque Notes Fork stanchion fixing screw on the upper plate M8x30 25 Nm (18.44 lbf ft) Fork stanchion fixing screw on the lower plate M8x25 25 Nm (18.44 lbf ft) Upper yoke fixing cap 100 Nm (73.76 lbf ft)
Page 268 Norge GT 8v Suspensions Adjusting play • Remove the two Side covers removal of the control panel by unscrewing the two fixing screws and releasing the in- ternal peg. • Unscrew the screws on the cable re- tainer plate. •...
Page 269 Norge GT 8v Suspensions • Unscrew the headstock fixing bolt to the upper plate. • Collect 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.
Page 270 Norge GT 8v Suspensions • Rivet the safety washer on the head- stock. CAUTION UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE. • Undo the upper ring nut CAUTION UPON REFITTING TIGHTEN THE UPPER RING NUT MAN- UALLY AND THEN FORCE IT SLIGHTLY UNTIL THE NOTCHES ARE ALIGNED WITH THE RING NUTS.
Page 271: Shock Absorbers
Norge GT 8v Suspensions Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Shock absorber to chassis fixing screw M10x80 50 Nm (36.87 lbf ft) Shock absorber to double connecting rod fix- M10x82 40 Nm (29.50 lbf ft) ing screw...
Page 272 THE VEHICLE USE CONDITIONS. HYDRAULIC REBOUND DAMPING MUST ALWAYS BE IN- CREASED TOGETHER WITH SPRING PRELOAD TO PREVENT UNDESIRABLE BOUNCING. IF NECESSARY, CONTACT AN Official Moto Guzzi Dealer. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
Page 273 Norge GT 8v Suspensions NOTE (2) IF FITTED. Removing • Remove the saddle. • Remove the side fairings. • Screw in the preloading knob until reaching the end of the stroke. • Remove the preloading knob by un- screwing the central screw.
Page 274 Norge GT 8v Suspensions • Remove the lower screw of the single shock absorber. CAUTION BEFORE REMOVING THE LOWER SCREW OF THE SIN- GLE SHOCK ABSORBER, HOLT THE SWINGARM-WHEEL UNIT. • Remove the upper screw of the single shock absorber.
Page 275 INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 276 Norge GT 8v Chassis Swinging arm EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp fixing screw on the bushing M6x25 10 Nm (7.37 lbf ft) 2 - Swingarm fixing screw on the transmission M10x35 50 Nm (36.87 lbf ft)
Page 277 Norge GT 8v Chassis • Engage the first gear. • Unscrew and remove the four screws, collecting the spacers and the dust pro- tection ring. • Remove the rear wheel. • Unscrew and remove the nut fixing the reaction rod.
Page 278 Norge GT 8v Chassis • Loosen the two swingarm terminal screws. • Unscrew and remove the fixing nut of the connecting rod assembly and col- lect the screw. • Disconnect the speed sensor connec- tor and release the cable from the clamps on the chassis.
Page 279 Norge GT 8v Chassis • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft. Checking • Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged;...
Page 280 Norge GT 8v Chassis • Working from both sides, grease the cardan shaft cables with the recom- mended product from the recommen- ded products table. • Block the swingarm, insert the univer- sal joint, align the holes and, at the same time, helped by a second opera- tor, insert the pin completely.
Page 281 Norge GT 8v Chassis • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod. • Place the connecting rod assembly on the swingarm. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly.
Page 282 Norge GT 8v Chassis • Place the rear wheel on the swingarm. • Tighten the four screws with their spacers and the dust-protection ring. • Place the cover. • Place the rear brake calliper on the disc and the brake pipe on the swingarm.
Page 283 Norge GT 8v Chassis • Remove the transmission casing slid- ing off the universal joint. Checking Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. CHAS - 283 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 284 Norge GT 8v Chassis Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). CHAS - 284 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 285 Norge GT 8v Chassis Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). Collect the ring (13). CHAS - 285 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 286 Norge GT 8v Chassis Remove the support unit (8). Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool. Clean the casing faying surfaces carefully. Heat the casing.
Page 287 Norge GT 8v Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. CHAS - 287 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 288 Norge GT 8v Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
Page 289 Norge GT 8v Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer.
Page 290 Norge GT 8v Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
Page 291 Norge GT 8v Chassis Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F).
Page 292 Norge GT 8v Chassis Turn the unit over. Assemble the bearings to the wheel axle. Pinion unit Removal Remove the stop 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.
Page 293 Norge GT 8v Chassis Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (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.
Page 294 Norge GT 8v Chassis Insert the stop ring (1) in the 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. CHAS - 294 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 295 Norge GT 8v Chassis Support unit Removal Remove the bushing (1) with a punch. Turn the support (5) over and remove the 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.
Page 296 Norge GT 8v Chassis Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer.
Page 297: Troubleshooting
Norge GT 8v Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). TROUBLESHOOTING Possible Cause Operation 1.
Page 298 Norge GT 8v Chassis Installing • Insert the transmission casing on the swingarm making sure that the univer- sal joint engages correctly. • Tighten the four screws to the prescri- bed torque operating diagonally. • Place the reaction rod into its seat.
Page 299 Norge GT 8v Chassis • Place the rear wheel on the fork. • Tighten the four screws with their spacers and the dust-protection ring. • Place the cover. • Place the rear brake calliper on the disc and the brake pipe on the fork.
Page 300 Norge GT 8v Chassis • Release and remove the spring be- tween the exhaust end and the cata- lytic converter. • Loosen the clamp between the ex- haust end and the catalytic converter. • Unscrew and remove the muffler fixing nut and collect the screw and the bush- ing.
Page 301 Norge GT 8v Chassis Removing the tail pipe Removing the exhaust manifold CAUTION THE ENGINE AND THE EXHAUST SYSTEM COMPONENTS CAN GET VERY HOT AND REMAIN SO FOR SOME TIME EVEN AFTER THE ENGINE IS TURNED OFF. WEAR INSULATING GLOVES BEFORE HANDLING THESE PARTS OR WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM COOL DOWN.
Page 302 Norge GT 8v Chassis • Loosen the clamp. • Remove the exhaust manifold. Removing the lambda sensor • Unscrew and remove the lambda sensor. • Remove the exhaust manifold. See also Removing the exhaust manifold CHAS - 302 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 303 Norge GT 8v Chassis Engine oil cooler ADIATOR pos. Description Type Quantity Torque Notes Solenoid valve to radiator fixing screw M5x60 4 Nm (2.95 lbf ft) Radiator fixing pin on the grille 4 Nm (2.95 lbf ft) Radiator to grille fixing screw 4 Nm (2.95 lbf ft)
Page 304 Norge GT 8v Chassis • Unscrew the two right fairing lug side fixing screws. • 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.
Page 305 Norge GT 8v Chassis • Unscrew and remove the side fixing screw of the left fairing lug. • Remove the left fairing lug. • Drain the engine oil. • Undo and remove the two front fixing screws of the oil radiator.
Page 306 Norge GT 8v Chassis See also Replacement Side fairings CHAS - 306 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 307 INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 308 Norge GT 8v Braking system RAKE YSTEM pos. Description Type Quantity Torque Notes Brake pipe slot screw on the pump 25 Nm (18.44 lbf ft) Joint with brake pipes retainer bleeding on the 25 Nm (18.44 lbf ft) calliper Brake pipes joint on the ABS hydraulic unit 25 Nm (18.44 lbf ft)
Page 309 Norge GT 8v Braking system Key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. ECU 6. Instrument panel 7. K line (diagnosis) 8. Key 9. Right Light Switch ABS ECU control unit pin configuration: •...
Page 310 Norge GT 8v Braking system • PIN 2 - PCC1 - Vehicle identification ground connection • PIN 3 - Speed signal to the ECU control unit • PIN 4 - IGN - Key • PIN 7 - ABS OFF - ABS Deactivation button •...
Page 311 Norge GT 8v Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 311 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 312 Norge GT 8v Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS CONTROL UNIT 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed)
Page 313 Norge GT 8v Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
Page 314 Norge GT 8v Braking system - the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel; it is not possible to brake for an instant. - if the speed difference lasts long, the system may detect an error and deactivates the ABS system.
Page 315 Norge GT 8v Braking system • Once riding, the ABS system will be re- activated only after riding faster than 5 km/h (3.1 mi/h) and the ABS warning light (5) on the instrument panel (4) turns off. CAUTION IF THE ABS SWITCH IS PRESSED FOR MORE THAN TEN SECONDS, THE SYSTEM DETECTS A FAILURE.
Page 316 Norge GT 8v Braking system The system operates perfectly just as any other braking system without ABS. The detection of malfunctions may require more or less time according to the type of failure. Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time.
Page 317 Norge GT 8v Braking system ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Characteristic Value/example Unit of Notes measure ment...
Page 318 Norge GT 8v Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION Characteristic Value/example Unit of Notes measure ment Front brake bleeding procedure...
Page 319 Norge GT 8v Braking system ERRORS Characteristic Value/example Unit of Notes measure ment Front speed sensor: 5D90 electric Electrical fault in sensor or cable harness malfunction Front speed sensor: 5D91 the signal Faulty sensor or signal interference works irregularly Front speed sensor: 5D92 the signal...
Page 320 Norge GT 8v Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters. ADJUSTMENTS Characteristic Value/example Unit of Notes measure ment Coding (1) Used for re-coding the control unit or coding a new one.
Page 321 Norge GT 8v Braking system • Undo and remove the two control unit fixing screws. See also Fuel tank • Disconnect the ABS control unit con- nector. • Remove the ABS control unit. INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR •...
Page 322 Norge GT 8v Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig.
Page 323 Norge GT 8v Braking system 0.3 - 2.00 mm (0.012 - 0.079 in) for the front one; 0.3 - 2.00 mm (0.012 - 0.079 in) for the rear one; CAUTION IF A VALUE BEYOND THE TOLERANCE RANGE IS MEAS- URED, REPLACE THE SENSOR (1) AND/OR THE TONE WHEEL (2) AND REPEAT THE CHECKS;...
Page 324 Norge GT 8v Braking system RAKE ALLIPER pos. Description Type Quantity Torque Notes Rear brake calliper fixing screw 50 Nm (36.87 lbf ft) Front brake calliper RONT BRAKE CALLIPERS pos. Description Type Quantity Torque Notes Front brake calliper fixing screws 50 Nm (36.87 lbf ft)
Page 325: Front Brake Pads
Norge GT 8v Braking system • The following operations are to be car- ried out with brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points. If the mini-...
Page 326: Rear Brake Pads
Norge GT 8v Braking system Removal • Turn the pins and remove both split pins. • Remove both pins. • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 327 Norge GT 8v Braking system Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. • Remove the split pin. • Remove the pin.
Page 328 Norge GT 8v Braking system • Insert the pin. • Place the split pin. • Check the brake fluid level in the res- ervoir. Installing • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes.
Page 329 Norge GT 8v Braking system Bleeding the braking system VEHICLE PREPARATION • It is important to check that there is always enough brake fluid in the reservoir. • Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid replacement"...
Page 330 Norge GT 8v Braking system REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it. • Fully press down the lever and the brake pedal and fix them into position with the respective locking devices.
Page 331 Norge GT 8v Braking system • 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 system and if everything is ok, continue bleeding operations using Navigator as described.
Page 332 Norge GT 8v Braking system BLEEDING SYSTEM WITH NAVIGATOR This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy. The operations described here are valid for both systems even though the description refers to the front system.
Page 333 Norge GT 8v Braking system REGULAR AIR BLEEDING SYSTEM • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid.
Page 334 Norge GT 8v Braking system WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. REGULAR AIR BLEEDING SYSTEM • Remove the rubber protection cover from the bleed valve. •...
Page 335 Norge GT 8v Braking system Front brake pump RONT RAKE EVER pos. Description Type Quantity Torque Notes Front brake pump U-bolt fixing screw 10 Nm (7.37 lbf ft) Sequence 1-2-1 BRAK SYS - 335 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 336 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 337 Norge GT 8v Bodywork RONT IGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw 6 Nm (4.42 lbf ft) Horn fixing screw 10 Nm (7.37 lbf ft) NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Instrument panel fixing screw 3 Nm (2.21 lbf ft)
Page 338 Norge GT 8v Bodywork pos. Description Type Quantity Torque Notes Ignition lock fixing screw M8x30 25 Nm (18.44 lbf ft) Ignition lock shear head fixing screw M8x28 At the point of fail- INDSHIELD pos. Description Type Quantity Torque Notes Top fairing fixing screw M5x9 4 Nm (2.95 lbf ft)
Page 339 Norge GT 8v Bodywork INDSHIELD pos. Description Type Quantity Torque Notes Windshield link rod fixing screw on the frame M6x25 10 Nm (7.37 lbf ft) Aesthetic support fixing screw 4 Nm (2.95 lbf ft) Engine guide lock to frame upper fixing screw 10 Nm (7.37 lbf ft)
Page 340 Norge GT 8v Bodywork Tail pos. Description Type Quantity Torque Notes Handgrip to chassis fixing screw M8x25 25 Nm (18.44ft) Tail to handgrip and to rear fairings fixing M5x9 4 Nm (2.95 lbf ft) screw Hooks and tail fairing to chassis fixing screw 20 Nm (14.75 lbf ft)
Page 341 Norge GT 8v Bodywork EAR LIGHTS pos. Description Type Quantity Torque Notes Handgrip taillight fixing screw M5x16 4 Nm (2.95 lbf ft) Rear turn indicator fixing screw 2 Nm (1.47 lbf ft) PLASH GUARD pos. Description Type Quantity Torque Notes Splash guard fixing screw to the chassis 10 Nm (7.37 lbf ft)
Page 342 Norge GT 8v Bodywork • Remove the top fairing glass. Side fairings HEAD GUARD • Undo and remove the three fixing screws. • Remove the head guard. RIGHT SIDE FAIRING • Remove the head guard. • Undo and remove the three screws in- dicated.
Page 343 Norge GT 8v Bodywork • Remove the fairing, by pulling it from the centring screw. LEFT SIDE FAIRING • Remove the left fairing lug. • Remove the head guard. • Remove the fairing cover. • Undo and remove the two screws indi- cated.
Page 344 Norge GT 8v Bodywork Air box • Remove the fuel tank. • Disconnect the connector from the air temperature sensor. • Remove the oil breather pipe. • Unscrew and remove the two screws from the oil vapour recovery reservoir. •...
Page 345 Norge GT 8v Bodywork • Move the oil vapour recovery reservoir aside. • Unscrew and remove the two front screws from the air filter casing. • Operating from both sides, loosen the clamp and slide off the sleeve from the throttle body.
Page 346: Fuel Tank
Norge GT 8v Bodywork Fuel tank • Remove the saddle. • Working from both sides, undo and re- move the screw. • Operating from both sides, lift the side fairing to remove it and slide it off the pin. •...
Page 347 Norge GT 8v Bodywork • Lift the fuel tank and remove the pipes from the "T" joint. • Disconnect the connector. • Disconnect the fuel pipe. • Remove the fuel tank by sliding it off and back. BODYW - 347...
Page 348 Norge GT 8v Bodywork Instrument cluster cover • Remove the two side covers of the con- trol panel. • Remove the top fairing glass. • Operating from both sides, unscrew the four screws indicated. • Undo and remove the upper front screw.
Page 349 Norge GT 8v Bodywork Headlight fairing • Remove the left side fairing. • Remove the fuel tank. • Remove the control panel with the in- strument panel. • Working from both sides, unscrew and remove the two screws indicated. •...
Page 350 Norge GT 8v Bodywork • Disconnect the connectors of the turn indicators. • Disconnect the two connectors from the front headlight. • Remove the upper fairings together with the headlight. See also Side fairings Fuel tank Adjustable windscreen • Remove the upper fairings.
Page 351 Norge GT 8v Bodywork • Undo and remove the two upper screws. • Working from both sides, unscrew and remove the upper windshield fixing screws. • Disconnect the windshield driving en- gine connector. • Unscrew and remove the two fixing...
Page 352 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 353 Norge GT 8v Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 354: Road Test
Norge GT 8v Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 355 Norge GT 8v Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 356 ABS: 309, 316 Air filter: 64 Air temperature sensor: 111, 125 Alternator: Battery: 99, 102 Brake: 323–326, 335 Brake calliper: 323, 324 Brake disc: 324, 325 Brake lever: Brake pads: 325, 326 Brake pump: 335 Clutch: 122, 175, 178, 179, 216 Coil: 118 Connectors: 127 Crankcase: 49, 215, 222...
Page 357 Identification: 10 Instrument panel: 125 Maintenance: 8, 59, 322 Maintenance Table: Mudguard: Oil filter: 63 Oil pressure sensor: 120 Oil sump: 231, 234 Primary shaft: 155, 160–162 Radiator: Rear wheel: Recommended products: 50, 281 Run/Stop switch: 126 Secondary shaft: 157, 160, 162 Shock absorber: Shock absorbers: 271 Side fairings: 342...

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