MOTO GUZZI 1200 SPORT 4V Service Station Manual
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MOTO GUZZI 1200 SPORT 4V Service Station Manual

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SERVICE STATION MANUAL
981092
1200 SPORT 4V

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  • Page 1 SERVICE STATION MANUAL 981092 1200 SPORT 4V...
  • Page 2 Not all versions shown in this publication are available in all countries. The availability of individual versions should be checked with the official Moto Guzzi sales network. © Copyright 2008- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Moto Guzzi - After sales service.
  • 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

    1200 SPORT 4V 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 run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 1200 SPORT 4V Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES.
  • 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 1200 SPORT 4V Characteristics This number consists of numbers and letters, as in the example shown below. ZGULPR000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LP: model; R00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario);...
  • Page 12 1200 SPORT 4V Characteristics Specification Desc./Quantity Compression ratio 11: 1 Electric starter Idle speed 1100 ± 100 rpm Clutch hydraulic single plate dry clutch with integrated flexible coupling Lubrication system Pressurised circuit with regulator valves and trochoidal pump Air filter...
  • Page 13 1200 SPORT 4V Characteristics Specification Desc./Quantity Instrument panel lighting License plate light 12V - 5 W Turn indicator warning light Neutral gear warning light Alarm warning light Side stand down warning light Low fuel warning light High beam warning light...
  • Page 14 1200 SPORT 4V Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Type hollow 3-spoke rim in chilled cast aluminium alloy Front wheel rim 3.50" x 17" Rear wheel rim 5.50" x 17" Tyres METZELER Roadtec Z6 MICHELIN Pilot Road...

  • Page 15: Oil Sump

    1200 SPORT 4V Characteristics OIL SUMP Name Torque in Nm Oil pipe on sump reduction (1) 20 Nm (14.75 lbf ft) Oil pipe on sump 20 Nm (14.75 lbf ft) Oil sump lower screw - TCEI M6x30 (4) 10 Nm (7.38 lbf ft) Oil sump screw - TCEI M6x55 (14) 10 Nm (7.38 lbf ft)

  • Page 16: Side Stand

    1200 SPORT 4V Characteristics CHASSIS TO ENGINE UNIT Name Torque in Nm M6x40 TCEI DA screw 8 -12 Nm Reduction 20 Nm FUEL SUPPLY CONTROL UNIT Name Torque in Nm M5x12 TCEI screw 6 -7 Nm Stainless M5x16 TBEI flanged screw...

  • Page 17: Rear Suspension

    1200 SPORT 4V Characteristics Name Torque in Nm Tube lock plate to steering base retainer 6 Nm Fork stem to lower / upper plate retainer 25 Nm Headstock ring nut 40 Nm Headstock counter ring nut manual + 90 degrees...

  • Page 18: Fuel Tank

    1200 SPORT 4V Characteristics ELECTRICAL SYSTEM Name Torque in Nm Horn retainer 15 Nm Speed sensor to front fork retainer 12 Nm INSTRUMENT PANEL AND LIGHTS Name Torque in Nm Instrument panel support to light support retainer 10 Nm Instrument panel support to fork upper plate retainer...
  • Page 19 1200 SPORT 4V Characteristics Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value speci- fied, it is necessary to replace cylinders and pistons. The pistons of an engine must be balanced; a weight difference of up to 1.5 g (0.0033 lb) is allowed.
  • Page 20 1200 SPORT 4V Characteristics CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON Specification Desc./Quantity Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in) Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in) Oil scraper ring 0.010 - 0.045 mm (0.00039 - 0.00177 in) Gap between the end of the piston rings inserted in the cylinder: •...
  • Page 21 1200 SPORT 4V Characteristics 020676Y Comparator support for piston posi- tion checking • 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 22 1200 SPORT 4V Characteristics Product Description Specifications exceed the requirements of SAE J1703, NHTSA 116 DOT 4, ISO 4925 synthetic fluid specifications. AGIP BRAKE 4 / BRAKE 5.1 Clutch fluid As an alternative for recommended flu- ids, use top branded fluids that meet or...
  • Page 23 INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 24: Special Tools

    1200 SPORT 4V Special tools SPECIAL TOOLS Stores code Description 020677Y Alternator belt tensioner, Belt tensioning lever 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 25 1200 SPORT 4V Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow 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...
  • Page 26 1200 SPORT 4V Special tools Stores code Description 14.92.71.00 Tool to fit the sealing ring on the flywheel- side flange 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with sealing ring on the crankshaft 19.92.71.00 Tool to fit the sealing ring on the flywheel-...
  • Page 27 1200 SPORT 4V Special tools Stores code Description 020676Y Comparator support for piston position checking 020678Y Tool for clutch rod checking 05.91.26.30 Tool for tightening the swingarm pin ring nut - clutch hub AP8140190 Tool for steering tightening 05.90.27.30 Gearbox support 05.90.27.31...
  • Page 28 1200 SPORT 4V Special tools Stores code Description 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 05.90.27.36 Bevel gear pair support 020689Y Spark plug removal Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 29 INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 30: Maintenance Chart

    1200 SPORT 4V Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check and clean, adjust or replace if necessary before every ride.

  • Page 31: Spark Plug

    1200 SPORT 4V Maintenance Spark plug For removal: • With a flat screwdriver, remove the Mo- to Guzzi oval symbol. • Undo and remove the fixing screw of the spark plug tube protection. • Remove the spark plug tube protec- tion.

  • Page 32: Transmission Fluid

    1200 SPORT 4V Maintenance CAUTION DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP. The electrode gap should be between 0.6 - 0.7 mm (0.023 - 0.027 in). Replace the spark plug if the gap is different. • Make sure that the washer (6) is in good conditions.

  • Page 33: Engine Oil

    1200 SPORT 4V Maintenance Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN. NOTE RIDE SOME km (miles) TO WARM UP ENGINE OIL • Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3).
  • Page 34 1200 SPORT 4V Maintenance • Shut off the engine. • Keep the vehicle upright with the two wheels on the ground. • Unscrew and remove the dipstick (1). • Clean the dipstick (1). • Reinsert the dipstick (1) into the open- ing but do not screw it.

  • Page 35: Engine Oil Filter

    1200 SPORT 4V Maintenance • Unscrew and remove the filler plug (1). • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and if necessary, replace the sealing washers of drainage plug (2).
  • Page 36 1200 SPORT 4V Maintenance • Shut off the engine. • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1) placed on the gearbox right side. • • The level is correct if the oil is on the rim of the hole of the cap/dipstick (1).

  • Page 37: Air Filter

    1200 SPORT 4V Maintenance Air filter • Remove the fuel tank. • Disconnect the connector from the air temperature sensor. • Remove the oil breather pipe. • Unscrew and remove the five screws. • Lift the filter casing cover. •...

  • Page 38: Braking System

    1200 SPORT 4V Maintenance ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION STROKE (VALVES CLOSED). • Disconnect both spark plug tubes. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings.
  • Page 39 1200 SPORT 4V Maintenance • For the front brake, turn the handlebar fully to the right. • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug.
  • Page 40 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 41 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 42 1200 SPORT 4V Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 42...
  • Page 43 1200 SPORT 4V Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Battery 9 Main fuses 10 Lambda probe 11 Intake air temperature sensor 12 Engine revolution sensor 13 Auxiliary fuses 14 Head temperature sensor 15 Engine control unit...
  • Page 44 1200 SPORT 4V Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. CLUTCH SWITCH 3. MAINTENANCE RELAY 4. START-UP RELAY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 44...
  • Page 45 1200 SPORT 4V Electrical system 5. LIGHT RELAY 6. RIGHT LIGHT SWITCH 7. HAZARD BUTTON 8. HORN 9. LEFT LIGHT SWITCH 10.INSTRUMENT PANEL AIR TEMPERATURE THERMISTOR 11.INSTRUMENT PANEL 12.KEY SWITCH 13.IMMOBILIZER AERIAL 14.HEATED HANDGRIPS 15.HEATED HANDGRIP CONTROL 16.REAR RIGHT TURN INDICATOR 17.REAR LIGHT (LED)
  • Page 46 1200 SPORT 4V Electrical system 43.LEFT SPARK PLUG 44.--- 45.RIGHT CYLINDER COIL 46.LEFT CYLINDER COIL 47.RIGHT CYLINDER INJECTOR 48.LEFT CYLINDER INJECTOR 49.SPEED SENSOR 50.Fall sensor 51.PICK-UP 52.PICK-UP WIRE SHIELDING 53.ECU 54.Front left turn indicator 55.TAIL LIGHT BULB 56.LOW-BEAM BULB 57.HIGH-BEAM BULB 58.FRONT HEADLAMP...
  • Page 47 1200 SPORT 4V Electrical system 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 48 1200 SPORT 4V Electrical system Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25 Injector 1 Error DC V DC ECU 26 Injector 1 Error DC Gnd ECU 27 Injector 2 Error DC V DC ECU 30...
  • Page 49 Use the Ditech connector in the Axone 2000 Apri- lia-Moto Guzzi package to connect to the Axone cable. KEY CHANGE FUNCTION This function can be used: 1) if one key is lost;...
  • Page 50 1200 SPORT 4V 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 51 1200 SPORT 4V Electrical system Lights list FRONT HEADLAMP Tail light: 12V - 5W Low-beam light: 12 V - 55 W H7 High-beam light: 12 V - 65 W H9 REAR LIGHT Fuses AUXILIARY FUSES A - Stop, horn, Hazard button illumination, light re- lay coil (15 A).

  • Page 52: Control Unit

    1200 SPORT 4V Electrical system MAIN FUSES 1 - From battery to voltage regulator (30 A). 2 - From battery to key and auxiliary fuses C - D (30 A). NOTE THERE IS ONE SPARE FUSE. Control unit Model: Magneti Marelli IAW 5 AM2...
  • Page 53 1200 SPORT 4V Electrical system 19 Stepper motor (-) 20 5V power supply (NTC sensors) 21 Not used 22 Not used 23 Neutral sensor signal 24 Not used 25 Engine revolution sensor signal 26 Not used 27 Not used 28 Left cylinder injector control...
  • Page 54 1200 SPORT 4V Electrical system 17 Power supply from main relay 18 Not used 19 Not used 20 CAN - H line (ccm/instrument panel) 21 Not used 22 Oxygen probe signal 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 "Engine stop"...

  • Page 55: Speed Sensor

    1200 SPORT 4V Electrical system Speed sensor Function To indicate the vehicle speed by reading the front wheel turning speed. Operation / operating principle HALL effect sensor: a square-wave pulse is gen- erated with voltage approx. between 0 V and 11 V...
  • Page 56 1200 SPORT 4V Electrical system • Check continuity of the cable between PIN 2 of the sensor and PIN 24 of the ECU blue connector. • Check PIN 24 of the blue connector. • If after all these checks the failure is not found, replace the sensor.
  • Page 57 1200 SPORT 4V Electrical system 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 58 1200 SPORT 4V Electrical system • PINS A-C: throttle closed approx. 2.5 kOhm; throttle open approx. 1.5 kOhm. • PINS A-B: approx. 1.1 kOhm Pin-out: • PIN A: ground connection • PIN B: supply voltage +5V • PIN C: potentiometer signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS;...
  • Page 59 1200 SPORT 4V Electrical system resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive and the cable harness should be restored • shorted to negative: disconnect the sensor connector and check the ground insulation of the red cable (from throttle sensor connector or control unit connector): if there is continuity to ground, restore the cable harness;...
  • Page 60 1200 SPORT 4V Electrical system Specification Desc./Quantity Resistance at +60 °C (140 °F) 0.750 kOhm Resistance at +70 °C (158 °F) 0.530 kOhm Resistance at +80 °C (176 °F) 0.380 kOhm Resistance at +90 °C (194 °F) 0.280 kOhm Resistance at +100 °C (212 °F) 0.204 kOhm...
  • Page 61 1200 SPORT 4V Electrical system error is displayed at the same time, this means that the grey cable common for both sensors is shorted to positive. • If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;...
  • Page 62 1200 SPORT 4V Electrical system Air temperature In case of failure, 25°C is set as temperature AXONE: ELECTRICAL ERRORS Air temperature sensor P0110 - Open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of the BROWN connector.
  • Page 63 1200 SPORT 4V 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 64 1200 SPORT 4V Electrical system AXONE: STATUSES Lambda check Example value: Open loop / Closed loop Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value.
  • Page 65 1200 SPORT 4V Electrical system PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector) and restore the cable harness. Injector Function To supply the correct amount of petrol at the right timing. Operation / operating principle Injector coil is excited for the petrol passage to open.
  • Page 66 1200 SPORT 4V Electrical system • Shorted to positive: disconnect the injector connector, take the key to ON and check if there is voltage on the grey/red cable: if there is voltage, restore the cable harness. If there is no voltage, replace the injector.
  • Page 67 1200 SPORT 4V Electrical system tween PIN 37 of the BROWN connector and the component PIN - and restore the cable harness. Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark. Operation / operating principle...
  • Page 68 1200 SPORT 4V Electrical system • If shorted to positive: excessive voltage has been detected at PIN 38 of the BROWN con- nector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 38...
  • Page 69 1200 SPORT 4V Electrical system continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON, check the cable ground insulation (from coil connector or control unit connector). If this is not OK, restore the cable harness.
  • Page 70 1200 SPORT 4V Electrical system It this error persists, use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit: in neutral or in gear.
  • Page 71 1200 SPORT 4V Electrical system that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is shorted to ground: restore the cable harness. Clutch lever sensor Function It tells the clutch lever position to the control unit.
  • Page 72 1200 SPORT 4V Electrical system the sensor. If the circuit is open, it means that the yellow/purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground: restore the cable harness Side stand sensor Function It tells the side stand position to the control unit.

  • Page 73: Bank Angle Sensor

    1200 SPORT 4V Electrical system Bank angle sensor Function it tells the vehicle position to the control unit. Operation / operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this earthing, it disables the fuel pump circuit and the engine start-up circuit via the injection relay.
  • Page 74 1200 SPORT 4V Electrical system Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel. Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:Temperature sensors Location: •...
  • Page 75 1200 SPORT 4V Electrical system If a short circuit to ground is detected at PIN 9 of the instrument panel connector, the display will show a full scale air temperature indication of 60°C Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the cable harness;...
  • Page 76 1200 SPORT 4V Electrical system Example value:Run/Stop DIAGNOSIS • Indication on Axone always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity between the blue/green (PIN 1) cable and the grey/sky blue (PIN 4) cable (sensor side): if there is not continuity, replace the sensor; if there is, check the connector.
  • Page 77 1200 SPORT 4V Electrical system 15 ANTITHEFT DEVICE LED (IF CONNECTED) 16 SELECT 3 17 SENSORS EARTH CONNECTION 18 GENERAL EARTH CONNECTION 19 GENERAL EARTH CONNECTION 20 GENERAL EARTH CONNECTION 21 + BATTERY 22 + BATTERY 23 LOW-BEAM LIGHT RELAY ACTIVATION...
  • Page 78 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 79 1200 SPORT 4V Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • From the back, secure the vehicle with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
  • Page 80 1200 SPORT 4V Engine from vehicle • Disconnect the engine temperature sensor connector • Disconnect the revolution sensor con- nector. • Disconnect the alternator connectors. • Disconnect the neutral sensor connec- tor. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 81 1200 SPORT 4V Engine from vehicle • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the starter motor connec- tors. • Unscrew and remove the three screws and remove the clutch control cylinder. • Lock the cylinder using a clamp to pre- vent oil leaks.
  • Page 82 1200 SPORT 4V Engine from vehicle • Unscrew and remove the nut. • Remove the front tank protection. • Disconnect the stand sensor connec- tor and release it from the clamps. • Unscrew and remove the oil cooling ra- diator upper fixing stud bolt.
  • Page 83 1200 SPORT 4V Engine from vehicle • Working from both sides, unscrew and remove the three inlet manifold screws. • Collect the gasket. • Remove both footrest holding plates. • Unscrew and remove the lower nut fix- ing the engine and collect the washer.
  • Page 84 1200 SPORT 4V Engine from vehicle • Unscrew and remove the upper nut fix- ing the engine and collect the washer. • Remove the upper pin and collect the washer. • Lower the engine completely. • Lift the rear part of the vehicle.
  • Page 85 1200 SPORT 4V 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 86 1200 SPORT 4V Engine from vehicle • Working from both sides, place the in- let manifold fitting a new gasket be- tween the manifold and head. • Fasten the inlet manifold with the three screws. • Connect the stand sensor connector and fix it to the chassis with new clamps.
  • Page 87 1200 SPORT 4V Engine from vehicle • Place the front tank protection. • Screw the nut. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors.
  • Page 88 1200 SPORT 4V Engine from vehicle • Connect the ground leads and tighten the stud bolt. • Connect the neutral sensor connector. • Connect the alternator connectors. • Connect the revolution sensor connec- tor. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 89 1200 SPORT 4V Engine from vehicle • Connect the engine temperature sen- sor connector. • Connect and adjust the throttle grip ca- ble clearance. • Place the swingarm with cardan shaft and the rear wheel. • Working on both sides, connect the in- jector connectors.
  • Page 90 INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 91 1200 SPORT 4V Engine Gearbox Diagram Key: 1. Ball bearing Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 91...
  • Page 92 1200 SPORT 4V 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 93 1200 SPORT 4V 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 94 1200 SPORT 4V 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 fitting on the sump.
  • Page 95 1200 SPORT 4V Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 96 1200 SPORT 4V 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 97 1200 SPORT 4V 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 98 1200 SPORT 4V 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 99 1200 SPORT 4V Engine • Remove the forks and collect the shaft. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 99...
  • Page 100 1200 SPORT 4V 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 101 1200 SPORT 4V Engine • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fifth gear and collect the ball bearing cage.
  • Page 102 1200 SPORT 4V Engine • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft. • Operate on the shaft from the grooved side. • Remove the shoulder washer.
  • Page 103 1200 SPORT 4V Engine • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fourth gear and collect the ball bearing cage. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 104 1200 SPORT 4V Engine • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the fifth gear. • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage.
  • Page 105 1200 SPORT 4V Engine Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications. Characteristic Shaft coaxiality limit 0.08 mm (0.0031 in) Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
  • Page 106 1200 SPORT 4V Engine Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS. • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if nec- essary.
  • Page 107 1200 SPORT 4V Engine 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. If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.
  • Page 108 1200 SPORT 4V 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 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 109: Removing The Generator

    1200 SPORT 4V Engine Removing the generator • Remove the fuel tank. • Remove the control unit from its seat. • Disconnect the alternator connectors. • Undo and remove the five screws and collect the bushings. • Remove the cover.
  • Page 110 1200 SPORT 4V Engine • 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. • Using a compressed air gun, unscrew and remove the nut and collect the spacer.
  • Page 111 1200 SPORT 4V Engine • Undo and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 111...
  • Page 112 1200 SPORT 4V Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Remove both side fairings of the fuel tank. • Remove the right exhaust manifold. • Remove the grille under the head- stock.
  • Page 113 1200 SPORT 4V Engine • Remove the engine oil radiator. • Disconnect the horn connectors. • Remove the support plate of the en- gine oil radiator. • Remove the four fixing screws of the timing system cover. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 114: Installing The Generator

    1200 SPORT 4V Engine • Remove the timing system cover. • Loosen the lock nut of the set screw. • By using the belt tensioning tools, ten- sion the belt to the prescribed torque. Specific tooling 020677Y Alternator belt tensioner, Belt ten- sioning lever •...
  • Page 115 1200 SPORT 4V Engine • Replace the gasket and place the al- ternator frame using the front cover in- sertion cone. • Remove the insertion cone afterwards. Specific tooling 05.91.17.30 Front cover insertion cone • Tighten the two screws. •...
  • Page 116 1200 SPORT 4V Engine • Position the lower pulley and the spacer. • Tighten the nut to the prescribed tor- que. • Position the alternator and the timing system belt. • Position the screw and pre-tighten it. • Position the screw and tighten the nut.
  • Page 117 1200 SPORT 4V Engine • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool. • Lock the set screw in position by screwing the lock nut.

  • Page 118: Starter Motor

    1200 SPORT 4V Engine Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor. Clutch side Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 119 1200 SPORT 4V Engine Disassembling the clutch Key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch disc 6. Crown 7. TCEI screw 8. Clutch pressure plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing...
  • Page 120 1200 SPORT 4V Engine 20.TE flanged screw • Remove the complete gearbox. • Undo and remove the six screws. • Remove the start-up crown gear. • Remove the clutch bell and the friction disc. • Remove the Seeger ring. •...
  • Page 121 1200 SPORT 4V Engine • Undo and remove the six screws and collect the belleville springs. • Remove the clutch disc. 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 122 1200 SPORT 4V 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 123 1200 SPORT 4V 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 124 1200 SPORT 4V Engine Head and timing 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 125 1200 SPORT 4V Engine 20.TE flanged screw 21.O-ring 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...

  • Page 126: Removing The Cylinder Head

    1200 SPORT 4V Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD 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 127 1200 SPORT 4V 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 128 1200 SPORT 4V 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 129: Cylinder Head

    1200 SPORT 4V 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 130 1200 SPORT 4V 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 131: Removing The Valves

    1200 SPORT 4V 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 132: Checking The Cylinder Head

    1200 SPORT 4V Engine The valve guides should be replaced only if the clearance between them and the stem cannot be elim- inated by simply replacing the valves. To refit the valve guides on the head, follow this procedure: •...

  • Page 133: Installing The Valves

    1200 SPORT 4V 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 134 1200 SPORT 4V 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 135 1200 SPORT 4V 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 136 1200 SPORT 4V Engine Removing the phonic wheel • Remove the generator and the timing system cover. • Unscrew and remove the nut and col- lect the washer. • Remove the timing system gear on the service shaft. • Remove the timing sensor and any shim washers.
  • Page 137 1200 SPORT 4V Engine • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting. • Slide off the service shaft from the chains. • Remove both chains. See also Removing the phonic wheel Installing the service shaft •...
  • Page 138 1200 SPORT 4V Engine • Partially fit the service shaft closing cap. • To screw the cap until it stops, use two M6 flanged screws larger than the orig- inal screws. • Tighten the two M6 flanged screws op- erating in stages until the cap stops against the crankcase.
  • Page 139 1200 SPORT 4V 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 140 1200 SPORT 4V 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 141 1200 SPORT 4V 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 142 1200 SPORT 4V 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 143 1200 SPORT 4V 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. Snap ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket 13.Left cylinder...
  • Page 144 1200 SPORT 4V Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head, the gasket between the head and the cylinder and the two dowel pins.
  • Page 145 1200 SPORT 4V 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 146 1200 SPORT 4V 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 147 1200 SPORT 4V 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 148 1200 SPORT 4V 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 149: Installing The Cylinder Head

    1200 SPORT 4V 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 150 1200 SPORT 4V 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 151 1200 SPORT 4V 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 152 1200 SPORT 4V 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 153 1200 SPORT 4V 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 154 1200 SPORT 4V 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 155 1200 SPORT 4V 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 156 1200 SPORT 4V 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 157 1200 SPORT 4V 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 158 1200 SPORT 4V 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 159 1200 SPORT 4V 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 160 1200 SPORT 4V 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 161 1200 SPORT 4V Engine 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 162 1200 SPORT 4V Engine • Remove the nipple - oil pump fitting. • 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 163 1200 SPORT 4V Engine • Undo and remove the three screws. • Remove the oil pump. • Remove the gasket between the crankcase and the oil pump. See also Replacement Removing the generator Installing • Place a new gasket between the crank- case and the oil pump.
  • Page 164 1200 SPORT 4V Engine • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque.
  • Page 165 1200 SPORT 4V Engine • Insert the joint in the oil pump. • 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 166 1200 SPORT 4V Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Undo and remove the four screws. • Remove the flange. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 167 1200 SPORT 4V Engine • Undo and remove the two screws. • Remove both filters. • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com-...
  • Page 168 1200 SPORT 4V 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 169 1200 SPORT 4V Engine • Tighten the thermostatic valve plug. • 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.
  • Page 170 1200 SPORT 4V Engine • Check that the O-rings are fitted on the oil pump. • Fit the cooling oil intake filter. • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque.
  • Page 171 1200 SPORT 4V Engine • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 171...
  • Page 172 INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 173: Circuit Diagram

    1200 SPORT 4V Power supply Circuit diagram Key: 1. Full fuel tank 2. Fuel pipe 3. Throttle body 4. Joint 5. Three-way joint 6. Pipe Injection Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten P SUPP - 173...
  • Page 174 1200 SPORT 4V 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 12.
  • Page 175 1200 SPORT 4V Power supply 13 Lambda probe 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. The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right.
  • Page 176 1200 SPORT 4V Power supply • Turn on the scanner. • Screw the joints connecting the vacuometer pipes on the inlet pipe holes. • Connect the vacuometer pipes to the relative joints. • Set the key to ON. • Make sure there are no errors in the control unit; otherwise, solve them and repeat the procedure.
  • Page 177 1200 SPORT 4V Power supply Otherwise, open only the screw with higher depression, using the by-pass screws, to compensate. If there is a larger difference: • act on the set screw of the throttle body connecting rod to reduce the pressure difference in the two pipes.
  • Page 178 1200 SPORT 4V Power supply Iso screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO DISPLAY Specification Desc./Quantity Mapping Engine parameter reading screen page ENGINE PARAMETER READING...
  • Page 179 1200 SPORT 4V Power supply Specification Desc./Quantity Target engine revs 1150 rpm (approximate values) Parameter valid at idle, setting depends especially on the en- gine temperature: the control unit will try to keep the engine running at this revs, acting on the ignition advance and the...
  • Page 180 1200 SPORT 4V Power supply Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. DEVICES ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times...
  • Page 181 1200 SPORT 4V Power supply Specification Desc./Quantity Right injector Possible short circuit in the earth lead, battery or open circuit. If both injectors do not work, the engine does not work Fuel pump relay Possible short circuit in the earth lead, battery or open circuit: the engine does not start.
  • Page 182 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 183: Front Fork

    1200 SPORT 4V Suspensions Front Front fork Diagram Key: 1. Left pumping member rod 2. Sticker 3. Complete cap 4. Right sleeve 5. Left sleeve 6. Upper bushing 7. Cap 8. Sealing ring 9. Snap ring 10.Dust guard 11.TCEI screw 12.Washer...

  • Page 184: Removing The Fork Legs

    1200 SPORT 4V Suspensions 15.Right pumping member rod 16.Lock nut 17.Washer 18.Preloading pipe 19.Spring 20.Lower bushing 21.Stem 22.Complete cap 23.Screw with O-ring 24.Sticker 25.Pin 26.Spring 27.Ball 28.O-ring 29.Set screw 30.O-ring Removing the fork legs • Unscrew the screws fixing the front mudguard and remove it.
  • Page 185 1200 SPORT 4V 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 186 1200 SPORT 4V Suspensions • Remove the wheel pin by inserting a screwdriver in the holes on the pin. • During extraction, support the wheel and then remove it. • Collect the spacer from the front wheel right side. •...
  • Page 187 1200 SPORT 4V Suspensions • Remove the fork stem. 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 188 1200 SPORT 4V Suspensions • Drain out all the oil inside the stem. • Collect the preload tube. 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.
  • Page 189 1200 SPORT 4V 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 190 1200 SPORT 4V 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 191 1200 SPORT 4V Suspensions Check that the following components are in good conditions: • upper bushing; • lower bushing; • pumping member pin. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR- FACE.
  • Page 192 1200 SPORT 4V Suspensions • O-Ring on the cap. Reassembling the fork CAUTION ALL COMPONENTS MUST BE CAREFULLY WASHED AND DRIED WITH COMPRESSED AIR BE- FORE REFITTING. • Carry out any necessary service oper- ation. • On the stem, fit the entire pumping unit together with the lock nut and the washer.
  • Page 193 1200 SPORT 4V Suspensions • Screw the bottom screw and tighten it to the prescribed torque. • 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.
  • Page 194 1200 SPORT 4V Suspensions • Fit the dust scraper. Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve.

  • Page 195: Installing The Fork Legs

    1200 SPORT 4V 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 fork stem in position.
  • Page 196 1200 SPORT 4V Suspensions • Tighten the screws on the fork plates to the prescribed torque. • Remove the wheel pin • Place the right side wheel with spacer. • Insert the pin. • Tighten the terminal screws (nut side)
  • Page 197 1200 SPORT 4V Suspensions • Insert the sealing washer on the wheel pin. • Tighten the nut fixing the wheel pin to the prescribed torque • Make sure the stems are aligned mak- ing the fork work. • Tighten the terminal screws that lock the wheel pin to the prescribed torque.
  • Page 198 1200 SPORT 4V Suspensions • Fit the front mud guard. Steering bearing Adjusting play • Remove the top fairing. • Unscrew and remove the screws and move the instrument panel forward. • Unscrew and remove the screws and collect the U-bolts, holding the handle- bar.
  • Page 199 1200 SPORT 4V Suspensions • Working on both sides, unscrew and remove the upper plate fixing screw on the fork stems. • Lift the fork upper plate sliding it off from the stems. • Rivet the safety washer on the head- stock.
  • Page 200 1200 SPORT 4V Suspensions • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten SUSP - 200...
  • Page 201 INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 202 1200 SPORT 4V Chassis Swinging arm Removing • To remove the swingarm, first remove both footrest supporting plates and the exhaust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Remove the cover.
  • Page 203 1200 SPORT 4V Chassis • Remove the clamp from the dust guard cap. • 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 204 1200 SPORT 4V Chassis • Loosen the ring nut. Specific tooling 05.91.26.30 Tool for tightening the swingarm pin ring nut - clutch hub • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft.
  • Page 205 1200 SPORT 4V Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the ring nut in the swingarm pin and screw it manually. • Working from both sides, grease the cardan shaft cables with the recom- mended product from the recommen- ded products table.
  • Page 206 1200 SPORT 4V Chassis • Fit the dust guard cap in the gearbox. • Lock the dust guard cap with a new clamp. • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod.
  • Page 207 1200 SPORT 4V Chassis • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit. • Place the rear wheel on the swingarm. • Tighten the four screws with their spacers and the dust-protection ring.
  • Page 208 1200 SPORT 4V Chassis • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint. Checking Casing unit removal Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 208...
  • Page 209 1200 SPORT 4V Chassis Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 210 1200 SPORT 4V Chassis Collect the ring (15). Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 210...
  • Page 211 1200 SPORT 4V Chassis Collect the ring (13). 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.
  • Page 212 1200 SPORT 4V Chassis Heat the casing. Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 213 1200 SPORT 4V Chassis Screw the clamp with the specific pliers. 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 214 1200 SPORT 4V Chassis Fit the casing. Remove the two dowel pins. 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.
  • Page 215 1200 SPORT 4V Chassis Fit the cap with the washer. Screw the cap to the prescribed torque. 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.
  • Page 216 1200 SPORT 4V Chassis Fit the cap in its seat. Wheel axle unit 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.
  • Page 217 1200 SPORT 4V Chassis Assemble the bearings to the wheel axle. 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).
  • Page 218 1200 SPORT 4V Chassis Remove the ring nut (2) and remove the sealing ring from the ring nut. NOTE THIS OPERATION DESTROYS THE SEALING RING. Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a ham- mer.
  • Page 219 1200 SPORT 4V Chassis Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1).
  • Page 220 1200 SPORT 4V Chassis 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 221 1200 SPORT 4V 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 222: Troubleshooting

    1200 SPORT 4V 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 223 1200 SPORT 4V 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 224 1200 SPORT 4V 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 225 1200 SPORT 4V Chassis 8. Left clamp 9. Expansion chamber 10.Rubber ring 11.Washer for shafts 12.Lambda probe 13.Spring 14.Gasket 15.Clamp 16.Silencer 17.Screw 18.Silencer fixing bushing 19.Muffler rubber ring 20.Spacer 21.Nut 22.Screw 23.Washer Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold.
  • Page 226 1200 SPORT 4V Chassis • Remove the exhaust end. Removing the catalytic converter • Remove the exhaust end and the ex- haust manifolds. • Remove the starter motor protection in order to disconnect the lambda probe connector. • Slide off the retaining hooks from the rubber rings.
  • Page 227 1200 SPORT 4V Chassis Removing the exhaust manifold • Unscrew and remove the two nuts on the head exhaust stud bolts. • Retrieve the washers. • Loosen the clamp. • Remove the exhaust manifold. Engine oil cooler Removing • Place a collecting container and empty the lubrication system.
  • Page 228 1200 SPORT 4V Chassis • Unscrew and remove the screw and collect the washer. • Unscrew and remove the nut. • Remove the front tank protection. • Unscrew and remove the oil cooling ra- diator upper fixing stud bolt. •...
  • Page 229 1200 SPORT 4V Chassis • Start the vehicle and let the engine run for a few minutes so that the oil circu- lates and fills the radiator internal ducts. • Stop the engine and check the oil level with the dipstick (1).
  • Page 230 INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 231: Front Brake Pads

    1200 SPORT 4V Braking system Front brake pads 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 232: Rear Brake Pads

    1200 SPORT 4V Braking system Installing • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes. CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. •...
  • Page 233 1200 SPORT 4V Braking system Removal • Free the brake pipe and the throttle grip cable from the clamps. • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin.
  • Page 234 1200 SPORT 4V Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
  • Page 235 1200 SPORT 4V Braking system Bleeding the braking system Front If there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from the brake pump and minimising calliper efficiency during braking.
  • Page 236 1200 SPORT 4V Braking system the brake lever and will make it reach the end of stroke. • Close the bleed valve before the lever reaches its end of stroke. • Repeat the operation until the fluid draining into the container is air-bubble free.
  • Page 237 1200 SPORT 4V Braking system tainer. This will release the tension on the brake lever and will make it reach the end of stroke. • Close the bleed valve before the lever reaches its end of stroke. • Repeat the operation until the fluid draining into the container is air-bubble free.
  • Page 238 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 239 1200 SPORT 4V Bodywork Headlight assy. REMOVAL OF FRONT HEADLIGHT ASSEM- • Working from both sides, unscrew and remove the two lateral screws (1). • Working from both sides, unscrew and remove the two screws (2) on the in- strument panel.
  • Page 240 1200 SPORT 4V Bodywork • Unscrew and remove the rear upper screw and collect the nut. • Unscrew and remove the front upper screw. • Remove the air filter housing. • Disconnect the connector of the rear brake lever switch and release it from the clamps.
  • Page 241 1200 SPORT 4V Bodywork • Unscrew and remove the rear upper screw and collect the nut. • Unscrew and remove the front upper screw. • Unscrew and remove the screw and remove the left footrest plate. Air box • Remove the fuel tank.
  • Page 242 1200 SPORT 4V Bodywork • Unscrew and remove the two screws from the oil vapour recovery reservoir. • Release the clamp. • Slide off the pipe. • Move the oil vapour recovery reservoir aside. • Unscrew and remove the two front screws from the air filter casing.
  • Page 243 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 244 1200 SPORT 4V Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit...

  • Page 245: Road Test

    1200 SPORT 4V 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 246 1200 SPORT 4V 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 247 Air filter: 37 Battery: 49, 54 Brake: 231, 232 Centre stand: Clutch: 71, 118, 119, 121, 122, 154 Clutch lever: 71 Display: 180 Engine oil: 33, 69, 227 Fork: 183, 184, 188, 192, 195 Forks: 106 Fuel: 112 Fuses: 51 Gearbox oil: 35 Headlight: 239 Identification: 10...
  • Page 248 Spark plug: 31 Stand: 72 Start-up: 50 Tank: 112 Transmission: 12, 32 Tyres: 14 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

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