MOTO GUZZI Griso1200 8V Service Station Manual
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MOTO GUZZI Griso1200 8V Service Station Manual

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SERVICE STATION MANUAL
854378
GRISO 8V - 1200

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Summary of Contents for MOTO GUZZI Griso1200 8V

  • Page 1 SERVICE STATION MANUAL 854378 GRISO 8V - 1200...
  • 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 2007- 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

    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 CLU SYS LUTCH 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

    GRISO 8V - 1200 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, 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 smoke-extraction system.

  • Page 8: Maintenance Rules

    GRISO 8V - 1200 Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE 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 THE SYS- TEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUN- DANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.
  • Page 9 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables usage 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" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.

  • Page 11: Chassis Number

    GRISO 8V - 1200 Characteristics This number is composed by numbers and letters, as in the example shown below. ZGULSE000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LS: model; E00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: progressive number (6 digits);...
  • Page 12 GRISO 8V - 1200 Characteristics Specification Desc./Quantity Compression ratio 11: 1 Start-up electric Engine revs at idle speed 1100 ± 100 rpm Clutch dry single disc with integrated hydraulic drive and anti-vibration buffer Lubrication system Pressure-fed lubrication system adjusted through valves and a trochoidal pump Air filter cartridge, dry...
  • Page 13 GRISO 8V - 1200 Characteristics Specification Desc./Quantity Instrument panel lighting License plate light 12V - 5 W Turn indicator warning light Gear in neutral warning light Alarm warning light - Gear shift Side stand down warning light Low fuel warning light High-beam warning light Oil pressure warning light Frame and suspensions...

  • Page 14: Wheels And Tyres

    GRISO 8V - 1200 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 Sportec M3 Front 120/70 - ZR 17" 58 W Inflation pressure (front) 2.3 bar (230 kPa) (33.4 PSI) Inflation pressure with passenger (front)

  • Page 15: Timing System

    GRISO 8V - 1200 Characteristics Name Torque in Nm 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) Oil sump screw - TCEI M6x60 (2) 10 Nm (7.38 lbf ft) Oil drainage plug - M10x1 (1)

  • Page 16: Side Stand

    GRISO 8V - 1200 Characteristics Name Torque in Nm Oil radiator spacer (1) 50 Nm (36.88 lbf ft) Oil radiator fixing screws - M8x40 (3) 25 Nm (18.44 lbf ft) Screws fixing oil radiator grille - TBEI M5x12 (4) 4 Nm (2.95 lbf ft) Screws fixing oil radiator air deflector - TE M6x30 (3) 10 Nm (7.38 lbf ft) CHASSIS TO ENGINE UNIT...

  • Page 17: Front Suspension

    GRISO 8V - 1200 Characteristics Name Torque in Nm Preloading bushing to fork bolt retainer 10 Nm FRONT SUSPENSION Name Torque in Nm Tube lock plate to steering base retainer 6 Nm Fork stem on upper plate retainer 18 Nm Upper and lower screws fixing fork stem on lower plate 22 Nm Central screw fixing fork stem on lower plate...
  • Page 18 GRISO 8V - 1200 Characteristics HANDLEBAR AND CONTROLS Name Torque in Nm Retainer for handlebar lower U-bolts on steering upper plate 50 Nm Retainer for handlebar upper U-bolts 25 Nm Anti-vibration weights retainer 10 Nm Brake pump and clutch U-bolts retainer 10 Nm Right and left light switch retainer 1.5 Nm...

  • Page 19: Overhaul Data

    GRISO 8V - 1200 Characteristics Overhaul data Assembly clearances Cylinder - piston assy. Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°. Check that cylinders and pistons are of the same selection types (D, E, F). Check clearance between cylinders and pistons on the selected diameter;...
  • Page 20 GRISO 8V - 1200 Characteristics Piston rings On each piston there are: • 1 top piston ring; • 1 middle piston ring; • 1 oil scraper piston ring. Turn the rings so that the coupling ends are 120 degrees from each other. CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON Specification Desc./Quantity...

  • Page 21: Specific Tooling

    GRISO 8V - 1200 Characteristics • Thoroughly clean the upper surface of both cylinders. • Place the tool on the left cylinder to de- termine the "squish" (X). • Fasten the tool with the nuts of the stud bolts. Specific tooling 020676Y Comparator support for piston posi- tion checking •...
  • Page 22 GRISO 8V - 1200 Characteristics Recommended products chart ECOMMENDED PRODUCTS Product Description Specifications AGIP RACING 4T 10W-60 Engine oil SAE 10W - 60. As an alternative for rec- ommended oils, use top-branded oils that meet or exceed the requirements of CCMC G-4 API SG specifications.

  • Page 23: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 24: Special Tools

    GRISO 8V - 1200 Special tools SPECIAL TOOLS Stores code Description 020677Y Alternator belt tensioner 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 Wrench for removing the cover on sump and filter S-TOOLS - 24 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 25 GRISO 8V - 1200 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 flywheel and start-up crown gear 12.91.36.00 Tool to remove the flywheel-side flange AP8140179 Support for valve fitting/removal AP9100838...
  • Page 26 GRISO 8V - 1200 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- side flange 020673Y Graduated dial hub...
  • Page 27 GRISO 8V - 1200 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 fork pin ring nut - clutch hub AP8140190 Tool for steering tightening 05.90.27.30 Gearbox support 05.90.27.31 Gearbox oil seal buffer...
  • Page 28 GRISO 8V - 1200 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 AP8140145 fitting tool for Ø 41 mm sealing rings AP8140146 Weight AP8140147 Spacer tool...
  • Page 29 GRISO 8V - 1200 Special tools Stores code Description AP8140148 Spacer-pumping element separating plate AP8140149 Protection for fitting operations AP8140150 Perforated rod for pumping member air bleed AP8140151 Complete tool kit for fork S-TOOLS - 29 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 30: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 31: At Every Start-Up

    GRISO 8V - 1200 Maintenance Maintenance chart NOTE CARRY OUT THE MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VE- HICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTS APPLICATIONS. AT EVERY START-UP Action Engine oil pressure warning light - check and clean, adjust, grease or replace if necessary BEFORE EACH RIDE AND EVERY 2000 (1250 Action...

  • Page 32: Transmission Fluid

    GRISO 8V - 1200 Maintenance Action Wheel bearings - Check and clean, adjust, grease or replace if necessary Disc brakes - Check and clean, adjust or replace if necessary Air filter - Check and clean, adjust, grease or replace if necessary Engine oil filter - Replace General vehicle operation - Check and clean, adjust, grease or replace if necessary.

  • Page 33: Engine Oil

    GRISO 8V - 1200 Maintenance 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 GRISO 8V - 1200 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

    GRISO 8V - 1200 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 GRISO 8V - 1200 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

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

  • Page 38: Checking The Valve Clearance

    GRISO 8V - 1200 Maintenance • Remove the air filter frame. • Remove the air filter. • Cover the inlet duct with a clean cloth so that no foreign bodies get into the inlet ducts. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. TO CLEAN THE FILTERING ELEMENT, USE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE.

  • Page 39: Braking System

    GRISO 8V - 1200 Maintenance • Undo and remove the four head cover fixing screws and collect the sealing O- rings. • Remove the head cover together with the gasket. • Loosen the nut (1). • Use a screwdriver to act on the set screw (2) until the following clearances are obtained: Inlet valve: 0.10 mm (0.0039 in)
  • Page 40 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 - 40...
  • Page 41 GRISO 8V - 1200 Maintenance MAIN - 41 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 42: Electrical System

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

  • Page 44: Electrical System Installation

    GRISO 8V - 1200 Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp...
  • Page 45 GRISO 8V - 1200 Electrical system Central part TABLE A - LAMBDA PROBE • Fasten the lambda probe cable har- ness to the chassis but do not tauten it. TABLE A1 - LAMBDA PROBE • Fasten the lambda probe cable har- ness to the engine oil breather pipe but do not tauten it.

  • Page 46: General Wiring Diagram

    GRISO 8V - 1200 Electrical system General wiring diagram Key: 1. Multiple connectors 2. Start-up relay 3. Maintenance relay 4. Clutch switch ELE SYS - 46 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 47 GRISO 8V - 1200 Electrical system 5. Right light switch 6. Light relay 7. GPS coupling 8. Horn 9. Left light switch 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Instrument panel diagnosis 13.Key switch 14.Immobilizer aerial 15.Right rear turn indicator 16.Rear light (LED) 17.Left rear turn indicator 18.License plate light...

  • Page 48: Checks And Inspections

    GRISO 8V - 1200 Electrical system 43.Left cylinder spark plug 44.Right cylinder coil 45.Left cylinder coil 46.Right cylinder injector 47.Left cylinder injector 48.Speed sensor 49.Fall sensor 50.Flywheel pick up 51.Pick-up wire shielding 52.ECU 53.Left front turn indicator 54.Tail light bulb 55.High-/low-beam bulb 56.Front headlamp 57.Right front turn indicator...
  • Page 49 GRISO 8V - 1200 Electrical system Resetting the CODE This function is used to set a new code when the old one is not available; in this case, at least two of the programmed keys have to be inserted in the ignition lock. After the first key has been inserted, the second one is requested with the following message: INSERT KEY II If the second key is not inserted within 20 seconds, the operation is finished.
  • Page 50 GRISO 8V - 1200 Electrical system Injector 2 Error DC V DC ECU 30 Pump Relay Error ECU 36 Local Loopback Error ECU 37 Start-up Remote Error DC V DC ECU 44 Remote Error Start-up DC Gnd ECU 45 Canister Error DC V DC ECU 46 Canister Error DC Gnd ECU 47 Battery Error Hig ECU 50 Generic ECU Error ECU 51...

  • Page 51: Checking The Stator

    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 52: Front Headlamp

    GRISO 8V - 1200 Electrical system 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 2 with 12V voltage) Fuel level sensor: Resistance (to be measured between pins 3 and 250-300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11.25 litres (20.43 10-20 Ohm with fuel level equal to 22.5 litres...

  • Page 53: Rear Light

    GRISO 8V - 1200 Electrical system REAR LIGHT Fuses AUXILIARY FUSES A - Stop, horn, lights, coil, light relay (15 A). B - Tail lights, license plate light, passing, ignition relay (15 A). C - Fuel pump, coils, injectors (15 A). D - Lambda burner, secondary injection relay coil, start-up relay coil, speed sensor power supply, ECU control unit power supply, engine kill (15 A).

  • Page 54: Control Unit

    GRISO 8V - 1200 Electrical system Control unit Model: Magneti Marelli IAW 5 AM2 BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal 6 Not used 7 Not used 8 Not used 9 Stepper motor (+)
  • Page 55 GRISO 8V - 1200 Electrical system 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer power supply 30 Not used 31 Not used 32 Ignition potentiometer negative 33 Not used 34 Revolution sensor anti-jamming cable 35 Engine revolution sensor signal 36 Not used 37 Right cylinder injector control 38 Left cylinder coil control...

  • Page 56: Speed Sensor

    GRISO 8V - 1200 Electrical system 25 Not used 26 Not used 27 "Engine stop" signal input 28 Ignition signal input 29 CAN - L line (ccm/instrument panel) 30 Not used 31 Not used 32 Oxygen probe power supply 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used...
  • Page 57 GRISO 8V - 1200 Electrical system • sensor: on swingarm, right side, near the rear brake calliper • connector: under the saddle, next to the right fairing Pin-out: • PINS 1-3 Voltage: approx. 12 V • PINS 2-3 Voltage: variable 0.4V-12V (by turning the rear wheel) PIN: 1.

  • Page 58: Engine Rpm Sensor

    GRISO 8V - 1200 Electrical system Engine rpm sensor Function It informs crankshaft position and speed to the Marelli control unit. Operation / Operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position.

  • Page 59: Throttle Position Sensor

    GRISO 8V - 1200 Electrical system if there is not continuity, restore the cable harness; if there is continuity, check the interruption on the sensor and replace it. WARNING If the electric circuit is short-circuited, no error is displayed. Check the sensor electrical specifications: If they are not correct, replace the sensor.

  • Page 60: Reset Procedure

    GRISO 8V - 1200 Electrical system AXONE: PARAMETERS Throttle Example value: 4.9° AXONE: STATUSES Throttle position Example value:Released/Pressed/Full load It indicates if the throttle potentiometer is open or closed in the released position. AXONE: ELECTRICAL ERRORS Throttle actuator position sensor P0120 Example value:open circuit, shorted to positive / shorted to negative.

  • Page 61: Engine Temperature Sensor

    GRISO 8V - 1200 Electrical system Engine temperature sensor Function tells the engine temperature to the control unit so as to optimise carburetion and idle control Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature) Level in wiring diagram:Temperature sensors Location: •...
  • Page 62 GRISO 8V - 1200 Electrical system In case of recovery, this value is set by the control unit. ELECTRICAL ERRORS engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of the BROWN connector.

  • Page 63: Air Temperature Sensor

    GRISO 8V - 1200 Electrical system Air temperature sensor Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).

  • Page 64: Lambda Sensor

    GRISO 8V - 1200 Electrical system the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 14 of the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 1 and the vehicle ground connection: if there is not continuity, restore the cable harness;...
  • Page 65 GRISO 8V - 1200 Electrical system 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white) 4. Heater power supply (white) AXONE: PARAMETERS Lambda probe Example value: 0 - 1000 mV If there is a short circuit at + 5 V or above, the value read is approx. 5.000 mV. If there is a short circuit to ground instead, the value read is equal to 0 mV and the Lambda Sensor Correction parameter shows 25%: no error is displayed, though.
  • Page 66 GRISO 8V - 1200 Electrical system • if shorted to positive: disconnect the probe connector and check the sensor correct resist- ance: replace the sensor if not OK; if it is OK, restore the cable harness. • if the circuit is open, shorted to negative: check the continuity from probe connector (PIN 3 and 4) towards the probe: if not OK, replace the probe;...
  • Page 67 GRISO 8V - 1200 Electrical system The auxiliary injection relay (No. 31 in the wiring diagram, placed on the front right side of the motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the grey/red cable of the injector is closed to ground for 4 ms per second.
  • Page 68 GRISO 8V - 1200 Electrical system • If shorted to positive: excessive voltage has been detected at PIN 37 of the BROWN con- nector. • If shorted to negative: no voltage has been detected. • If the circuit is open: an interruption has been detected. Troubleshooting •...
  • Page 69 GRISO 8V - 1200 Electrical system 2. Circuit earthing AXONE: PARAMETERS Left coil ignition advance. AXONE: ACTIVATION Left coil: The auxiliary injection relay (No. 29 in the wiring diagram, placed under the right side fairing of the motorcycle; 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 70: Engine Oil Pressure Sensor

    GRISO 8V - 1200 Electrical system AXONE: ELECTRICAL ERRORS Right coil P0352 - shorted to positive / open circuit, shorted to negative. Error cause • If shorted to positive: excessive voltage has been detected at PIN 10 of the (BROWN) con- nector.
  • Page 71 GRISO 8V - 1200 Electrical system • An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. This error is signalled by the bulb icon and the general warning light turns on as well.
  • Page 72 GRISO 8V - 1200 Electrical system Gear in neutral Example value:yes/no DIAGNOSIS • Indication on the instrument panel always gear engaged: check the control unit connector and the sensor connector: if they are not OK, restore the cable harness; if OK, disconnect 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);...
  • Page 73 GRISO 8V - 1200 Electrical system Example value:Yes/No The statuses regularly viewed are YES / NO DIAGNOSIS Troubleshooting: • Indication on Axone 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;...

  • Page 74: Bank Angle Sensor

    GRISO 8V - 1200 Electrical system • Indication on Axone always EXTENDED: check the side stand sensor connector and the ECU connector: if they are not OK, restore; if OK, disconnect both terminals from the sensor and check continuity to ground of PIN 1 (blue/green, cable harness side): if there is not continuity, restore the cable harness;...
  • Page 75 GRISO 8V - 1200 Electrical system • Indication on Axone always Normal, even when the sensor is inverted: disconnect the con- nector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is no continuity, replace the sensor; if there is, check the connector. If not OK, restore the cable harness;...

  • Page 76: Run/Stop Switch

    GRISO 8V - 1200 Electrical system and the instrument panel connector PIN 10: if not OK, restore the cable harness; if OK, 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 (cable harness side) and PIN 18 of the instrument panel connector: If not OK, restore the cable harness;...
  • Page 77 GRISO 8V - 1200 Electrical system • Sky blue/orange cable (cable harness side): 0V voltage if engine kill in STOP; 12V if engine kill in RUN. • Red/black cable (cable harness side): always 12 V voltage CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL CON- CEPTS OF ELECTRICAL TROUBLESHOOTING FOUND AT THE BEGINNING OF THE CHECKS AND CONTROLS SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 78 GRISO 8V - 1200 Electrical system 3 HIGH-BEAM LIGHT INPUT 6 K LINE 8 SELECT 1 - SET 9 FUEL LEVEL SENSOR 10 AIR TEMPERATURE SENSOR 11 + BATTERY 12 LEFT TURN INDICATOR CONTROL 13 - 14 - 15 - 16 GENERAL EARTH CONNECTION 17 OIL PRESSURE SENSOR INTAKE 18 SENSORS EARTH CONNECTION...
  • Page 79 GRISO 8V - 1200 Electrical system 39 - 40 SELECT 3 ELE SYS - 79 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 80: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 81: Vehicle Preparation

    GRISO 8V - 1200 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as fol- lows: • 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 82 GRISO 8V - 1200 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. ENG VE - 82 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 83 GRISO 8V - 1200 Engine from vehicle • Undo and remove the two screws and collect the washers. • Remove the starter motor cover. • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the starter motor connec- tors.
  • Page 84 GRISO 8V - 1200 Engine from vehicle • Working on both sides, release the clamp and slide off the engine oil breather pipe. • Undo and remove the two screws fixing the oil vapour union. • Remove the oil vapour union. •...
  • Page 85 GRISO 8V - 1200 Engine from vehicle • Undo and remove the screws and move the oil vapour recovery reservoir. • Unscrew and remove the stud bolt. • Slide off the oil pipe from the blow-by tank and keep it fitted to the oil sump. •...
  • Page 86 GRISO 8V - 1200 Engine from vehicle • Undo and remove the two screws and collect the cable guide. • Remove the plate. CAUTION PERFORM THE OPERATIONS BELOW HELPED BY A SEC- OND OPERATOR. • Working on both sides, undo and re- move the front screw and collect the washer.
  • Page 87 GRISO 8V - 1200 Engine from vehicle Installing the engine to the vehicle • Place the vehicle chassis over the en- gine with the gear. • From the back, secure the chassis 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 88 GRISO 8V - 1200 Engine from vehicle • Working from the left side, fit the en- gine lower bolt with the washer. • From the opposite side, fit the washer and tighten the nut. • Working on both sides, tighten the front screw to the prescribed torque. •...
  • Page 89 GRISO 8V - 1200 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 90 GRISO 8V - 1200 Engine from vehicle • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors. • Connect the ground cables and tighten the screw. •...
  • Page 91 GRISO 8V - 1200 Engine from vehicle • Connect the neutral sensor connector. • Connect the alternator connectors. • Connect the revolution sensor connec- tor. • Connect the engine temperature sen- sor connector. ENG VE - 91 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 92 GRISO 8V - 1200 Engine from vehicle • Connect and adjust the throttle grip ca- ble clearance. • Place the fork 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.

  • Page 93: Index Of Topics

    INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 94 GRISO 8V - 1200 Engine Gearbox Diagram Key: 1. Ball bearing ENG - 94 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 95 GRISO 8V - 1200 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 22.Ball bearing...

  • Page 96: Removing The Gearbox

    GRISO 8V - 1200 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 60.Transmission shaft...
  • Page 97 GRISO 8V - 1200 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 98: Gearbox Shafts

    GRISO 8V - 1200 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 - 98 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 99 GRISO 8V - 1200 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 100 GRISO 8V - 1200 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 101 GRISO 8V - 1200 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 102 GRISO 8V - 1200 Engine • Remove the forks and collect the shaft. ENG - 102 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 103 GRISO 8V - 1200 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 104 GRISO 8V - 1200 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. ENG - 104 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 105 GRISO 8V - 1200 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 106 GRISO 8V - 1200 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. ENG - 106 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 107 GRISO 8V - 1200 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 108: Checking The Secondary Shaft

    GRISO 8V - 1200 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. Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.

  • Page 109: Assembling The Gearbox

    GRISO 8V - 1200 Engine Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL TRANSMISSION 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 110: Specific Tooling

    GRISO 8V - 1200 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 111 GRISO 8V - 1200 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 - 111 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 112: Removing The Generator

    GRISO 8V - 1200 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 113 GRISO 8V - 1200 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 114 GRISO 8V - 1200 Engine • Undo and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. ENG - 114 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 115: Tensioning The Belt

    GRISO 8V - 1200 Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Remove both fuel tank side fairings. • Remove the right exhaust manifold. • Remove the control unit. •...

  • Page 116: Installing The Generator

    GRISO 8V - 1200 Engine • Using the belt tensioning tool, tension the belt to the prescribed torque. • Tighten the set screw. • Tighten the lock nut. Specific tooling 020677Y Alternator belt tensioner Installing the generator • If the sealing ring has been previously removed, replace it using the punch of the timing system cover sealing ring.
  • Page 117 GRISO 8V - 1200 Engine • Place the bolt and the pin in the gen- erator cover. • Replace the gasket and place the al- ternator frame using the front cover in- sertion cone. • Remove the insertion cone afterwards. Specific tooling 05.91.17.30 Front cover insertion cone •...
  • Page 118 GRISO 8V - 1200 Engine • Tighten the four screws, operating di- agonally and in stages. • Position the lower pulley and the spacer. • Tighten the nut to the prescribed tor- que. • Position the alternator and the timing system belt.
  • Page 119 GRISO 8V - 1200 Engine • 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. • Lock the set screw in position by screwing the lock nut.

  • Page 120: Removing The Starter Motor

    GRISO 8V - 1200 Engine • Position the timing system cover. • Tighten the five screws, operating in oblique direction and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers. •...

  • Page 121: Disassembling The Clutch

    GRISO 8V - 1200 Engine Clutch side 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 122 GRISO 8V - 1200 Engine 18.Thrust cylinder 19.Clutch control cylinder 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. •...
  • Page 123 GRISO 8V - 1200 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 124: Assembling The Clutch

    GRISO 8V - 1200 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) Protrusion: 6.8 - 8.2 mm (0.268 - 0.323 in) Clutch control rod length (code 976595) = 186 mm (7.323 in)
  • Page 125 GRISO 8V - 1200 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 126 GRISO 8V - 1200 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 11.Nut 12.Rocking lever rod...
  • Page 127 GRISO 8V - 1200 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 34.Pin 35.Nut...

  • Page 128: Removing The Head Cover

    GRISO 8V - 1200 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. • Undo and remove the four head cover fixing screws and collect the sealing O- rings.
  • Page 129 GRISO 8V - 1200 Engine • Undo 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 130 GRISO 8V - 1200 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. • Undo and remove the two screws.

  • Page 131: Cylinder Head

    GRISO 8V - 1200 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 132 GRISO 8V - 1200 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 133: Removing The Valves

    GRISO 8V - 1200 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 134: Checking The Cylinder Head

    GRISO 8V - 1200 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 135: Installing The Valves

    GRISO 8V - 1200 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. Installing the valves NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH...
  • Page 136 GRISO 8V - 1200 Engine Installing the rocker arms • Fit the camshaft. • Fit the two rods. • Place the two rocking levers in the cam cap seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam cap.
  • Page 137 GRISO 8V - 1200 Engine Installing the overhead camshaft • Place the bowls in the cam cap, if those previously removed are refitted be careful not to interchange them. • Place the camshaft with the gear seat on the dowel side. •...
  • Page 138 GRISO 8V - 1200 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 139 GRISO 8V - 1200 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 140 GRISO 8V - 1200 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 141: Cam Timing

    GRISO 8V - 1200 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 142 GRISO 8V - 1200 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 143 GRISO 8V - 1200 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 144 GRISO 8V - 1200 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 145 GRISO 8V - 1200 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 14.Washer...

  • Page 146: Removing The Cylinder

    GRISO 8V - 1200 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 147: Fitting The Piston

    GRISO 8V - 1200 Engine • Mark the piston crown on the outlet side to remember its position when re- fitting. • Remove the piston. Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.

  • Page 148: Installing The Cylinder

    GRISO 8V - 1200 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 149 GRISO 8V - 1200 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 150 GRISO 8V - 1200 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 151: Installing The Cylinder Head

    GRISO 8V - 1200 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 152 GRISO 8V - 1200 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 153 GRISO 8V - 1200 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 154 GRISO 8V - 1200 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 155: Crankcase - Crankshaft

    GRISO 8V - 1200 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 156 GRISO 8V - 1200 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 157 GRISO 8V - 1200 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 158 GRISO 8V - 1200 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 159 GRISO 8V - 1200 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) Connecting rod - black...

  • Page 160: Installing The Crankshaft

    GRISO 8V - 1200 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 161 GRISO 8V - 1200 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 162 GRISO 8V - 1200 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 163: Oil Pump

    GRISO 8V - 1200 Engine 1. Oil 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 164 GRISO 8V - 1200 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 165 GRISO 8V - 1200 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 166 GRISO 8V - 1200 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 167 GRISO 8V - 1200 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 168 GRISO 8V - 1200 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. ENG - 168 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 169 GRISO 8V - 1200 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- ponents ENG - 169 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 170 GRISO 8V - 1200 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. ENG - 170 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 171 GRISO 8V - 1200 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. ENG - 171 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 172 GRISO 8V - 1200 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 173 GRISO 8V - 1200 Engine • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. Blow-by The figure illustrates the correct position for the fastening clamps of the pipes on the blow-by tank. Both blow-by and clutch pipes should be laid, in the front part of the chassis, underneath the main cable harness.
  • Page 174 GRISO 8V - 1200 Engine Blow-by pipes laying on the right-hand size of the vehicle. Blow-by pipes laying on the left-hand size of the vehicle. ENG - 174 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 175: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 176: Circuit Diagram

    GRISO 8V - 1200 Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Screw 3. Fuel pipe 4. Pipe 5. Screw FUEL PIPES LAYING The fuel pipes should be laid in the innermost po- sition compared to the electrical connections. P SUPP - 176 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 177 GRISO 8V - 1200 Power supply The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right. Fuel pipes in the area underneath the fuel tank should be laid over the (grey) blow-by pipes. Injection P SUPP - 177 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 178 GRISO 8V - 1200 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 179 GRISO 8V - 1200 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 180 GRISO 8V - 1200 Power supply • Make sure there are no errors in the control unit; otherwise, solve them and repeat the procedure. • Make sure the left throttle is fully in. DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE REPLACED.

  • Page 181: Recovery Function

    GRISO 8V - 1200 Power supply 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. • Repeat the procedure "Throttle posi- tion self-learning" as explained above. •...
  • Page 182 GRISO 8V - 1200 Power supply Iso screen page This display shows general data regarding the control unit, for example software type, mapping, control unit programming date ISO DISPLAY Specification Desc./Quantity Mapping Engine parameter reading screen page ENGINE PARAMETER READING This display shows the parameters measured by the several sensors (engine revs, engine temper- ature, etc.) or values set by the control unit (injec-...

  • Page 183: Device Status

    GRISO 8V - 1200 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 Stepper motor Stepper base 70 - 100 (approximate values)

  • Page 184: Errors Display

    GRISO 8V - 1200 Power supply Devices activation screen page DEVICES ACTIVATION This displays is used to delete errors in the control unit memory and activate some systems control- led by the control unit DEVICES ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times Right coil operation for 2.5 m, 5 times...

  • Page 185: Adjustable Parameters

    GRISO 8V - 1200 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 186 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 187: Removing The Front Wheel

    GRISO 8V - 1200 Suspensions Front Removing the front wheel • Working from both sides, undo and re- move the two fixing screws from the front brake callipers and remove them from their seats. • Support the front part of the vehicle. •...

  • Page 188: Front Fork

    GRISO 8V - 1200 Suspensions • Take out the wheel bolt by inserting a screwdriver in the bolt holes. • Upon extracting the wheel, hold it and then remove it. • Collect the spacer from the front wheel right side. Front fork Diagram Key:...
  • Page 189 GRISO 8V - 1200 Suspensions 1. Radial fork right stem 2. Radial fork left stem 3. Sleeve 4. Pumping member attachment bushing 5. Spring 6. Complete preloading pipe 7. Spacer 8. Washer 9. Complete pumping element 10.Washer 11.Ring 12.Complete sleeve cap 13.O-ring 14.O-ring 15.O-ring...

  • Page 190: Removing The Fork Legs

    Stems (A) protrusion from top plate (excluding cover) (standard 4 protrusion notches adjustment) Take your vehicle only to a Moto Guzzi Official Dealer for this type of adjustment. Stems (A) protrusion from top plate (excluding cover) (sports 5 protrusion notches...

  • Page 191: Draining Oil

    GRISO 8V - 1200 Suspensions See also Removing the front wheel Draining oil • Lock the sleeve in a vice with the spe- cific tool (code AP8140149). • Set the minimum spring preloading. Specific tooling AP8140149 Protection for fitting operations •...
  • Page 192 GRISO 8V - 1200 Suspensions • Push the tool against the spring and compress it. Fit the spacer of the tool under the cartridge lock nut. Specific tooling AP8140148 Spacer-pumping element separat- ing plate • Loosen the cap acting on the wrench slot and making the lock nut turn.

  • Page 193: Disassembling The Fork

    GRISO 8V - 1200 Suspensions • Slide off the spring joint. • Empty the oil into a container and re- move the spring. Disassembling the fork • After emptying the oil, fasten the fork stem end in a vice. • Take out the washer and the lower spacer.
  • Page 194 GRISO 8V - 1200 Suspensions • Undo the screw fixing the cartridge on the fork end. • Collect the centring bushing. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • Do not damage the sleeve edge while doing this.
  • Page 195 GRISO 8V - 1200 Suspensions • Take out the sleeve from the stem us- ing the stem as a hammer puller. • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal. SUSP - 195 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 196: Checking The Components

    GRISO 8V - 1200 Suspensions • Remove the ring and the dust guard. See also Draining oil 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.
  • Page 197 GRISO 8V - 1200 Suspensions Check that the following components are in good conditions: • sliding bushing; • guide bushing; • pumping member. 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 198 GRISO 8V - 1200 Suspensions Reassembling the fork • Lock the stem in a vice without dam- aging the surfaces. • Protect the bearing tube end with ad- hesive tape. • Lubricate the sliding edges with fork oil or with seal grease. •...
  • Page 199 GRISO 8V - 1200 Suspensions • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and with the specified tool fit the oil seal into posi- tion. Specific tooling AP8140189 Oil seal fitting tool for Ø...
  • Page 200 GRISO 8V - 1200 Suspensions • Insert the snap ring in its position. • Fit the oil seal with the specific tool. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) holes 8140145 Fitting tool for Ø 41 mm (1.61 in) seal- ing ring 8140146 Weight to be applied to the tool: 8140145 and 8140189...

  • Page 201: Filling Oil

    GRISO 8V - 1200 Suspensions • Position the lower spacer and the washer. Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve. •...
  • Page 202 GRISO 8V - 1200 Suspensions • Fit the spring. • Fit the complete preloading pipe. • Fit the specified tool on the spring cou- pling so that the cartridge stem is locked in position. Specific tooling 8140147 Spacer tool 8140148 Spacer / pumping member separating plate •...

  • Page 203: Steering Bearing

    GRISO 8V - 1200 Suspensions • Screw the upper cover on the cartridge stem. • Place the sleeve in the vice using the specified tool. • Screw the upper cap to the prescribed torque. Specific tooling AP8140149 Protection for fitting operations Steering bearing SUSP - 203 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 204 GRISO 8V - 1200 Suspensions Adjusting play • Undo and remove the two front screws. • Undo and remove the two external screws and move the instrument panel forwards. • Undo and remove the screws and col- lect the U-bolts, holding the handlebar. •...
  • Page 205 GRISO 8V - 1200 Suspensions • Unscrew and remove the fork upper plate cover; collect the shim. • Working on both sides, undo and re- move the upper plate fixing screw on the fork stems. • Lift the fork upper plate sliding it off from the stems.
  • Page 206 GRISO 8V - 1200 Suspensions • Using the suitable special tool, un- screw and remove the upper ring nut. Specific tooling AP8140190 Tool for steering tightening • Remove the safety washer. • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening •...

  • Page 207: Removing The Rear Wheel

    GRISO 8V - 1200 Suspensions • Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut. Specific tooling AP8140190 Tool for steering tightening • Rivet the tongues of the new safety washer.

  • Page 208: Shock Absorbers

    GRISO 8V - 1200 Suspensions • Engage the first gear. • Undo and remove the four screws, col- lect the spacers and the dust-protec- tion ring. • Remove rear wheel. Shock absorbers Adjusting The rear suspension consists of a spring-shock absorber unit linked to the frame via silent-block and to the rear fork via a linkage system.

  • Page 209: Shock Absorber Adjustment

    SION / REBOUND DAMPING. GRADUALLY TURN THE SET SCREWS (1 -2) ONE NOTCH AT A TIME. • Using the specific spanner available at any Moto Guzzi Official Dealer, unscrew the locking ring nut (4). • Operate on the ring nut (3) to adjust preloading for spring (A).
  • Page 210 GRISO 8V - 1200 Suspensions • Support the vehicle from below with a suitable underpan jack. • Support the vehicle from the front with a suitable stand. • Unscrew and remove the fixing nut. • Take out the screw tapping lightly with a rubber hammer and follow as the as- sembly slides out of its position.
  • Page 211 GRISO 8V - 1200 Suspensions • Undo and remove the suspension low- er screw. • Undo and remove the suspension up- per screw. SUSP - 211 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 212: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 213: Swinging Arm

    GRISO 8V - 1200 Chassis Swinging arm Removing • To remove the fork, first remove both footrest supporting plates and the ex- haust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Remove the cover.
  • Page 214 GRISO 8V - 1200 Chassis • Remove the clamp from the dust guard cap. • Loosen the two fork 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 clamp on the chassis.
  • Page 215 GRISO 8V - 1200 Chassis • Loosen the ring nut. Specific tooling 05.91.26.30 Tool for tightening the fork pin ring nut - clutch hub • Helped by a second operator, remove the pin and remove the fork with cardan shaft. Checking •...
  • Page 216 GRISO 8V - 1200 Chassis Installing • Spread a thin layer of lubricating grease all along the fork pin. • Fit the ring nut in the fork 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 217 GRISO 8V - 1200 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 218 GRISO 8V - 1200 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. See also Recommended products chart Bevel gears...
  • Page 219 GRISO 8V - 1200 Chassis • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint. Checking Support unit CHAS - 219 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 220 GRISO 8V - 1200 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 GRISO 8V - 1200 Chassis Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer. Fit the stop ring (3) in the support (5) with suitable pliers. Manually assemble the new sealing rings (2) and (7).
  • Page 222 GRISO 8V - 1200 Chassis 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. NOTE THIS OPERATION DESTROYS THE SEALING RING.
  • Page 223 GRISO 8V - 1200 Chassis Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction.
  • Page 224 GRISO 8V - 1200 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. 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 225 GRISO 8V - 1200 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. CHAS - 225 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 226 GRISO 8V - 1200 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 227 GRISO 8V - 1200 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. CHAS - 227 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 228 GRISO 8V - 1200 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. Screw the cap to the prescribed torque.
  • Page 229 GRISO 8V - 1200 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. FITTING Heat the bearings to 100°C (212 °F).
  • Page 230 GRISO 8V - 1200 Chassis Assemble the bearings to the wheel axle. Turn the unit over. Assemble the bearings to the wheel axle. Casing unit removal CHAS - 230 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 231 GRISO 8V - 1200 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). CHAS - 231 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 232 GRISO 8V - 1200 Chassis Collect the ring (15). Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). CHAS - 232 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 233: Troubleshooting

    GRISO 8V - 1200 Chassis Collect the ring (13). Remove the support unit (8). TROUBLESHOOTING Possible Cause Operation 1. Fitting error of the radial seal or seal damaged 2. Sliding 1. Replace the sealing ring and fit it correctly with the suitable surface of the wheel axle seal spoiled or damaged tool 2.
  • Page 234 GRISO 8V - 1200 Chassis Installing • Insert the transmission casing on the fork making sure that the universal joint engages correctly. • Tighten the four screws to the prescri- bed torque operating diagonally. • Place the reaction rod into its seat. •...
  • Page 235 GRISO 8V - 1200 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. Exhaust Key: 1.
  • Page 236 GRISO 8V - 1200 Chassis 11.Central exhaust pipe 12.Heat-protecting cover 13.Lambda Probe 14.Clamp 15.Gasket 16.Silencer 17.Screw 18.Washer 19.Muffler rubber ring 20.Spacer 21.Silencer fixing bushing 22.Nut 23.Silent-block 24.Screw 25.Screw 26.Washer 27.Nut Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold.

  • Page 237: Removing The Exhaust Manifold

    GRISO 8V - 1200 Chassis • Undo and remove the rear attachment screw fixing the exhaust to the chassis; collect the locking nut, the spacer and the washer. DURING THIS OPERATION SUPPORT THE EXHAUST SO THAT IT DOES NOT FALL. Locking torques (N*m) Silencer to chassis connecting pipe retainer •...
  • Page 238 GRISO 8V - 1200 Chassis • Undo and remove the three screws from the protection of the exhaust clamps. • Remove the protection. • Unscrew and remove the two nuts on the head exhaust stud bolts. • Collect the washers. •...

  • Page 239: Engine Oil Cooler

    GRISO 8V - 1200 Chassis Engine oil cooler Key: 1. Complete oil radiator 2. From the oil pump 3. To the heads 4. T-shaped bushing 5. Screw 6. Radiator grille 7. Air deflector 8. Screw 9. Washer 10.Bushing 11.Spacer 12.Rubber ring 13.Cover 14.Spacer 15.Screw...
  • Page 240 GRISO 8V - 1200 Chassis Removing • Place a collecting container and empty the lubrication system. • Undo and remove the two screws; col- lect the pipes and the four washers. • Undo and remove the rear screw; col- lect the washer. •...
  • Page 241 GRISO 8V - 1200 Chassis Installing • Fit the oil radiator on the vehicle fol- lowing the operations described in the removal chapter but in reverse order. • Unscrew the filler cap / dipstick (1). • Pour new oil until it goes over the min- imum level marked "MIN"...

  • Page 242: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 243: Rear Brake Calliper

    GRISO 8V - 1200 Braking system Rear brake calliper Key: 1. Rear brake calliper 2. Screw 3. Pads 4. Pin + calliper split pin 5. Spring 6. Gasket 7. Screw 8. Air bleed 9. Air bleed cap 10.Rear brake pipe 11.Oil pipe screw BRAK SYS - 243 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 244: Front Brake Calliper

    GRISO 8V - 1200 Braking system Front brake calliper Key: 1. Front right brake calliper 2. Front left brake calliper 3. Pads 4. Air bleed 5. Air bleed cap 6. Pins + Calliper springs 7. Spring 8. Aluminium gasket 9. Screw Front brake pads BRAK SYS - 244 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 245 GRISO 8V - 1200 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 BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.

  • Page 246: Rear Brake Pads

    GRISO 8V - 1200 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 247 GRISO 8V - 1200 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 remove the split pin. •...
  • Page 248 GRISO 8V - 1200 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 249 GRISO 8V - 1200 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. The presence of air is signalled by the "sponginess"...
  • Page 250 GRISO 8V - 1200 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 251 GRISO 8V - 1200 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 252: Clutch System

    INDEX OF TOPICS CLU SYS LUTCH SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 253 GRISO 8V - 1200 Clutch system Both blow-by and clutch pipes should be laid, in the front part of the chassis, underneath the main cable harness. Clutch system pipes laying on the right-hand size of the vehicle. CLU SYS - 253 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 254 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 255 GRISO 8V - 1200 Bodywork Rider footrest plate RIGHT • Undo and remove the two lower screws and collect the nuts and the spacers. • Free the rear brake pipe from the clamps and from pipe guide. • Remove the rear brake calliper from the disc.
  • Page 256 GRISO 8V - 1200 Bodywork • Remove the right footrest plate, keep- ing the brake fluid reservoir in vertical position. LEFT • Remove the exhaust silencer. • Undo and remove the screw and col- lect the nut and the spacer. •...
  • Page 257 GRISO 8V - 1200 Bodywork • Undo and remove the screw and re- move the left footrest plate. See also Air box Air box • Remove the fuel tank. • Disconnect the connector from the air temperature sensor. • Slide off and remove the main fuse box from its holder.
  • Page 258 GRISO 8V - 1200 Bodywork • Slide off and remove the secondary fuse box from its holder. • Undo and remove the two screws. • Disconnect the low pressure pipe. • Disconnect the blow-by tank breather pipe. • Free the pipes from the clamps. BODYW - 258 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 259 GRISO 8V - 1200 Bodywork • Release the breather pipe from the clamp on the right side of the filter cas- ing and the remove the pipe. • Working on both sides, loosen the clamp. • Remove the filter casing by sliding it backwards;...
  • Page 260 GRISO 8V - 1200 Bodywork • Disconnect the connector. • Remove the fuel tank. BODYW - 260 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 261 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 262 GRISO 8V - 1200 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 front and rear brake calliper retainer unit front and rear wheel unit...

  • Page 263: Road Test

    GRISO 8V - 1200 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. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

  • Page 264: Static Test

    GRISO 8V - 1200 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 - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
  • Page 265 Air filter: 37 Battery: 51, 56 Brake: 243, 244, 246 Clutch: 72, 121, 123, 124, 156, 253 Clutch lever: 72 Display: 184 Engine oil: 33, 70, 239 Fork: 188, 190, 193, 198 Forks: 109 Fuel: 86, 115, 259 Fuses: 53 Gearbox oil: 35 Identification: 10 Instrument panel: 75...
  • Page 266 Tank: 86, 115, 259 Transmission: 12, 32 Tyres: 14 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

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