MOTO GUZZI GRISO 8V - 1200 Service Station Manual
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MOTO GUZZI GRISO 8V - 1200 Service Station Manual

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SERVICE STATION MANUAL
854378
GRISO 8V - 1200

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Summary of Contents for MOTO GUZZI GRISO 8V - 1200

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

  • Page 2: The Value Of Service

    Not all versions/models 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 2010- 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 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...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    GRISO 8V - 1200 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 GRISO 8V - 1200 Characteristics Brake and clutch fluid 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.

  • Page 9: Electric Connectors

    CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, 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: Dimensions And Mass

    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 GRISO 8V - 1200 Characteristics Engine NGINE Specification Desc./Quantity Type traverse-mounted twin-cylinder four-stroke V 90° Cylinder number Cylinder arrangement V 90° Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in) Engine capacity 1151 cm³ (70 cu.in) Compression ratio...
  • Page 12 GRISO 8V - 1200 Characteristics Specification Desc./Quantity Alternatively: Spark plug NGK CR8EKB (long life) Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in) Battery 12 V - 18 Ampere/hour Alternator (permanent magnet type) 12 V - 550 W Main fuses...

  • Page 13: Wheels And Tyres

    GRISO 8V - 1200 Characteristics Brakes BRAKES Specification Desc./Quantity Front Double stainless steel floating disc, Ø 320 mm (12.6 in), wawe type, radial callipers with 4 differentiated and opposed pistons. - (Special edition) Double stainless steel floating disc, Ø 320 mm (12.6 in), wawe type, radial callipers with 4 differentiated...
  • Page 14 GRISO 8V - 1200 Characteristics Name Torque in Nm Spark plug (2) 15 Nm (11.06 lb ft) - Molykote OPTION 01 CRANKCASE Name Torque in Nm Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lb ft) Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lb ft)
  • Page 15 GRISO 8V - 1200 Characteristics CRANKSHAFT - FLYWHEEL Name Torque in Nm Connecting rod screw (4) - pre-tightening 40 Nm (29.5 lb ft) Connecting rod screw (4) - final tightening 80 Nm (59 lb ft) Screw fixing clutch plate on crankshaft - M8x25 (6) 42 Nm (30.98 lb ft) - Loctite 243...

  • Page 16: Side Stand

    GRISO 8V - 1200 Characteristics FUEL SUPPLY CONTROL UNIT Name Torque in Nm M5x12 TCEI screw 6 -7 Nm Stainless M5x16 TBEI flanged screw 6 -7 Nm M6x25 TCEI DA screw 8 -12 Nm FRAME Name Torque in Nm Front engine to chassis retainer...

  • Page 17: Rear Suspension

    GRISO 8V - 1200 Characteristics Name Torque in Nm Upper yoke fixing cap 100 Nm Fork hubs closing 25 Nm REAR SUSPENSION Name Torque in Nm Shock absorber to chassis retainer - 8.8 50 Nm Double connecting rod/shock absorber retainer - 10.9 40 Nm Single connecting rod/double connecting rod retainer - 10.9...
  • Page 18 GRISO 8V - 1200 Characteristics ELECTRICAL SYSTEM Name Torque in Nm Coil retainer 2 Nm Horn retainer 15 Nm Odometer sensor on bevel gear pair retainer 3 Nm INSTRUMENT PANEL AND LIGHTS Name Torque in Nm Instrument panel support to light support retainer...

  • Page 19: Piston Rings

    GRISO 8V - 1200 Characteristics 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; if it exceeds the value speci- fied, it is necessary to replace cylinders and pistons.
  • Page 20 GRISO 8V - 1200 Characteristics • 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 Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in) Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in)
  • Page 21 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...
  • Page 22 GRISO 8V - 1200 Characteristics Recommended products chart Piaggio & C. S.p.A. prescribes eni products for the scheduled maintenance of its vehicles ECOMMENDED PRODUCTS Product Description Specifications ENI i-RIDE PG 10W-60 Lubricant formulated with advanced syn- JASO MA, MA2 - API SG...

  • Page 23: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 24: Special Tools

    GRISO 8V - 1200 Special tools SPECIAL TOOLS Stores code Description 020677Y Generator belt tensioner, lever for belt tensioning 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00...
  • Page 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 the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange...
  • 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 seal ring on the crankshaft 19.92.71.00 Tool to fit the seal ring on the flywheel-...
  • Page 27 GRISO 8V - 1200 Special tools Stores code Description 020676Y Dial gauge support for piston position checking 020678Y Tool for clutch rod checking 020953Y Cam shaft lock for fixing 020954Y Centring cam shaft cup spring AP8140190 Tool for steering tightening 05.90.27.30...
  • Page 28 GRISO 8V - 1200 Special tools Stores code Description 05.90.27.32 Buffer handgrip 05.90.27.33 Ball joint sealing buffer 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer 05.90.27.36 Bevel gear pair support AP8140145 fitting tool for Ø 41 mm seal rings...
  • Page 29 GRISO 8V - 1200 Special tools Stores code Description AP8140147 Spacer tool AP8140148 Spacer-piston separating plate AP8140149 Protection for fitting operations AP8140150 Perforated rod for piston air bleed AP8140151 Complete tool kit for fork GU14912603 Hook spanner for fixing ring nut of the...

  • Page 30: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 31: Scheduled Maintenance Table

    GRISO 8V - 1200 Maintenance Scheduled maintenance table 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 (1) Check and clean and adjust or replace, if necessary, before every journey.

  • Page 32: Transmission Fluid

    GRISO 8V - 1200 Maintenance AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT. Transmission fluid Check • Keep the vehicle upright with both wheels on the ground.

  • Page 33: Engine Oil

    GRISO 8V - 1200 Maintenance • Screw and tighten the caps (1 - 2). Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL. NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL.

  • Page 34: Engine Oil Filter

    GRISO 8V - 1200 Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER.

  • Page 35: Air Filter

    GRISO 8V - 1200 Maintenance Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Place a container with suitable capaci- ty under the drainage plug (2). • Unscrew and remove the drainage plug (2).
  • Page 36 GRISO 8V - 1200 Maintenance • Slide off and remove the main fuse box from its holder. • Undo and remove the six screws. • Lift the filter housing cover. • Remove the air filter frame. MAIN - 36...

  • Page 37: Checking The Valve Clearance

    GRISO 8V - 1200 Maintenance • Remove the air filter. • Plug the intake duct with a clean cloth to prevent any foreign objects from en- tering the intake manifold. 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 38: Braking System

    GRISO 8V - 1200 Maintenance Braking system Level check Brake fluid check • Rest the vehicle on its stand. • 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 39 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 - 39...

  • Page 40: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 41 GRISO 8V - 1200 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 41...

  • Page 42: 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...
  • Page 43 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 44: 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 - 44...
  • Page 45 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)
  • Page 46 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...

  • Page 47: Enter New Code

    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.
  • Page 48 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...

  • Page 49: 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 50: 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...

  • Page 51: 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).

  • Page 52: 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...
  • Page 53 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...

  • Page 54: 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...
  • Page 55 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...

  • Page 56: 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 57: Throttle Position Sensor

    GRISO 8V - 1200 Electrical system Check the sensor connector and the injection control unit connector A (BROWN): it they are not OK, restore. If OK, check continuity of the two cables leading to PINS 25 and 35 of the control unit connector: if there is not continuity, restore the cable harness;...
  • Page 58 GRISO 8V - 1200 Electrical system THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.

  • Page 59: Reset Procedure

    GRISO 8V - 1200 Electrical system RESET PROCEDURE Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis instrument selecting FUEL INJECTION and carry out the operation: Throttle position autodetection. Engine temperature sensor...
  • Page 60 GRISO 8V - 1200 Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM AXONE: PARAMETERS Engine temperature In case of recovery, this value is set by the control unit.

  • Page 61: 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 62: 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;...
  • Page 63 GRISO 8V - 1200 Electrical system Pin-out: 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 64 GRISO 8V - 1200 Electrical system • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 11 of the BLUE connector Troubleshooting • shorted to positive: disconnect the probe connector and check the sensor correct resistance: replace the sensor if not OK;...
  • Page 65 GRISO 8V - 1200 Electrical system Left cylinder injection time AXONE: ACTIVATION Left injector: Operation for 4 ms, 5 times The auxiliary injection relay (No. 29 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 66 GRISO 8V - 1200 Electrical system AXONE: ELECTRICAL ERRORS Front injector P0202 - shorted to positive / shorted to negative / open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 37 of the BROWN con- nector.
  • Page 67 GRISO 8V - 1200 Electrical system • Secondary winding resistance: 3 mΩ ± 10%, at approx. 23 °C (73.4 °F). • Tube resistance: 5 kΩ. Pin-out: 1. Power supply + Vbatt 2. Circuit ground AXONE: PARAMETERS Left coil ignition advance.

  • Page 68: Engine Oil Pressure Sensor

    GRISO 8V - 1200 Electrical system 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 sky blue/green cable of the coil is closed to ground for 2 ms per second.
  • Page 69 GRISO 8V - 1200 Electrical system • Connector: on the sensor. Pin-out: Voltage 12V Instrument panel Oil sensor failure DSB 07 Error cause • An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open.
  • Page 70 GRISO 8V - 1200 Electrical system • Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity). • Gearshift engaged: open circuit (12 V on wire from control unit to sensor / open switch,...
  • Page 71 GRISO 8V - 1200 Electrical system • Clutch pulled: closed circuit (continuity) • Clutch released: open circuit (infinite resistance) Pin-out: 1. Voltage 12V 2. Ground connection AXONE: STATUSES Clutch Example value:Yes/No The statuses regularly viewed are YES / NO DIAGNOSIS Troubleshooting: •...

  • Page 72: Bank Angle Sensor

    GRISO 8V - 1200 Electrical system • Side Stand Down: open circuit (infinite resistance) Pin-out: 1. Ground connection 2. Voltage 12 V (brown, sensor side) AXONE: STATUSES Side stand Example value:retracted / extended DIAGNOSIS • Indication on Axone always EXTENDED: check the side stand sensor connector and the ECU connector: if they are not OK, restore;...
  • Page 73 GRISO 8V - 1200 Electrical system • Sensor inverted: closed circuit (resist- ance below 0.5 kOhm) Pin-out: • PIN 1: Voltage 12V • PIN 2: Ground connection AXONE: STATUSES Fall sensor Example value: Normal / Tip over DIAGNOSIS • 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;...

  • Page 74: Run/Stop Switch

    GRISO 8V - 1200 Electrical system 1. Voltage 5V 2. Ground connection Instrument panel Air temperature sensor failure DSB 06 Error cause • An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted...
  • Page 75 GRISO 8V - 1200 Electrical system Location: • Switch: right light switch • Connector: next to the headstock, right side Electrical characteristics: • STOP position: the circuit is open • RUN position: closed circuit (continui- Pin-out: • Sky blue/orange cable (cable harness side): 0V voltage if engine kill in STOP;...
  • Page 76 GRISO 8V - 1200 Electrical system key set to KEY ON, the sky blue/orange cable is shorted to positive: restore the cable har- ness. Connectors Dashboard The pin configuration of the grey-bodied connector is as follows: PIN USE 1 + KEY...
  • Page 77 GRISO 8V - 1200 Electrical system 29 - 30 SELECT 2 31 + BATTERY 32 RIGHT FRONT TURN INDICATOR ACTIVATION 33 RIGHT REAR TURN INDICATOR ACTIVATION 34 AERIAL 2 35 - 36 CAN L 37 - 38 - 39 -...

  • Page 78: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 79: 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 80 GRISO 8V - 1200 Engine from vehicle • Disconnect the engine temperature sensor connector • Disconnect the revolution sensor con- nector. • Disconnect the alternator connectors. • Disconnect the gear in neutral sensor connector. ENG VE - 80...
  • Page 81 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 connectors of the start- er motor.
  • Page 82 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 83 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 84 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 AIDED BY A SEC- OND OPERATOR. • Working on both sides, unscrew and remove the front screw and collect the washer.
  • Page 85 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 86 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 87 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 88 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 89 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 - 89...
  • Page 90 GRISO 8V - 1200 Engine from vehicle • 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. • Working from both sides, connect the spark plug tube.

  • Page 91: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 92 GRISO 8V - 1200 Engine Gearbox Diagram key: 1. Ball bearing ENG - 92...
  • Page 93 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.Roller cage 16.Gear 17.Seal ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft...

  • Page 94: Removing The Gearbox

    GRISO 8V - 1200 Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Roller cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Primary 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 95 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 joint on the sump.

  • Page 96: Gearbox Shafts

    GRISO 8V - 1200 Engine • Undo and remove the two screws. • Unscrew and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 96...
  • Page 97 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 98 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 99 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 100 GRISO 8V - 1200 Engine • Remove the forks and collect the shaft. ENG - 100...
  • Page 101 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 102 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.
  • Page 103 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 104 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.
  • Page 105 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 106: 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.
  • Page 107 GRISO 8V - 1200 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 108: Assembling The Gearbox

    GRISO 8V - 1200 Engine Assembling the gearbox NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.
  • Page 109 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 - 109...

  • Page 110: 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 111 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 112 GRISO 8V - 1200 Engine • Unscrew and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. ENG - 112...
  • Page 113 GRISO 8V - 1200 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. •...
  • Page 114 GRISO 8V - 1200 Engine • Remove the 2 fixing screws of the tim- ing system in the upper section. • Remove the 4 fixing screws of the tim- ing system cover in the lower section. ENG - 114...

  • Page 115: Installing The Generator

    GRISO 8V - 1200 Engine • Remove the timing system cover. • Loosen the lock nut of the set screw. • Using the belt tensioning tool, tension the belt to the prescribed torque. Specific tooling 020677Y Generator belt tensioner, lever for belt tensioning •...
  • Page 116 GRISO 8V - 1200 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 117 GRISO 8V - 1200 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 118 GRISO 8V - 1200 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 119 GRISO 8V - 1200 Engine Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers. • Slide off the starter motor. Clutch side ENG - 119...

  • Page 120: Disassembling The Clutch

    GRISO 8V - 1200 Engine Disassembling the clutch key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch plate 6. Sprocket 7. TCEI screw 8. Clutch thrust plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod...
  • Page 121 GRISO 8V - 1200 Engine 20.TE flanged screw • Remove the complete gearbox. • Unscrew and remove the six screws. • Remove the start-up crown gear. • Remove the clutch housing and the friction disc. • Remove the retainer ring.
  • Page 122 GRISO 8V - 1200 Engine • Undo and remove the six screws and collect the Belleville springs. • Remove the clutch plate. See also Removing the gearbox Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.

  • Page 123: 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)
  • Page 124 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 125 GRISO 8V - 1200 Engine Heads YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lb ft)
  • Page 126 GRISO 8V - 1200 Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
  • Page 127 GRISO 8V - 1200 Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
  • Page 128 GRISO 8V - 1200 Engine YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
  • Page 129 GRISO 8V - 1200 Engine key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw...
  • Page 130 GRISO 8V - 1200 Engine 22.Complete breather cover 23.TBEI screw 24.Timing system chain 25.Chain guide slider 26.Chain tensioner pad 27.Chain tensioner screw 28.Right chain tensioner 29.Left cylinder head 30.Stud bolt 31.Cylinder head gasket 32.Left rocking lever support 33.Screw 34.Pin 35.Nut 36.Right exhaust, left intake rocking lever...
  • Page 131 GRISO 8V - 1200 Engine key: 1. Pad 2. Hydraulic tappet 3. Right rocker axle support 4. Pin D. 2.5 5. Screw M8x30 6. Threaded cap M6x10 7. Camshaft 8. Pin 9. Intake and exhaust com. rockers 10.Rocker adjustment nut 11.Adjustment screw...

  • Page 132: Removing The Head Cover

    GRISO 8V - 1200 Engine 22.Nut M10x1.25 6H 23.Flanged screw M6x120 24.Flat washer 12x6.1x2 25.Timing system gear 26.Breather plate 27.Flanged screw 28.Seal ring 2.62x46.52 29.Timing chain 30.Chain guide slider 31.Chain tensioner pad 32.Spacer screw M8 Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS.

  • Page 133: Removing The Cylinder Head

    GRISO 8V - 1200 Engine • Remove the head cover together with the gaskets. Removing the cylinder head OPTION 01 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 134 GRISO 8V - 1200 Engine For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner.
  • Page 135 GRISO 8V - 1200 Engine • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. • Unscrew and remove the two screws. • Remove the head. • Fit the timing system upper gear back to the chain.
  • Page 136 GRISO 8V - 1200 Engine • Remove the head cover. • Unscrew and remove the two screws in the points indicated in the figure. • Remove the blow-by spout. • Undo and remove the centrifugal sep- arator fixing screw. •...
  • Page 137 GRISO 8V - 1200 Engine For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner.

  • Page 138: Cylinder Head

    GRISO 8V - 1200 Engine • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. • Unscrew and remove the two screws. • Remove the head. • Fit the timing system upper gear back to the chain.
  • Page 139 GRISO 8V - 1200 Engine WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING. OPTION 01 - TRADITIONAL TIMING SYSTEM • Remove the two rocking levers from the cam cap.
  • Page 140 GRISO 8V - 1200 Engine • Unscrew and remove the four screws. • Remove the U-bolt. • Remove the camshaft. • Remove the roller hydraulic tappets from the cam tower, marking the posi- tion to not invert when refitting. Removing the rocker arms...
  • Page 141 GRISO 8V - 1200 Engine • Remove the cam cap from the stud bolts. • Undo and remove the two screws. • Remove the U-bolt. • Remove the two rocking levers from the cam cap. OPTION 02 - ROLLER TIMING SYSTEM •...

  • Page 142: Removing The Valves

    GRISO 8V - 1200 Engine 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. Specific tooling 10.90.72.00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate •...

  • Page 143: Checking The Cylinder Head

    GRISO 8V - 1200 Engine • Use a reamer to bore the holes the valve stems slide through so that the inside diameter is at the prescribed value. The interference between the seat on the head and the valve guide must be 0.046 - 0.075 mm (0.0018 - 0.0030 in)

  • Page 144: Installing The Valves

    GRISO 8V - 1200 Engine - 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 HEADS. • Place the valve guide oil seal (4) in the head.
  • Page 145 GRISO 8V - 1200 Engine WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • Place the two rocking levers in the cam tower seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam tower.
  • Page 146 GRISO 8V - 1200 Engine • Place the half spheres (1) into the ap- propriate seats (2) of the rocker. • Place the two rocking levers in the cam tower seats. • Position the U-bolt on the rockers. • Position the ground plate and tighten the two screws.
  • Page 147 GRISO 8V - 1200 Engine • Place the camshaft with the gear seat on the dowel side. • Insert and tighten the shim washer. • Place the U-bolt on the camshaft mak- ing sure the two reference pins match the seats on the cam tower.
  • Page 148 GRISO 8V - 1200 Engine • Position the cam shaft paying attention to the direction. • Position the U-bolt on the camshaft matching up the reference pins. • Tighten the four fixing screws to the prescribed torque, proceeding diago- nally.
  • Page 149 GRISO 8V - 1200 Engine • Tighten the camshaft fixing screw. • Between the two washers, there is a cup spring which recovers the axial clearance of the shaft. The spring must necessarily be centred using the ap- propriate tool.
  • Page 150 GRISO 8V - 1200 Engine Removing the generator Service shaft removal • Remove the tone wheel. • Remove both cylinders. • Undo and remove the two screws. • Remove the service shaft closing cap. • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting.
  • Page 151 GRISO 8V - 1200 Engine • Fit the timing chains according to the references marked at the removal phase. • Lubricate the service shaft. • Insert the service shaft in its crankcase seat by sliding it through the two chains.

  • Page 152: Cam Timing

    GRISO 8V - 1200 Engine Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws. • Tighten the chain caps with O-rings. • The operations related to the movable chain sliders are described in the cyl- inder fitting section.
  • Page 153 GRISO 8V - 1200 Engine • Lock crankshaft rotation. • Unscrew and remove the nut fixing the crankshaft gear. • Remove the oil pump control gear. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
  • Page 154 GRISO 8V - 1200 Engine • Place a new gasket between the crank- case and the oil pump. • Fit the oil pump. • Tighten the three oil pump fixing screws. • Place the driving pin on the oil pump shaft.
  • Page 155 GRISO 8V - 1200 Engine • 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 156 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 157 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. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket...

  • Page 158: Removing The Cylinder

    GRISO 8V - 1200 Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Remove the head, the gasket between the head and the cylinder and the two dowel pins.

  • Page 159: Fitting The Piston

    GRISO 8V - 1200 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 160: 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 161 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 162: Installing The Cylinder Head

    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 163 GRISO 8V - 1200 Engine • 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 164 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 165 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 166 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 OPTION 02 •...
  • Page 167 GRISO 8V - 1200 Engine • Fix the cam cap with the four nuts on the stud bolts. • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages.
  • Page 168 GRISO 8V - 1200 Engine • Block the left chain tensioner hole with screw and washer. • Rotate the crankshaft clockwise by 270° from the timing system side so that the right cylinder piston reaches the TDC; lock crankshaft rotation.
  • Page 169 GRISO 8V - 1200 Engine • Screw the cap of the right chain ten- sioner. • Undo and remove the screws used to place the gear on the camshaft. • Place the centrifugal separator align- ing the reference pins with timing sys-...
  • Page 170 GRISO 8V - 1200 Engine Installing the head cover • Replace the gaskets and install the head cover. • Place the plastic half-cover. • Replace the four rubber rings. • Tighten the four screws to the prescri- bed torque. •...

  • Page 171: Removing The Crankshaft

    GRISO 8V - 1200 Engine 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. • Remove the connecting rods.
  • Page 172 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 173 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 174 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 175 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)

  • Page 176: 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 177 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 178 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 179: 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 180 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 181 GRISO 8V - 1200 Engine • Unscrew and remove the three screws. • Remove the oil pump. • Remove the gasket between the crankcase and the oil pump. See also Removing the generator Installing • Place a new gasket between the crank- case and the oil pump.
  • Page 182 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 183 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. Oil sump OPTION 01 ENG - 183...
  • Page 184 GRISO 8V - 1200 Engine RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lb ft) Oil cap on the crankcase 25 Nm (18.44 lb ft)
  • Page 185 GRISO 8V - 1200 Engine RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lb ft) Oil cap on the crankcase 25 Nm (18.44 lb ft)

  • Page 186: Specific Tooling

    GRISO 8V - 1200 Engine IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cooling oil intake filter fixing screw M4x10 By hand Complete oil pressure control valve 20 Nm (14.75 lb ft) Loctite 243 Mesh type oil filter fixing screw M6x14 6 Nm (4.42 lb ft)
  • Page 187 GRISO 8V - 1200 Engine • Unscrew and remove the oil level plug and collect the O-Ring. • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws.
  • Page 188 GRISO 8V - 1200 Engine • Unscrew and remove the two screws. • Remove both side filters.. • Unscrew and remove the cap. • Remove the thermostatic valve. ENG - 188...
  • Page 189 GRISO 8V - 1200 Engine • Unscrew and remove the overpressure valve plug. • Remove the overpressure valve ele- ments OPTION 02 key: 1. Flange 2. Pressure adjuster valve ENG - 189...
  • Page 190 GRISO 8V - 1200 Engine 3. Flange inlet pipe 4. Pump inlet pipe 5. Pump inlet filter 6. Oil filter 7. Cartridge-type oil filter 8. Joint 9. Special gasket 10.Exhaust cap 11.Oil sump gasket NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
  • Page 191 GRISO 8V - 1200 Engine • Unscrew and remove the filter fixing screw. • Remove the filter. • Remove the overpressure valve. Refitting the oil sump OPTION 01 ENG - 191...
  • Page 192 GRISO 8V - 1200 Engine • Place the overpressure valve elements correctly. • Tighten the overpressure valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED. • Tighten the thermostatic valve plug. ENG - 192...
  • Page 193 GRISO 8V - 1200 Engine • Place a new gasket between the crank- case and the flange. • Insert the flange • Fix the flange with the four screws. • Insert the lubrication oil intake filter • Check that on the oil pump are the OR rings.
  • Page 194 GRISO 8V - 1200 Engine • Fix both filters by tightening the two screws to the prescribed torque. • Fit a new oil filter by tightening it to the prescribed torque. • Place a new gasket between the flange and the sump.
  • Page 195 GRISO 8V - 1200 Engine • Position the gasket of the overpressure valve. • Apply threadlock on the overpressure valve. • Tighten it to the prescribed torque. • Make sure that the OR is in good con- dition, otherwise replace it.
  • Page 196 GRISO 8V - 1200 Engine • Insert the joint in the oil sump, making sure the OR is in good condition. • Replace the OR if necessary. • Place a new gasket between the crank- case and the flange. •...
  • Page 197 GRISO 8V - 1200 Engine • Fit the filter and tighten it to the speci- fied torque. • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level.
  • Page 198 GRISO 8V - 1200 Engine Both blow-by and clutch pipes should be laid, in the front part of the chassis, underneath the main cable harness. Fuel pipes in the area underneath the fuel tank should be laid over the (grey) blow-by pipes.

  • Page 199: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 200: 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.
  • Page 201 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.
  • Page 202 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 203 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.
  • Page 204 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 205: 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-acquisition" as explained above.
  • Page 206 GRISO 8V - 1200 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 207: 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...

  • Page 208: Errors Display

    GRISO 8V - 1200 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 209: Adjustable Parameters

    GRISO 8V - 1200 Power supply Specification Desc./Quantity Lambda probe Possible short circuit on the earth lead, battery or open circuit or plausibility: recovery function hardly noticeable for customer. Left injector Possible short circuit in the earth lead, battery or open circuit.
  • Page 210 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 211: 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. • Hold the vehicle front part.
  • Page 212 GRISO 8V - 1200 Suspensions • Remove the wheel axle 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 213: Front Fork

    GRISO 8V - 1200 Suspensions • Tighten the two M10 fixing screws of the steering wheel with a torque of 50 Nm (36.88 lbf ft) applying Loctite 243 Front fork Diagram Key: 1. Radial fork right stem 2. Radial fork left stem 3.
  • Page 214 GRISO 8V - 1200 Suspensions 15.O-ring 16.Snap ring 17.TE flanged screw M8x40 18.Stem + right wheel holder 19.Stem + left wheel holder 20.Dust guard 21.Seeger ring 22.Oil seal 23.Ring 24.Bushing 25.Sliding bushing 26.Special washer 27.screws M10x1.5 Adjustment The standard front fork setting is adjusted to suit most low and high speed riding conditions, wheth- er the vehicle is partially or fully loaded.

  • Page 215: 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 216 GRISO 8V - 1200 Suspensions • Unscrew the sleeve top cap. • Lock the calliper mounting bracket in a vice paying attention not to damage it. • Fit the tool on the spring joint. Specific tooling AP8140147 Spacer tool •...
  • Page 217 GRISO 8V - 1200 Suspensions • Loosen the cap by the key grip and by making the lock nut turn. • Remove the complete cap. • Remove the spacer and the washer. • Press down and force the spring to compress.

  • Page 218: Disassembling The Fork

    GRISO 8V - 1200 Suspensions • Remove the spring joint. • Drain off oil into a collecting container and remove the spring. Disassembling the fork • After emptying the oil, fasten the cal- liper mounting bracket of the fork stan- chion in a vice.
  • Page 219 GRISO 8V - 1200 Suspensions • Unscrew the cartridge fixing screw on the fork feet. • Retrieve the centring bushing. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim.
  • Page 220 GRISO 8V - 1200 Suspensions • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal. SUSP - 220...

  • Page 221: 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).
  • Page 222 GRISO 8V - 1200 Suspensions • piston. 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. Replace the following components with new ones: •...
  • Page 223 GRISO 8V - 1200 Suspensions • The sealing ring must be placed with the stamped part facing the dust gaiter. • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. SUSP - 223...
  • Page 224 GRISO 8V - 1200 Suspensions • 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 43 mm (1.69 in) orifices 8140145 Fitting tool for Ø 41 mm (1.61 in) seal-...
  • Page 225 GRISO 8V - 1200 Suspensions • Fit the oil seal with the specific tool. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices 8140145 Fitting tool for Ø 41 mm (1.61 in) seal- ing ring...

  • Page 226: Filling Oil

    GRISO 8V - 1200 Suspensions 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. • Wait some minutes until the oil fills all the ducts.
  • Page 227 GRISO 8V - 1200 Suspensions • 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 AP8140147 Spacer tool 8140148 Spacer / pumping member separating plate •...

  • Page 228: 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 cover, tightening it to the prescribed torque. Specific tooling AP8140149 Protection for fitting operations...
  • Page 229 GRISO 8V - 1200 Suspensions • Undo and remove the two external screws and move the instrument panel forwards. • Unscrew and remove the screws and collect the U-bolts, holding the handle- bar. • Move the handlebar forward without tilting the clutch and the front brake flu- id reservoirs.
  • Page 230 GRISO 8V - 1200 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 231 GRISO 8V - 1200 Suspensions • Remove the safety washer. • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening • Fit a new safety washer. • Screw the upper ring nut manually and...

  • Page 232: Removing The Rear Wheel

    GRISO 8V - 1200 Suspensions • Rivet the tongues of the new safety washer. • Fit the fork upper plate on the stems. Rear Removing the rear wheel • Support the vehicle from the rear with an adequate stand. •...

  • Page 233: Shock Absorbers

    GRISO 8V - 1200 Suspensions 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. To set vehicle suspension, the shock absorber has: - a set screw (1) to adjust the hydraulic rebound damping;...

  • Page 234: Shock Absorber Adjustment

    GRISO 8V - 1200 Suspensions • 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). • Once adjusted, tighten the locking ring nut (4).
  • Page 235 GRISO 8V - 1200 Suspensions • 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 236 GRISO 8V - 1200 Suspensions • Undo and remove the suspension up- per screw. SUSP - 236...

  • Page 237: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 238: Swinging Arm

    GRISO 8V - 1200 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 239 GRISO 8V - 1200 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 240 GRISO 8V - 1200 Chassis • Loosen the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft.
  • Page 241 GRISO 8V - 1200 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 242 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 243 GRISO 8V - 1200 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 244 GRISO 8V - 1200 Chassis • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint. Checking Support unit CHAS - 244...
  • Page 245 GRISO 8V - 1200 Chassis Support unit Removal Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screw- driver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers.
  • Page 246 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 247 GRISO 8V - 1200 Chassis Pinion unit Removal Remove the stop ring (1) from the ring nut. Unscrew the ring nut (2) with the special spanner (s4). Remove the ring nut (2) and remove the sealing ring from the ring nut.
  • Page 248 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 249 GRISO 8V - 1200 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Casing unit fitting Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer.
  • Page 250 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 - 250...
  • Page 251 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 252 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.
  • Page 253 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.
  • Page 254 GRISO 8V - 1200 Chassis Fit the cap in its seat. Wheel axle unit Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor.
  • Page 255 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 - 255...
  • Page 256 GRISO 8V - 1200 Chassis Casing unit removal 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 - 256...
  • Page 257 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 - 257...

  • Page 258: 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...
  • Page 259 GRISO 8V - 1200 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 260 GRISO 8V - 1200 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 261 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 262: Removing The Exhaust Manifold

    GRISO 8V - 1200 Chassis • Unscrew and remove the rear attach- ment screw fixing the exhaust pipe to the chassis; collect the lock nut, the spacer and the washer. DURING THIS OPERATION SUPPORT THE EXHAUST PIPE SO THAT IT DOES NOT FALL.
  • Page 263 GRISO 8V - 1200 Chassis • Unscrew 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. • Retrieve the washers.

  • Page 264: 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...
  • Page 265 GRISO 8V - 1200 Chassis Removing • Place a collecting container and empty the lubrication system. • Unscrew and remove the two screws; collect the pipes and the four washers. • Undo and remove the rear screw; col- lect the washer.
  • Page 266 GRISO 8V - 1200 Chassis Installing • Fit the oil cooling radiator on the vehi- cle following 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 267: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 268: 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...

  • Page 269: 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...
  • Page 270 GRISO 8V - 1200 Braking system Removal • Turn the pins and remove both cotter 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 271: 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 272 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 pull out the cotter pin.
  • Page 273 GRISO 8V - 1200 Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
  • Page 274 GRISO 8V - 1200 Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper.
  • Page 275 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 276 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 277: Clutch System

    INDEX OF TOPICS CLU SYS LUTCH SYSTEM...
  • Page 278 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 - 278...
  • Page 279 INDEX OF TOPICS BODYW ODYWORK...
  • Page 280 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 281 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 282 GRISO 8V - 1200 Bodywork • Unscrew and remove the screw and remove 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 283 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.
  • Page 284 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 285 GRISO 8V - 1200 Bodywork • Disconnect the connector. • Remove the fuel tank. BODYW - 285...
  • Page 286 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 287 GRISO 8V - 1200 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...

  • Page 288: 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.

  • Page 289: 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...
  • Page 290 Air filter: 35 Air temperature sensor: 61, 73 Alternator: Battery: 49, 54 Brake: 268, 269, 271 Brake calliper: 268, 269 Brake pads: 269, 271 Clutch: 70, 119, 120, 122, 123, 172, 278 Coil: 66 Connectors: 76 Crankcase: 20, 170, 178 Crankshaft: 20, 152, 155, 170, 171, 173, 176 Cylinder: 19, 133, 138, 143, 158, 160, 162, 172 Desmodromic drum: 106...
  • Page 291 Maintenance: 8, 31 Maintenance Table: Oil filter: 34 Oil pressure sensor: 68 Oil sump: 183, 186, 191 Primary shaft: 101, 106, 107 Radiator: Rear wheel: 232 Recommended products: 22, 243 Run/Stop switch: 74 Scheduled maintenance: 31 Secondary shaft: 103, 106, 107 Shock absorber: Shock absorbers: 233 Side stand: 71...

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