Page 1 SERVICE STATION MANUAL 854366 BELLAGIO...
Page 2: The Value Of Service
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 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 BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
BELLAGIO 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 BELLAGIO 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: Electrical Connectors
REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10: Vehicle Identification
That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
Page 11: Chassis Number
BELLAGIO Characteristics This number is composed by numbers and letters, as in the example shown below. ZGULY0000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LY: model; 000: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario);...
Page 12 BELLAGIO Characteristics Engine ENGINE Specification Desc./Quantity Type traverse-mounted twin-cylinder four-stroke V 90° No. of cylinders Cylinder arrangement V 90° Cubic capacity 935.6 cm³ (57.09 cu.in) Bore / stroke 95 x 66 mm (3.74 x 2.66 cu.in) Compression ratio 10:1 Electric...
Page 13 BELLAGIO Characteristics Specification Desc./Quantity Generator - alternator Output power: 350 W at 5000 rpm (12V - 25A) Main fuses 30 A Auxiliary fuses 3 A - 15 A Daylight running light 12V - 5 W Low/High beam headlight (halogen) 12 V - 55 W / 60 W H4...
Page 14: Wheels And Tyres
BELLAGIO Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Wheel rims with spokes Front wheel rim 3.5" x 18'' Rear wheel rim 5.50 x 17 Tyres - Front size 120/70 - ZR 18'' M/C 59 W Tyres - Rear size...
Page 15: Oil Pump
BELLAGIO Characteristics OIL SUMP Name Torque in Nm Oil sump centre lower screws - TE M6x90 (4) 10 Nm (7.38 lbf ft) Oil sump screw - TCEI M6x25 (14) 10 Nm (7.38 lbf ft) Oil drainage plug - M10x1 (1) 20 Nm (14.75 lbf ft)
Page 16: Side Stand
BELLAGIO Characteristics FOOTRESTS AND LEVERS Name Torque in Nm Footrest rubber retainer - M6x12 (8) 10 Nm (7.38 lbf ft) Gear shift lever cable retainer (nut) - M6x1 (2) 10 Nm (7.38 lbf ft) Gear shift lever / brake pin retainer - M6x16 (1+1) 10 Nm (7.38 lbf ft)
Page 17: Rear Wheel
BELLAGIO Characteristics Name Torque in Nm Wheel pin - M18x1.5 (1) 80 Nm (59 lbf ft) REAR WHEEL Name Torque in Nm Brake disc retainer - M8x20 (6) 30 Nm (22.13 lbf ft) - Loctite 243 Rear wheel retainer - 10.9 M12x65 (4) 110 Nm (81.13 lbf ft)
Page 18 BELLAGIO Characteristics CHASSIS / FAIRINGS (CENTRE) Name Torque in Nm Right and left throttle body cover upper retainer - M5x20 (2) 4 Nm (2.95 lbf ft) - Loctite 243 Right and left throttle body cover lower retainer - M5x20 (2)
Page 19: Piston Rings
BELLAGIO Characteristics Piston rings Check the sealing piston rings and the oil scraper. On each piston there are: 1 top piston ring; 1 middle stepped piston ring; 1 oil scraper piston ring. The ends of the fitted piston rings are out of phase.
Page 20 BELLAGIO Characteristics TAPPET-SEAT COUPLING ON CRANKCASE DATA (PRODUCTION) Specification Desc./Quantity Seats diameter 22.021 - 22.000 mm (0.86697 ÷ 0.86614 inch) Tappet external diameter 21.996 - 21.978 mm (0.86598 ÷ 0.86527 inch) Fitting clearances 0.004 - 0.043 mm (0.00016 ÷ 0.00169 in.)
Page 21: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 22: Special Tools
BELLAGIO Special tools SPECIAL TOOLS Stores code Description 05.90.25.30 Gearbox support 14.92.72.00 Tool for fitting the sealing ring on the tim- ing system cover 05.91.25.30 Gearbox opening 05.90.19.30 Inner spark plug removal 05.92.80.30 Piston ring clamp 14.92.91.00 Punch for pressing the sealing ring on the front fork sleeve and sealing ring inside the gearbox.
Page 23 BELLAGIO Special tools Stores code Description 19.92.96.00 Graduated dial to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange 10.90.72.00 Tool for valve removal and refitting 30.90.65.10 Tool for clutch fitting 14.92.71.00...
Page 24 BELLAGIO Special tools Stores code Description 19.92.71.00 Tool to fit the seal ring on the flywheel- side flange 14.92.73.00 Tool for camshaft gear sealing 981001 Graduated dial hub 30.91.28.10 Clutch body locking 000019663300 Tool for clutch shaft removal 05.90.27.30 Gearbox support 05.90.27.31...
Page 25 BELLAGIO 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 GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body S-TOOLS - 25...
Page 26: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 27: At Every Start-Up
BELLAGIO Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. AT EVERY START-UP Action Engine oil pressure warning light - check and clean, adjust, grease or replace if necessary...
Page 28: Transmission Fluid
BELLAGIO Maintenance Action Steering bearings and steering clearance - Check and clean, adjust, grease or replace if necessary. Wheel bearings - Check and clean, adjust, grease or replace if necessary Disc brakes - Check and clean, adjust or replace if necessary...
Page 29: Engine Oil
BELLAGIO Maintenance Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN. NOTE RIDE SOME km (miles) TO WARM UP ENGINE OIL • Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3).
Page 30 BELLAGIO Maintenance • Remove the dipstick (1). • Check oil level on the dipstick (1). • The oil level is correct when it close to the "MAX" mark. MAX = maximum level MIN = minimum level Add engine oil if required: •...
Page 31: Checking And Topping Up
BELLAGIO Maintenance • Screw and tighten the drainage plug (2). • Pour new oil until it goes above the minimum level marked "MIN". Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTION ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL.
Page 32: Air Filter
BELLAGIO Maintenance • Place a container with suitable capacity under the drainage plug (2). • Unscrew and remove the drainage plug (2). • Unscrew and remove the filler cap (1). • Drain the oil into the container; allow several mi- nutes for oil to drain out completely.
Page 33: Checking The Valve Clearance
BELLAGIO Maintenance • Remove the filter casing cover from the clamps. • Remove the air filter. NOTE 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 34: Braking System
BELLAGIO Maintenance • loosen the nut (1); • use a screwdriver on the set screw (2) until the following clearances are ob- tained: - inlet valve: 0.10 mm (0.0039 in) - outlet valve: 0.15 mm (0.0059 in). • The measurement must be done using a thickness gauge (3).
Page 35 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 - 35...
Page 36 BELLAGIO Maintenance MAIN - 36...
Page 37 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 38 BELLAGIO Electrical system Components arrangement Key: 1. Coil 2. Instrument panel 3. Fuel pump ELE SYS - 38...
Page 39: Electrical System Installation
BELLAGIO Electrical system 4. Injector 5. Throttle valve potentiometer 6. Rear light 7. Battery 8. Main fuses 9. Lambda Probe 10.Starter motor 11.Intake air temperature sensor 12.Engine revolution sensor 13.Secondary fuses 14.Head temperature sensor 15.Engine control unit 16.Instrument panel air temperature sensor 17.Front headlamp...
Page 40: General Wiring Diagram
BELLAGIO Electrical system General wiring diagram Key: 1. Multiple connectors 2. - 3. Start-up relay 4. Clutch switch ELE SYS - 40...
Page 41 BELLAGIO Electrical system 5. Light relay 6. Right light switch 7. Safety diode 8. Horn 9. Left light switch 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Instrument panel diagnosis 13.Key switch 14.Front stop switch 15.Right rear turn indicator 16.Rear light (LED) 17.Left rear turn indicator...
Page 42 BELLAGIO Electrical system 43.Left cylinder outer spark plug 44.Right cylinder double coil 45.Left cylinder double coil 46.Right injector 47.Left 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...
Page 43: Enter New Code
BELLAGIO Electrical system If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available; in this case, at least two of the programmed keys have to be inserted in the ignition lock.
Page 44 The white connector is placed under the saddle, beside the fuse box, close to the diagnosis con- nector for the injection system. Use the Ditech connector in the Axone 2000 Apri- lia-Moto Guzzi package to connect to the Axone cable. ELE SYS - 44...
Page 45: Alternator Check
BELLAGIO Electrical system Battery recharge circuit Checking the stator INVERTED CONNECTION WILL CAUSE IRREPARABLE DAMAGE TO THE REGULATOR. MAKE SURE THAT THE REGULATOR HAS A CORRECT GROUND CONNECTION. POSSIBLE CHECKS TO BE CARRIED OUT ON THE AL- TERNATOR AND ON THE REGULATOR IN CASE THAT THE BATTERY IS RECHARGED OR THAT VOLTAGE IS NO LONGER REGULATED.
Page 46 BELLAGIO Electrical system Voltage regulator check The regulator is calibrated to keep battery voltage between 14 and 14.6 V. Regulator checks Regular tools in the shop are not enough to carry out the regulator check, therefore, there follow some indications for effectively detecting a faulty regulator.
Page 47: Electrical System
BELLAGIO Electrical system Lights list ELECTRICAL SYSTEM Specification Desc./Quantity Daylight running light 12V - 5 W Low/High beam headlight (halogen) 12 V - 55 W / 60 W H4 Rear tail light /stop light 12 V - 5 / 21 W...
Page 48: Main Fuses
BELLAGIO Electrical system MAIN FUSES 1 - From battery to voltage regulator (30 A). 2 - From battery to key and auxiliary fuses C - D (30 A). NOTE THERE IS ONE SPARE FUSE. Control unit Model: Magneti Marelli IAW 5 AM...
Page 49 BELLAGIO Electrical system Ignition Example value: Enabled/Disabled Indicates whether the control unit will enable start-up when requested: in case these safety measures are not respected (correct position of side stand, neutral sensor and clutch), the status is NO. AXONE: ACTIVATIONS...
Page 50: Speed Sensor
BELLAGIO Electrical system Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed. Operation / Operating principle HALL effect sensor: a square-wave pulse is gen- erated with voltage between 12 V and 0.3-0.4V approx. Level in wiring diagram:...
Page 51: Engine Rpm Sensor
BELLAGIO Electrical system • Check continuity of the cable between PIN 2 of the sensor and PIN 24 of the ECU blue connector. • Check PIN 24 of the blue connector. • If after all these checks the failure is not found, replace the sensor.
Page 52: Throttle Position Sensor
BELLAGIO Electrical system Target engine revs Example value:1100 +/- 100 rpm Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance. NAVIGATOR: STATUSES...
Page 53 BELLAGIO Electrical system Electrical characteristics: • PINS A-C: throttle closed approx. 2.5 kOhm; throttle open approx. 1.5 kOhm. • PINS A-B: approx. 1.1 kOhm Pin-out: • PIN A: ground connection • PIN B: supply voltage +5V • PIN C: potentiometer signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS;...
Page 54: Engine Temperature Sensor
BELLAGIO Electrical system resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive and the cable harness should be restored • shorted to negative: disconnect the sensor connector and check the ground insulation of the red cable (from throttle sensor connector or control unit connector): if there is continuity to ground, restore the cable harness;...
Page 55 BELLAGIO Electrical system Specification Desc./Quantity Resistance at +60 °C (140 °F) 0.750 kOhm Resistance at +70 °C (158 °F) 0.530 kOhm Resistance at +80 °C (176 °F) 0.380 kOhm Resistance at +90 °C (194 °F) 0.280 kOhm Resistance at +100 °C (212 °F) 0.204 kOhm...
Page 56: Air Temperature Sensor
BELLAGIO Electrical system error is displayed at the same time, this means that the grey cable common for both sensors is shorted to positive. • If shorted to negative, check sensor correct resistance: if resistance is null, replace the sen- sor;...
Page 57 BELLAGIO 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 58: Lambda Sensor
BELLAGIO Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 59 BELLAGIO Electrical system Example value: Open loop / Closed loop Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value. AXONE: ELECTRICAL ERRORS Lambda probe P0130 - Shorted to positive.
Page 60 BELLAGIO Electrical system Injector Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in wiring diagram:Coils and injectors Location: • on the throttle bodies •...
Page 61 BELLAGIO Electrical system • If shorted to positive: excessive voltage has been detected at PIN 28 of the BROWN con- nector. • If shorted to negative: no voltage has been detected. • If the circuit is open: an interruption has been detected.
Page 62: Fuel Pump
BELLAGIO Electrical system • the circuit is open: check the component correct electrical characteristic: if it is not the correct one, replace the component; if it is correct, check the connector on the component and the Marelli control unit connector: If they are not OK, restore. If OK, check cable continuity be- tween PIN 37 of the BROWN connector and the component PIN - and restore the cable harness.
Page 63 BELLAGIO Electrical system THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN"...
Page 64: Engine Oil Pressure Sensor
BELLAGIO Electrical system to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation AXONE: ELECTRICAL ERRORS Right coil - shorted to positive / open circuit, shorted to negative.
Page 65 BELLAGIO Electrical system • With engine started: open circuit (infin- ite resistance). Pin-out: • PIN 1: 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 66 BELLAGIO Electrical system • Connector: on the sensor Electrical characteristics: • 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 67 BELLAGIO Electrical system • Clutch pulled: closed circuit (continuity) • Clutch released: open circuit (infinite resistance) Pin-out: 1. Voltage 12V 2. Ground connection Side stand sensor Function It tells the side stand position to the control unit. Operation / Operating principle If the gear is engaged and the side stand is unfolded, and therefore the circuit is open, the control unit does not enable vehicle start-up or shuts off the engine if it is rotating.
Page 68 BELLAGIO Electrical system Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel. Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:Temperature sensors Location: •...
Page 69: Run/Stop Switch
BELLAGIO Electrical system panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the battery).
Page 70 BELLAGIO 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 TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 71 BELLAGIO Electrical system 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 Not used 10 Right cylinder coil control 11 Not used...
Page 72 BELLAGIO Electrical system Vehicle connector pins (blue) Pin Use 1 Not used 2 Not used 3 Not used 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxiliary relay control 7 Immobilizer line 8 Not used...
Page 73 BELLAGIO Electrical system 37 Not used 38 Side stand sensor signal Dashboard PIN USE 1 + KEY 2 RIGHT TURN INDICATOR CONTROL 3 HIGH-BEAM LIGHT INPUT 6 K LINE 8 SCROLL 9 FUEL LEVEL SENSOR 10 EXTERNAL AIR TEMPERATURE SENSOR...
Page 74 BELLAGIO Electrical system 32 FRONT RIGHT TURN INDICATOR ACTUA- 33 REAR RIGHT TURN INDICATOR ACTUATOR 34 - 35 - 36 CAN L LINE 37 - 38 - 39 - 40 TRIP 1 ELE SYS - 74...
Page 75: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 76: Vehicle Preparation
BELLAGIO Engine from vehicle Vehicle preparation • Drain off the engine oil. • Remove the tank. • Remove the exhaust system. • Remove the fork. • Remove the shock absorber. • Remove the air filter casing. • Remove the battery.
Page 77: Removing The Engine From The Vehicle
BELLAGIO Engine from vehicle • Operating from both sides, remove the side plate. • Remove the throttle body. Removing the engine from the vehicle • Operating from both sides, undo and remove the two screws. • Disconnect the spark plug tubes.
Page 78 BELLAGIO Engine from vehicle • Disconnect the engine temperature sensor connector. • Undo and remove the two screws. • Remove the timing sensor. • Disconnect the oil pressure sensor. • Remove the clamp. ENG VE - 78...
Page 79 BELLAGIO Engine from vehicle • Disconnect the generator connector. • Operating on both sides, release the clamp. • Disconnect the oil vapour recovery pipe. NOTE UPON REFITTING, ALWAYS REPLACE WITH A NEW CLAMP. • Release the clamp and disconnect the crankcase / timing system vapour re- covery pipe.
Page 80 BELLAGIO Engine from vehicle • Disconnect the gear in neutral sensor connector. • Unscrew and remove the two screws. • Remove the starter motor protection. • Disconnect the side stand sensor con- nector. • Unscrew and remove the screw. •...
Page 81 BELLAGIO Engine from vehicle • Disconnect the starter motor connec- tors. • Undo and remove the screw. • Remove the gear transmission lever. • Unscrew and remove the three screws. • Remove the clutch control cylinder. • Lock the plunger using a clamp.
Page 82 BELLAGIO Engine from vehicle • Undo and remove the brake control fix- ing screw. • Turn the footrest to operate on the en- gine pin. • Undo and remove the lower rear pin. • Slide off the pin from the right side.
Page 83 BELLAGIO Engine from vehicle • Unscrew and remove the upper rear pin nut. • Remove the pin from the opposite side. • Lift the chassis. Installing the engine to the vehicle For refitting, follow the operations in reverse order observing the tightening torque.
Page 84 INDEX OF TOPICS NGINE...
Page 85 BELLAGIO Engine Gearbox Diagram KEY: 1. Ball bearing 2. Circlip ENG - 85...
Page 86 BELLAGIO Engine 3. Shim washer 4. Pin 5. Desmodromic compl. 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10. Fifth wheel 11. Linking pin 12. Gear 13. Circlip 14. Shoulder washer 15. Ball bearing cage 16. Gear 17. Sealing ring 18.
Page 87 BELLAGIO Engine 41. Transmission gear 42. Ball bearing 43. Gear 44. Gear 45. Ball bearing cage 46. Shoulder washer 47. Circlip 48. Gear 49. Circlip 50. Gear 51. Main shaft 52. Transmission gear 53. Ring nut 54. Washer 55. Clutch internal body 56.
Page 88: Removing The Gearbox
BELLAGIO Engine Removing the gearbox • Remove the starter motor. • Make sure the transmission is in idle. • Unscrew and remove the breather pipe. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil.
Page 89: Gearbox Shafts
BELLAGIO Engine • Unscrew and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts Disassembling the gearbox • Remove the gearbox. • Place the gearbox on the specific gearbox support tool and on a vice.
Page 90 BELLAGIO Engine • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer. • Remove the thrust bearing and the washer. • Slide off the two bushings (1) and re- move the rod (2), collect the bushing (3).
Page 91 BELLAGIO Engine • Open the gearbox using the specific tool. Specific tooling 05.91.25.30 Gearbox opening • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Unscrew and remove the threaded ref- erence pin. ENG - 91...
Page 92 BELLAGIO Engine • Use rubber bands to tie down the trans- mission shaft unit and extract it. • Remove the bearings from the gearbox if necessary. • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group.
Page 93 BELLAGIO Engine • Replace bearings if necessary and re- move the clutch shaft. ENG - 93...
Page 94 BELLAGIO Engine Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side. • Remove the gear of the second gear and collect the ball bearing cage. • Remove the gear of the sixth gear and collect the shoulder washer.
Page 95 BELLAGIO Engine • 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. • Heat the shaft with a specific heater and remove the helical transmission gear.
Page 96 BELLAGIO Engine Removing the secondary shaft • Remove the transmission shaft. • Operate on the shaft from the grooved side. • Remove the shoulder washer. • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer.
Page 97 BELLAGIO Engine • 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. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer.
Page 98 BELLAGIO Engine • 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. • Remove the bearing if necessary.
Page 99 BELLAGIO Engine • Remove the Belleville springs (10). • Remove the washer (11). • Remove the shaped washers (8). • Remove the sleeve (7). • Remove the circlip (6). • Remove the transmission gear (5). • Collect the clutch shaft (4).
Page 100: Checking The Secondary Shaft
BELLAGIO Engine Checking the secondary shaft Measure the coaxiality of the transmission shaft with a dial gauge and a centring device and re- place 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 101: Assembling The Gearbox
BELLAGIO Engine • Check the transmission fork move- ment and if it is not regular, replace the transmission forks. See also Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
Page 102: Removing The Flywheel
BELLAGIO Engine See also Disassembling the gearbox Flywheel Removing the flywheel • Remove the clutch. • Position the locking tool on the flywheel and loosen the six flywheel fixing screws operating diagonally and in stages. • Remove the locking tool.
Page 103: Installing The Flywheel
BELLAGIO Engine Installing the flywheel • Position the flywheel. NOTE RESPECT THE FLYWHEEL POSITIONING REFERENCES. CAUTION THE SCREWS MUST BE REPLACED WITH NEW ONES AT THE FOLLOWING REFITTING AS THEY ARE SUBJECT TO HIGH LOADS AND STRESS. • Position the locking tool on the flywheel...
Page 104 BELLAGIO Engine • Unscrew the four screws and remove the alternator cover. • Remove the gearbox. • Lock the rotation of the engine flywheel using the appropriate locking tool. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
Page 105: Removing The Starter Motor
BELLAGIO Engine • Remove the washer and take out the rotor. IN ORDER TO PREVENT DEMAGNETISATION INTRO- DUCE THE ROTOR AGAIN ON THE STATOR PREVIOUSLY REMOVED. • Remove the cotter. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers.
Page 106: Disassembling The Clutch
BELLAGIO Engine Clutch side Disassembling the clutch • Remove the gearbox from the engine. • Remove the pressure plate disc cover. • Use the locking tool and the clutch spring compression tool on the fly- wheel. Specific tooling 30.90.65.10 Tool for clutch fitting 12.91.18.01 Tool to lock the flywheel and the...
Page 107 BELLAGIO Engine Extract from the inside of the engine flywheel: • the clutch plate. • The intermediate plate. • The second clutch plate. • Remove the tool used to compress the clutch springs. Specific tooling 30.90.65.10 Tool for clutch fitting •...
Page 108: Checking The Clutch Plates
BELLAGIO Engine Checking the clutch plates Driven plates Check that the supporting surfaces with the driven plates are perfectly smooth and even and that the external toothing that works inside the flywheel is not damaged, otherwise, replace the plate. Crown gear for start-up Check that the supporting surface with the driven plate is perfectly smooth and even.
Page 109: Assembling The Clutch
BELLAGIO Engine Assembling the clutch Insert the components in the clutch bell in the fol- lowing order: • the pressure plate with springs. • Make sure that the reference marked on the pressure plate tooth is aligned with the reference on the flywheel.
Page 110 BELLAGIO Engine • Remove the locking tool. • Fit the clutch disc. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear • The intermediate disc. • The clutch disc. • Place the crown gear aligning its refer- ence with that on the flywheel.
Page 111: Removing The Head Cover
BELLAGIO Engine • Tighten the eight screws sealing the crown gear to the flywheel to the pre- scribed torque • Remove the special tool for clutch spring compression. Specific tooling 30.90.65.10 Tool for clutch fitting • Insert the pressure plate disc cover.
Page 112: Removing The Cylinder Head
BELLAGIO Engine • Remove the head cover and collect the gasket. Removing the cylinder head • Remove the rocker rods. • Unscrew and remove the outer spark plug. • Loosen the nut and disconnect the pipes that deliver oil to the head.
Page 113 BELLAGIO Engine • Unscrew and remove the joint of the pipe that delivers oil to the head and collect the washer. • Using the suitable special tool, un- screw and remove the inner spark plug. Specific tooling 05.90.19.30 Inner spark plug removal •...
Page 114: Cylinder Head
BELLAGIO Engine • Slightly detach the cylinder head and remove the four O-rings. • Remove the head and collect the gas- ket. Cylinder head Removing the rocker arms NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 115: Removing The Valves
BELLAGIO Engine • Remove the rocking lever shafts. • Remove the rocking levers and collect the three washers. See also Removing the head cover 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 116: Checking The Valve Guides
BELLAGIO Engine slid off the valve seats; unscrew the tool and remove it from the head. • Remove the upper retainer (2). • Remove the internal spring (3). • Remove the external spring (4). • Remove the lower retainer (5) and the shimming washers if necessary.
Page 117: Checking The Cylinder Head
BELLAGIO Engine VALVE AND GUIDES COUPLING DATA CHART (OUTLET) Specification Desc./Quantity Valve guide inside diameter 8.005 ÷ 8.022 (0.3152 ÷ mm (in) 0.3158) Valve stem diameter mm (in) 7.965 ÷ 7.980 (0.3136 ÷ 0.3142) Fitting clearance mm (in) 0.025 ÷ 0.057 (0.0010 ÷...
Page 118: Specific Tooling
BELLAGIO Engine • Place the valve (6) inside the head. • Place the lower retainer (5) and the shimming washers. • Place the external spring (4). • Place the internal spring (3). • Insert the upper retainer (2). • Place the two cotters (1) on the seats on the valves.
Page 119 BELLAGIO Engine Installing the rocker arms CAUTION UPON REFITTING, ALWAYS REPLACE THE O-RINGS CAUTION UPON REFITTING, DO NOT INVERT THE POSITION OF THE ROCKING LEVER SUPPORTS SO AS NOT TO COM- PROMISE LUBRICATION. • Install the rocking lever rods if they have been previously removed.
Page 120 BELLAGIO Engine • Place the six washers and install the rocking levers. • Insert the rocking lever shafts. • Rotate the crankshaft to TDC position in combustion phase (closed valves) for the left cylinder. • Tighten the two screws. See also...
Page 121: Chain Removal
BELLAGIO Engine Chain removal • Remove the engine assembly. • Remove the alternator. • Unscrew the fourteen screws (1 - 2 - 3). • Remove the timing system cover. • Collect the gasket. • Clearly indicate the distribution timing marks that should be restored at the next refitting (left cylinder TDC).
Page 122 BELLAGIO Engine • Unscrew the central sealing nut of the camshaft gear and collect the washer. • Slide off the spacer from the crank- shaft. • Unscrew and remove the central seal- ing nut of the timing system control gear on the crankshaft and collect the washer.
Page 123 BELLAGIO Engine • Remove the chain tensioner and col- lect the spring. • Slide off the three gears together with the chain. CAUTION BE CAREFUL WITH THE OIL PUMP PULLING COTTER. See also Removing the engine from the vehicle Removing the rods •...
Page 124 BELLAGIO Engine • Remove the two rocking lever rods See also Removing the rocker arms Removing the tappets • Remove the engine assembly. • Remove both heads. • Slide off and remove the tappets from their seat on both sides.
Page 125: Removing The Camshaft
BELLAGIO Engine Removing the camshaft • Remove the timing chain. • Remove the tone wheel. • Remove the tappets. • Remove the rods. • Unscrew and remove the three screws and collect the washers. • Remove the flange. • Remove the camshaft.
Page 126: Installing The Chain
BELLAGIO Engine FOR TIMING SYSTEM REFITTING, IT IS NECESSARY TO HEAT THE ENGINE WITH A SUITABLE HEATER IN ORDER TO INSERT THE CAMSHAFT CORRECTLY AND WITHOUT DAMAGING IT. Follow the camshaft removal instructions but in reverse order. Installing the rods •...
Page 127 BELLAGIO Engine • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC). • Fit the flywheel on the crankshaft align- ing the stamp arrow on the flywheel with the fixed reference on the crank- case.
Page 128 BELLAGIO Engine • Introduce the belleville spring and the nut to fasten the camshaft gear. • Introduce the washer and the nut to fasten the crankshaft gear. • Turn the oil pump shaft and introduce the gear pulling woodruff key.
Page 129 BELLAGIO Engine • Introduce the chain tensioner. • Remove the flywheel locking tool. • Check the crankshaft rotation. • Fit the rocking levers. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear Timing To check distribution timing, follow these instruc- tions: •...
Page 130 BELLAGIO Engine • Fit the dial gauge support and then the gauge itself on the left outer spark plug hole. • Rotate the crankshaft until the left cyl- inder piston is actually at the top dead centre (with valves closed).
Page 131 BELLAGIO Engine • Observing the timing system diagram, check timing considering that: A - intake start opens 22° before TDC B - exhaust end closes 24° after TDC C - exhaust start opens 52° before BDC D - intake end closes 54° after BDC •...
Page 132 BELLAGIO 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 timing system cover and cause it to make contact with the tone wheel.
Page 133: Removing The Cylinder
BELLAGIO Engine • Measure the clearance between the fixing plate and the cover with a feeler gauge. Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel. • Remove the washer and fit the sensor after applying adequate sealing paste on the fixing plate, then tighten the screws to the prescribed torque.
Page 134: Disassembling The Piston
BELLAGIO Engine Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Remove the cylinder. • Cover the crankcase opening with a clean cloth. • Release the snap ring. •...
Page 135: Installing The Cylinder
BELLAGIO Engine • Fit the piston. NOTE CHECK THE ORIENTATION OF THE PISTON ACCORDING TO THE REFERENCES AT THE TOP. DO NOT ASSEMBLE PISTONS AND CYLINDERS OF DIFFERENT SELECTOR TYPES. • Insert the pin. • Insert the pin clip. Installing the cylinder •...
Page 136 BELLAGIO Engine • Remove the piston ring clamp tool and finish positioning the cylinder. Specific tooling 05.92.80.30 Piston ring clamp CAUTION UPON REFITTING DO NOT INVERT THE POSITION OF THE CYLINDER GASKET SO AS NOT TO COMPROMISE LU- BRICATION. •...
Page 137: Installing The Cylinder Head
BELLAGIO Engine Installing the cylinder head • Fit the valves if they have been previ- ously removed. • Replace the gasket between head and cylinder. • Fit the head. • Place the two washers and tighten the two screws. •...
Page 138 BELLAGIO Engine • Insert the washer and screw the joint of the pipe that delivers oil to the head . • Screw the threaded cap. • Connect the pipes that deliver oil to the head and screw the nut. •...
Page 139 BELLAGIO Engine • Replace the gasket and install the head cover. See also Installing the valves Installing the head cover Installing the head cover • Replace the gasket and install the head cover. • Tighten the eight screws operating di- agonally.
Page 140 BELLAGIO Engine • Undo and remove the eight fixing screws and collect the washers. • Hold the crankshaft during flange re- moval. • Using the suitable special tool, remove the crankshaft flange. • Remove the sealing ring from the flange, if necessary.
Page 141: Connecting Rods
BELLAGIO Engine • Loosen the coupling screws 'A' from inside the crankcase and remove the connecting rods 'B'. See also Removing the flywheel Disassembling the piston Removing the cylinder Removing the cylinder head 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 flanges and the main journals.
Page 142 BELLAGIO Engine When examining the connecting rods, check that: • Bushings are in good conditions, their clearance and the pins; • Shaft parallelism; • Connecting rod bearings. These are thin shell bearings, anti-friction alloy that does not allow for any adaptation; replace them immediately if seizing or wear marks are found.
Page 143: Installing The Crankshaft
BELLAGIO Engine CRANKPIN DIAMETER (B) Specification Desc./Quantity Regular production 44.008 ÷ 44.020 mm - (1.73259 ÷ 1.73307 in) 'Blue' bushing half-shell regular production 44.008 ÷ 44.014 mm (1.73259 ÷ 1.73283 in) 'Red' bushing half-shell regular production 44.014 ÷ 44.020 mm (1.73283 ÷ 1.73307 in)
Page 144 BELLAGIO Engine 19.92.71.00 Tool to fit the seal ring on the flywheel-side flange • Fit a new gasket between the crankcase and the crankshaft flange, flywheel side. • Introduce the crankshaft. • Place the flywheel side crankshaft sup- port flange, taking into account the fit- ting order indicated by the holes.
Page 145 BELLAGIO Engine • Unscrew and remove the three screws fixing the oil pump. • Remove the oil pump. Installing • Fit the oil pump. • Tighten the three oil pump fixing screws. • Place the shim washer adequately so that the timing chain do not wear out the crankcase.
Page 146 BELLAGIO 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 and remove the engine oil sump.
Page 147: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 148: Circuit Diagram
BELLAGIO Power supply Circuit diagram Key: 1. Fuel tank 2. Complete fuel pump 3. Flanged screw 4. Three-way joint 5. Joint 6. Clamp 7. Throttle body 8. Fuel pipe Injection Removing the throttle body • Remove the air filter casing.
Page 149 BELLAGIO Power supply • Remove the injector connectors. • Remove the TPS connector from the left throttle body. • Operating on both sides, undo and re- move the three screws form the intake manifold. • Remove the throttle cable and starter.
Page 150 BELLAGIO Power supply • Remove the throttle body from one side of the vehicle. Cylinders synchronisation Procedure to control and set the throttle body ENGINE OFF - KEY OFF • Connect the vacuometer. • Connect the diagnosis instrument to the diagnosis connector and the bat- tery.
Page 151 BELLAGIO Power supply pression. If they are not balanced, ad- just the balance screw (3) (left side) to level both cylinders. DISCONNECT THE VACUOMETER (IMPORTANT) ENGINE TEMPERATURE SHOULD RANGE BETWEEN 70 °C (158 °F) AND 80 °C (176 °F) •...
Page 152 Power supply • On the next screens select: vehicle brand (MOTOGUZZI), model (if the model Bellagio is not available, choose Breva V1100 avoiding throttle position autodetection), engine, system type (injection system software), chassis in- itial numbers, type of electronic control unit fitted.
Page 153 BELLAGIO Power supply • Balance the depression on the right cylinder using the throttle adjustment dowel (5). • Connect the stem (1) of the left side throttle body. • Check the depression balance be- tween the two cylinders twisting the throttle grip a little (approximately 2000/3000 RPM).
Page 154 BELLAGIO Power supply that the voltage value measured is 150mV +/- 15mV. - In case the potentiometer reading does not match the above mentioned value, loosen the two poten- tiometer fixing screws and place it again correctly. Using axone for injection system...
Page 155: Device Status
BELLAGIO Power supply Specification Desc./Quantity Temperature of the air taken in by the engine, measured by the sensor in the filter casing. This is not the temperature indicated by the instrument panel Engine temperature °C Battery voltage Throttle Value corresponding to the throttle when closed (approximate value between 4.5 and 4.9°) (left throttle supported by the end...
Page 156 BELLAGIO Power supply Specification Desc./Quantity Clutch No / Yes indicates the clutch sensor status Gear engaged No / Yes indicates the gear sensor status fall sensor Normal / Tip over indicates the vehicle fall sensor status Lambda Open loop / Closed loop Indicates if the control unit is using (CLOSED) the lambda probe signal to keep the stoichiometric combustion.
Page 157: Errors Display
BELLAGIO Power supply Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS DISPLAY Specification Desc./Quantity Pressure sensor Possible short circuit in the earth lead, battery or open circuit: recovery function noticeable for customer.
Page 158: Adjustable Parameters
BELLAGIO Power supply Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters. ADJUSTABLE PARAMETERS Specification Desc./Quantity Throttle positioner autodetection Allows the control unit to detect the closed throttle position: just press the enter button...
Page 159 INDEX OF TOPICS SUSP USPENSIONS...
Page 160: Removing The Front Wheel
BELLAGIO Suspensions Front Removing the front wheel • Remove both brake callipers. • Loosen the screws on the wheel axle clamps. • Unscrew and remove the pin. • Remove the wheel. • If required, collect the spacers. Front fork SUSP - 160...
Page 161 BELLAGIO Suspensions Diagram Key: 1. Fork upper plate 2. TBEI screw 3. Washer 4. Screw 5. Cap 6. Rubber ring 7. Screw 8. Ring nut 9. Spacer 10.Chrome-plated cap 11.Base with headstock 12.Screw SUSP - 161...
Page 162 BELLAGIO Suspensions 13.Right adjustment ring nut 14.Screw with OR 15.Complete cap 16.Cap 17.Preload tube 18.Spring 19.Stem 20.Lower bushing 21.Ring 22.Right tube (extension) 23.Lock nut 24.Right pumping member rod (extension) 25.Counter spring 26.Right piston (extension) 27.Right piston ring (extension) 28.Right pin (extension) 29.Calibration tab...
Page 163: Removing The Fork Legs
BELLAGIO Suspensions 51.Nut 52.Complete right stem 53.Complete left stem 54.O-ring 55.Spring Removing the fork legs • Hold the front part of the vehicle with a belt and a hoist. • Remove the front wheel. • Unscrew the screws fixing the front mudguard and remove it.
Page 164: Draining Oil
BELLAGIO Suspensions Draining oil The vehicle is equipped with a hydraulic telescopic fork with separated shock absorber damping ad- justment in extension and compression: The left stem works in extension while the right one in compression. Although the two stems work in a different mode, their internal components are similar; therefore, oil drainage and topping up are carried out following the same operations;...
Page 165: Disassembling The Fork
BELLAGIO Suspensions • Remove the open washer for releasing the preloading tube and the spring. • Remove the preload tube and the spring. • Drain the oil from the stem again and for easy drainage of the oil inside the shock absorber unit more easily, push the shock absorber rod to pump oil out.
Page 166 BELLAGIO Suspensions • Remove the dust scraper using a screwdriver as a lever. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND THE DUST SCRAPER. • Remove the locking ring inside the sleeve using a thin screwdriver. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.
Page 167 BELLAGIO Suspensions • Slide off the pumping member unit from the holding tube. • Remove the bottom buffer; this could remain fitted on the wheel holder fork leg; in this case remove it from inside. • With the fingers, push the bottom valve inside the shock absorber sleeve.
Page 168 BELLAGIO Suspensions • With the shock absorber rod outside the sleeve, push the bottom valve. • Check the bottom valve and its O-Ring, replace them if they are damaged. • Slide off the shock absorber rod to- gether with the pumping member unit from the sleeve after unscrewing the lock nut on the rod end.
Page 169: Checking The Components
BELLAGIO Suspensions The removal procedure is similar to that of shock absorber "COMPRESSION" but the components of the pumping member unit fixed to the shock ab- sorber rod are different: - pos. 11, counter spring; - pos. 12, piston; - pos. 13, ring for piston;...
Page 170: Filling Oil
BELLAGIO Suspensions • seal ring; • dust gaiter; • O-Ring on the cap. Filling oil • Place the sleeve upright in a vice fitted with protection jaws. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve.
Page 171: Steering Bearing
BELLAGIO Suspensions 150 mm (5.9 in) • Introduce the spring and the preload tube. • Place the open washer locking the pre- loading tube and the spring. • Screw the lock nut on the pumping member rod. So as to compress the spring.
Page 172 BELLAGIO Suspensions Adjusting play • Operating from both sides, remove the screw fixing the fork stems to the upper plate. • Loosen the upper plate back screw. • Remove the chrome-plated cap. • Unscrew and remove the head fixing nut.
Page 173 BELLAGIO Suspensions • Unscrew and remove the two screws fixing the light support to the steering upper plate. • Undo and remove the two handlebar fixing screws. • Collect the two chrome-plate washers. • Slide off the fork upper plate moving it towards the instrument panel.
Page 174: Removing The Rear Wheel
BELLAGIO Suspensions Removing the rear wheel • Remove the exhaust terminals. • Slide off the rear calliper from the disc. • Lift the rear part of the vehicle with a belt and a hoist. • Engage the first gear. •...
Page 175 BELLAGIO Suspensions • Place a shim washer between the chassis and the rear wheel. • Operating from the right side, unscrew and remove the shock absorber upper screw. • Turn and remove the shock absorber from the left side of the vehicle.
Page 176: Index Of Topics
INDEX OF TOPICS CHAS HASSIS...
Page 177: Swinging Arm
BELLAGIO Chassis Swinging arm Removing • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the fixing nut of the connecting rod assembly and col- lect the screw.
Page 178 BELLAGIO Chassis • Remove the clamp from the dust guard cap. • Loosen the two swingarm terminal screws. • 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 179 BELLAGIO Chassis Checking • Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged; otherwise, replace the joint. • Check that the rubber bellows are not cut or pierced;...
Page 180 BELLAGIO Chassis • Use the suitable box-spanner to tight- en the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body • Tighten the two screws of the swing- arm clamp. • Place the rider left footrest protection.
Page 181 BELLAGIO Chassis • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod. • Place the connecting rod assembly on the swingarm. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly.
Page 182 BELLAGIO Chassis Removing • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fasten the reaction rod to the chassis with a clamp.
Page 183 BELLAGIO 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 184 BELLAGIO Chassis Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer.
Page 185 BELLAGIO Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). Pinion unit Pinion unit Removal Remove the stop ring (1) from the ring nut.
Page 186 BELLAGIO Chassis Remove the ring nut (2) and remove the sealing ring from the ring nut. NOTE THIS OPERATION DESTROYS THE SEALING RING. Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a ham- mer.
Page 187 BELLAGIO Chassis Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT.
Page 188 BELLAGIO Chassis Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F).
Page 189 BELLAGIO Chassis Turn the unit over. Assemble the bearings to the wheel axle. Casing unit fitting Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool.
Page 190 BELLAGIO Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. CHAS - 190...
Page 191 BELLAGIO Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
Page 192 BELLAGIO Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer. Screw the cap to the prescribed torque.
Page 193 BELLAGIO Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
Page 194 BELLAGIO Chassis Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 194...
Page 195 BELLAGIO Chassis Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). Remove the screws (7). Remove the casing (4). CHAS - 195...
Page 196: Troubleshooting
BELLAGIO Chassis Remove the clamp (12). Remove the cap (14). 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 197 BELLAGIO Chassis Possible Cause Operation 1. Casing not sealed 2. Closing screws of the casing shells not 1. Open the casing shells, clean the surfaces, seal and reas- tightened to the prescribed torque semble the casing shells 2. Tighten the closing screws to the correct torque 1.
Page 198 BELLAGIO Chassis • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit. • Place the speed sensor on the fork and screw the two screws. •...
Page 199: Removing The Exhaust Manifold
BELLAGIO Chassis • Undo and remove the external screw collecting the nut and the washer. Removing the exhaust manifold OPERATIONS VALID FOR BOTH MANIFOLDS • Loosen the fixing clamps. • Unscrew and remove the nuts from the head stud bolts.
Page 200 BELLAGIO Chassis • Cut the clamp. • Slide off the manifold - terminal cou- pling mounting brackets from the vibra- tion-damping rubber rings. • Remove the manifold - terminal cou- pling. CHAS - 200...
Page 201: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 202: Front Brake Pads
BELLAGIO Braking system Removal OPERATIONS VALID FOR BOTH CALLIPERS • Undo and remove the two screws and collect the spacers. • Remove the front brake calliper. Front brake pads Removal • Remove the front brake calliper. BRAK SYS - 202...
Page 203: Rear Brake Pads
BELLAGIO Braking system • Remove the split pin. • Slide off the pin. • 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.
Page 204 BELLAGIO Braking system • Remove the lock. • Remove the pin. • 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.
Page 205 INDEX OF TOPICS BODYW ODYWORK...
Page 206 BELLAGIO Bodywork Air box • Remove the air filter. • Undo and remove the three lower screws from the bracket. • Slide off the oil vapour recovery pipe from the blow-by tank. • Loosen the clamps on the throttle bod- ies and slide off the manifolds.
Page 207 BELLAGIO Bodywork • Lift the filter casing slightly. • Operating inside the filter slightly, un- screw and remove the oil vapour re- covery joint. • Collect the gasket. • Remove the filter casing by lifting it. See also Air filter Fuel tank •...
Page 208 BELLAGIO Bodywork • Slide off the fuel breather pipe. • Remove the fuel tank. Battery REMOVAL • Remove the saddle. • Disconnect the connector. • Slide off the fuse boxes. • Undo and remove the two screws. BODYW - 208...
Page 209 BELLAGIO Bodywork • Disconnect the elastic and remove the battery cover. • Undo and remove the screws fixing the terminals. • Remove the battery. BODYW - 209...
Page 210 INDEX OF TOPICS PRE DE DELIVERY...
Page 211 BELLAGIO 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 212: Road Test
BELLAGIO 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 213: Static Test
BELLAGIO 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 214 Air filter: 32, 207 Air temperature sensor: 56, 68 Alternator: Battery: 45, 49, 208 Brake: 202, 203 Brake pads: 202, 203 Chain: 121, 124–126 Clutch: 66, 98, 101–103, 106, 108, 109 Coil: 62 Connectors: 70 Crankcase: 19, 139 Crankshaft: 19, 139, 141, 143 Cylinder: 18, 112, 114, 117, 133–137, 141 Desmodromic drum: 100 Display: 157...
Page 215 Identification: 10 Instrument panel: 68 Maintenance: 8, 27 Oil pressure sensor: 64 Oil sump: 145 Primary shaft: 94, 99, 101 Rear wheel: 174 Recommended products: 20 Run/Stop switch: 69 Secondary shaft: 96, 100, 101 Shock absorbers: 174 Side stand: 67 Side stand sensor: 67 Speed sensor: 50 Stand: 67...

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