MOTO GUZZI GRISO 850 2007 Service Station Manual
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MOTO GUZZI GRISO 850 2007 Service Station Manual

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SERVICE STATION MANUAL
854337
GRISO 850

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Summary of Contents for MOTO GUZZI GRISO 850 2007

  • Page 1 SERVICE STATION MANUAL 854337 GRISO 850...

  • 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

    GRISO 850 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 850 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

    GRISO 850 Characteristics This number is composed by numbers and letters, as in the example shown below. ZGULSB000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LS: model; B00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: progressive number (6 digits);...
  • Page 12 GRISO 850 Characteristics Specification Desc./Quantity Compression ratio 9.8 :1 Electric starter Engine idle speed 1100 ± 100 rpm Clutch dry, twin disc with hydraulic control Lubrication Pressure-fed, controlled by valves and trochoidal pump Air filter cartridge-type dry filter Cooling Fuel system Electronic injection (Weber .
  • Page 13 GRISO 850 Characteristics Specification Desc./Quantity Dashboard lighting License plate light 12V - 5 W Turn indicator warning light Neutral gear warning light Alarm-shift warning light Side stand down warning light Low fuel warning light High beam warning light Oil pressure warning light Frame and suspensions CHASSIS Specification...

  • Page 14: Wheels And Tyres

    GRISO 850 Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Type hollow 3-spoke rim in chilled cast aluminium alloy Front wheel rim 3.50" x 17" Rear wheel rim 5.50" x 17" Tyres METZELER Rennsport; MICHELIN Pilot Power; DUNLOP D208 RR PIRELLI Diablo Corsa;...
  • Page 15 GRISO 850 Characteristics Name Torque in Nm Oil intake filter fixing screw - TCEI M6x16 (1) 10 Nm (7.38 lbf ft) - Loctite 648 OIL PUMP Name Torque in Nm Oil pump fixing screw - TBEI M6x30 (3) 10 Nm (7.38 lbf ft) - Loctite 243 Oil pump gear nut - M10x1.25 (1) 20 Nm (14.75 lbf ft) Oil delivery pipe screw (1)

  • Page 16: Side Stand

    GRISO 850 Characteristics Name Torque in Nm Coil plate retainer 10 Nm Electronic control unit retainer 10 Nm Bushings to electronic control unit retainer 10 Nm Retainer for tank to chassis rear support rubber rings Manual Filter casing fixing bolts 10 Nm Left and right footrest plate to chassis upper retainer 25 Nm...

  • Page 17: Front Wheel

    GRISO 850 Characteristics AIR FILTER CASING Name Torque in Nm Blow-by expansion tank spacer to engine retainer 10 Nm Blow-by expansion tank to spacer retainer 10 Nm Filter housing to chassis retainer 10 Nm EXHAUST Name Torque in Nm Exhaust pipe to engine retainer 25 Nm Silencer to chassis connecting pipe retainer 25 Nm...
  • Page 18 GRISO 850 Characteristics Name Torque in Nm Retainer for front and rear arrows 10 Nm Headlamp retainer 15 Nm Rear light to tail clamp retainer 3 Nm FUEL PUMP FLANGE Name Torque in Nm Pump support to tank retainer 6 Nm Tank breather joint 6 Nm FUEL TANK...

  • Page 19: Piston Rings

    GRISO 850 Characteristics Specification Desc./Quantity piston diameter 91.942 - 91.972 mm (3.6197 - 3.6209 in) fitting clearance 0.048 - 0.068 mm (0.00189 - 0.00268 in) Piston rings Check the sealing piston rings and the oil scraper. On each piston there are: 1 top piston ring;...
  • Page 20 GRISO 850 Characteristics Specification Desc./Quantity (1.85039 ÷ 1.84976 inch) Seat diameter on base 47.025 - 47.050 mm (1.85137 ÷ 1.85236 inch ) fitting clearance 0.025 - 0.066 mm (0.00098 ÷ 0.00260 inch) CAMSHAFT (CAM) SUPPORT DIAMETER AND THEIR SEATS ON THE CRANKCASE (FLYWHEEL SIDE) Specification Desc./Quantity...

  • Page 21: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 22: Special Tools

    GRISO 850 Special tools SPECIAL TOOLS Stores code Description 06.94.86.00 belt tensioning tool 05.91.17.30 Front cover insertion cone 05.91.25.30 Gearbox opening 05.92.80.30 Piston ring clamp 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00 Wrench for removing the cover on sump and filter S-TOOLS - 22...
  • Page 23 GRISO 850 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 10.90.72.00 Tool for valve removal and refitting 30.90.65.10...
  • Page 24 GRISO 850 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- side flange 14.92.73.00 Tool for camshaft gear sealing...
  • Page 25 GRISO 850 Special tools Stores code Description 30.91.28.10 Clutch body locking 05.90.27.30 Gearbox support 05.90.27.31 Gearbox oil seal buffer 05.90.27.32 Buffer handgrip 05.90.27.33 Ball joint sealing buffer 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer S-TOOLS - 25...
  • Page 26 GRISO 850 Special tools Stores code Description 05.90.27.36 Bevel gear pair support AP8140145 fitting tool for Ø 41 mm seal rings AP8140146 Weight AP8140147 Spacer tool AP8140148 Spacer-piston separating plate AP8140149 Protection for fitting operations AP8140150 Perforated rod for piston air bleed S-TOOLS - 26...
  • Page 27 GRISO 850 Special tools Stores code Description AP8140151 Complete tool kit for fork GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body S-TOOLS - 27...

  • Page 28: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 29: At Every Start-Up

    GRISO 850 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 BEFORE EACH RIDE AND EVERY 2000 (1250 Action...

  • Page 30: Transmission Fluid

    GRISO 850 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 Air filter - Check and clean, adjust, grease or replace if necessary Engine oil filter - Replace General vehicle operation - Check and clean, adjust, grease or replace if necessary.

  • Page 31: Engine Oil

    GRISO 850 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 32 GRISO 850 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 33: Engine Oil Filter

    GRISO 850 Maintenance • Screw and tighten the drainage plug (2). • Pour new oil until it goes above the minimum level marked "MIN". Engine oil filter • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER.

  • Page 34: Air Filter

    GRISO 850 Maintenance • Top-up with oil until it reaches the dip- stick opening (1). CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN. Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
  • Page 35 GRISO 850 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 - 35...

  • Page 36: Checking The Valve Clearance

    GRISO 850 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 37 GRISO 850 Maintenance • Working from both sides, unscrew and remove the two internal screws and re- move the insert. • Disconnect the spark plug boot. • Unscrew and remove the eight screws. • Remove the head cover. • Loosen the nut (1). •...

  • Page 38: Braking System

    GRISO 850 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 850 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 41...

  • Page 42: Electrical System Installation

    GRISO 850 Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp 18 Alternator...

  • Page 43: General Wiring Diagram

    GRISO 850 Electrical system General wiring diagram Key: 1. Multiple connectors 2. Diode pre-installation 3. Start-up relay 4. Clutch switch ELE SYS - 43...
  • Page 44 GRISO 850 Electrical system 5. Light relay 6. Right light switch 7. Condenser pre-installation 8. Horn 9. Left light switch 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Instrument panel diagnosis 13.Key switch 14.Immobilizer aerial 15.Right rear turn indicator 16.Rear light (LED) 17.Left rear turn indicator 18.License plate light 19.Rear stop switch...
  • Page 45 GRISO 850 Electrical system 43.Left cylinder outer spark plug 44.Right cylinder coil 45.Left cylinder coil 46.Right cylinder injector 47.Left cylinder injector 48.Speed sensor 49.Fall sensor 50.Flywheel pick up 51.Pick-up wire shielding 52.ECU 53.Left front turn indicator 54.Tail light bulb 55.High-/low-beam bulb 56.Front headlamp 57.Right front turn indicator 58.GPS attachment (if fitted)

  • Page 46: Enter New Code

    GRISO 850 Electrical system Resetting the CODE This function is used to set a new code when the old one is not available; in this case, at least two of the programmed keys have to be inserted in the ignition lock. After the first key has been inserted, the second one is requested with the following message: INSERT KEY II If the second key is not inserted within 20 seconds, the operation is finished.
  • Page 47 GRISO 850 Electrical system Injector 2 Error DC V DC ECU 30 Pump Relay Error ECU 36 Local Loopback Error ECU 37 Start-up Remote Error DC V DC ECU 44 Remote Error Start-up DC Gnd ECU 45 Canister Error DC V DC ECU 46 Canister Error DC Gnd ECU 47 Battery Error Hig ECU 50 Generic ECU Error ECU 51...

  • Page 48: 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 49: Front Headlamp

    GRISO 850 Electrical system Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and 2 with 12V voltage) Fuel level sensor: Resistance (to be measured between pins 3 and 250-300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11.25 litres (20.43 10-20 Ohm with fuel level equal to 22.5 litres...

  • Page 50: Rear Light

    GRISO 850 Electrical system REAR LIGHT Fuses AUXILIARY FUSES A - Stop, horn, coil, light relay (15 A). B - Tail lights, license plate light, passing (15 A). C - Fuel pump, coils, injectors, start-up relay (20 D - Lambda burner, secondary injection relay coil, start-up relay coil, speed sensor power supply, ECU control unit power supply, engine kill (15 A).

  • Page 51: Control Unit

    GRISO 850 Electrical system Control unit Model: Magneti Marelli IAW 5 AM2 Black connector pins Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal 6 Not used 7 Not used 8 Not used 9 Stepper motor (+) 10 Right cylinder coil control...
  • Page 52 GRISO 850 Electrical system 34 Revolution sensor anti-jamming cable 35 Engine revolution sensor signal 36 Not used 37 Right cylinder injector control 38 Left cylinder coil control Grey connector pins Pin Use 1 Pin 85 ignition relay control 2 Not used 3 Not used 4 Power supply protected from instrument panel 5 Not used...

  • Page 53: Speed Sensor

    GRISO 850 Electrical system 32 Oxygen probe power supply 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal Battery 12 V - 18 Ampere/hour Speed sensor Active inductive sensor 3-pin connector (Power supply - Signal-Earth con- nection).

  • Page 54: Engine Rpm Sensor

    GRISO 850 Electrical system Engine rpm sensor Measures the engine revolution speed and each cylinder timing in relation to the TDC Inductive type sensor, with three-way connector: • positive voltage pin; • negative voltage pin: resistance from 650 to 720 Ohm (to be measured be- tween pins 1 and 2);...

  • Page 55: Air Temperature Sensor

    GRISO 850 Electrical system Specification Desc./Quantity Resistance at +120 °C (257 °F) 0.102 kOhm Air temperature sensor NTC type sensor IR TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity Resistance at -40 °C (-40 °F) 100.950 kOhm Resistance at 0 °C (32 °F) 9.750 kOhm Resistance at 10 °C (50 °F) 5.970 kOhm...

  • Page 56: Engine Oil Pressure Sensor

    GRISO 850 Electrical system Injector Resistance 14 Ohm ± 2 Ohm measured at 20 °C (68 °F) Coil Characteristic Primary resistance: 0.9 - 1.1 Ω (measured between pins 1 and 15) Secondary resistance: 6.5 - 7.2 KΩ. Engine oil pressure sensor An oil pressure sensor anomaly is signalled by the lighting of the "bulb"...

  • Page 57: Bank Angle Sensor

    GRISO 850 Electrical system Bank angle sensor Normally open contact, 62 kOhm resistance, with vehicle upright (straight sensor); Closed contact, 0 Ohm resistance, when the sensor is turned by 90° with respect to its fitting position. Air temperature sensor - instrument panel Characteristic Resistance 10 kOhm (at 25°C - 77°F)
  • Page 58 GRISO 850 Electrical system 13 - 14 - 15 - 16 GENERAL EARTH CONNECTION 17 OIL PRESSURE SENSOR INTAKE 18 SENSORS EARTH CONNECTION 19 GENERAL GROUND (OPTIONAL) 20 GENERAL GROUND (OPTIONAL) The pin configuration of the black-bodied connector is as follows: PIN USE 21 + BATTERY 22 LEFT FRONT TURN INDICATOR ACTIVATION...
  • Page 59 GRISO 850 Electrical system ELE SYS - 59...

  • Page 60: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 61: Vehicle Preparation

    GRISO 850 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as fol- lows: • Hold the vehicle steady with a stand from the front and belts fixed to a hoist from the rear. • Place the engine service stand under the oil sump.
  • Page 62 GRISO 850 Engine from vehicle • Disconnect the idle motor connector. • Disconnect the engine temperature sensor connector • Disconnect the throttle valve position sensor connector • Unscrew and remove the two screws and collect the washer. • Disconnect the revolution sensor con- nector and collect the gasket.
  • Page 63 GRISO 850 Engine from vehicle • Disconnect the alternator connectors. • Disconnect the gear in neutral sensor connector. • Undo and remove the two screws and collect the washers. • Remove the starter motor cover. • Unscrew and remove the stud bolt. •...
  • Page 64 GRISO 850 Engine from vehicle • Unscrew and remove the three screws and remove the clutch control cylinder. • Slide off the gearbox oil breather pipe. • Working on both sides, release the clamp and slide off the engine oil breather pipe.
  • Page 65 GRISO 850 Engine from vehicle • Disconnect the stand sensor connec- tor and release it from the clamps. • Undo and remove the two screws and remove the control unit protection. • Undo and remove the two screws and move the control unit downwards. •...
  • Page 66 GRISO 850 Engine from vehicle • Working on both sides, unscrew and remove the front screw and collect the washer. • Unscrew and remove the upper nut fix- ing the engine and collect the washer. • Remove the upper pin and collect the washer.
  • Page 67 GRISO 850 Engine from vehicle Installing the engine to the vehicle • Secure the vehicle chassis with a hoist and onto a front stand and lift the en- gine to place it in position. • Connect the oil pressure sensor con- nector.
  • Page 68 GRISO 850 Engine from vehicle • Working from the right side, fit the washer and insert the lower bolt. • Fit the washer and tighten the engine lower fixing nut. • Working on both sides, tighten the front screw to the prescribed torque. •...
  • Page 69 GRISO 850 Engine from vehicle • Fit the oil vapour attachment pipe and tighten the two fixing screws. • Insert the oil breather pipe and fasten it with a new clamp. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. •...
  • Page 70 GRISO 850 Engine from vehicle • Fit the clutch bleed pipe on the cable guide. • Fill up the clutch system. • Connect the starter motor connectors. • Connect the ground cables and tighten the screw. • Fit the starter motor cover. •...
  • Page 71 GRISO 850 Engine from vehicle • Connect the alternator connectors. • Fit the gasket and connect the revolu- tion sensor connector. • Fit the washer and tighten the two screws. • Connect the throttle valve position sen- sor connector. • Connect the engine temperature sen- sor connector.
  • Page 72 GRISO 850 Engine from vehicle • Connect the idle motor connector. • Connect and adjust the throttle grip ca- ble clearance. • Working on both sides, connect the in- jector connectors. • Working on both sides, connect the spark plug tubes. •...

  • Page 73: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 74 GRISO 850 Engine Gearbox Diagram KEY: 1. Ball bearing 2. Circlip ENG - 74...
  • Page 75 GRISO 850 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 76 GRISO 850 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 77: Removing The Gearbox

    GRISO 850 Engine Removing the gearbox • Remove the starter motor. • Make sure the transmission is in idle. • Undo and remove the screw and re- move the gearbox lever. • Unscrew and remove the cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil.

  • Page 78: Gearbox Shafts

    GRISO 850 Engine • Unscrew and remove the two screws. • Unscrew and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 78...
  • Page 79 GRISO 850 Engine Disassembling the gearbox • Remove the gearbox. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox.
  • Page 80 GRISO 850 Engine • Slide off the two bushings (1) and re- move the rod (2), collect the bushing (3). • Fold the washer fins. • Using the adequate ring nut spanner and the clutch body locking tool, unscrew and remove the ring nut, and collect the clutch internal body.
  • Page 81 GRISO 850 Engine • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Unscrew and remove the threaded ref- erence pin. • Use rubber bands to tie down the trans- mission shaft unit and extract it. ENG - 81...
  • Page 82 GRISO 850 Engine • 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. • Detach the shafts and label the forks before removal.
  • Page 83 GRISO 850 Engine • Replace bearings if necessary and re- move the clutch shaft. Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side. ENG - 83...
  • Page 84 GRISO 850 Engine • 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. • Remove the circlip. • Remove the gear of the third and fourth gears.
  • Page 85 GRISO 850 Engine • 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. Removing the secondary shaft •...
  • Page 86 GRISO 850 Engine • Remove the shoulder washer. • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. ENG - 86...
  • Page 87 GRISO 850 Engine • 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 88 GRISO 850 Engine • 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. See also Disassembling the gearbox Disassembling the clutch shaft •...
  • Page 89 GRISO 850 Engine VEHICLES WITH CHASSIS NUMBER FROM ZGULSB0016M111111 TO ZGULSB0096M111454 MAY PRESENT SOME NOISE PROBLEMS AT IDLE SPEED. TO REDUCE THIS NOISE, ON THE CLUTCH SHAFT, FIT TWO SHAPED WASHERS (8) BESIDES THE ONE ALREADY PRESENT IN THE ASSEMBLY Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not...

  • Page 90: Checking The Secondary Shaft

    GRISO 850 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. Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.

  • Page 91: Assembling The Gearbox

    GRISO 850 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. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED.

  • Page 92: Removing The Flywheel

    GRISO 850 Engine 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. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...

  • Page 93: Installing The Flywheel

    GRISO 850 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 and tighten the six flywheel sealing screws operating diagonally and in stages.
  • Page 94 GRISO 850 Engine • Remove the cover. • Unscrew and remove the eight screws. • Undo and remove the two screws. • Unscrew the nut and collect the screw. ENG - 94...
  • Page 95 GRISO 850 Engine • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. ENG - 95...

  • Page 96: Tensioning The Belt

    GRISO 850 Engine • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley. • Undo and remove the two screws. • Remove the alternator frame. • Remove the sealing ring if necessary. Tensioning the belt •...

  • Page 97: Installing The Generator

    GRISO 850 Engine • Unscrew and remove the spacer. • Unscrew and remove the five fixing screws of the timing system cover. • Remove the timing system cover. • Loosen the set screw lock nut. • Using the belt tensioning tool (code 06.94.86.00), tension the belt to the prescribed torque.
  • Page 98 GRISO 850 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. • Tighten the eight lower screws. •...
  • Page 99 GRISO 850 Engine • Position the alternator and the timing system belt. • Position the screw and pre-tighten it. • Position the screw and tighten the nut. • Using the belt tensioning tool (code 06.94.86.00), tension the belt to the prescribed torque and screw the set screw.

  • Page 100: Removing The Starter Motor

    GRISO 850 Engine • Tighten the alternator fixing screws. • Tighten the four screws, operating di- agonally and in stages. • Position the timing system cover. • Tighten the five screws, operating in oblique direction and in stages. Starter motor Removing the starter motor •...

  • Page 101: Disassembling The Clutch

    GRISO 850 Engine • Slide off the starter motor. Clutch side Disassembling the clutch • Remove the gearbox from the engine. • 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 starting ring gear •...
  • Page 102 GRISO 850 Engine Extract from the inside of the engine flywheel: • the clutch plate. • The intermediate plate. • The second clutch plate. • The pressure plate disc cover. ENG - 102...

  • Page 103: Checking The Clutch Plates

    GRISO 850 Engine • The pressure plate disc with springs. 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 104: Assembling The Clutch

    GRISO 850 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 105 GRISO 850 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 106: Removing The Head Cover

    GRISO 850 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 107: Removing The Cylinder Head

    GRISO 850 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 108 GRISO 850 Engine • Unscrew and remove the joint of the pipe that delivers oil to the head and collect the washer. • Undo and remove the two screws and collect the two washers. • Slightly detach the cylinder head and remove the four O-rings.

  • Page 109: Cylinder Head

    GRISO 850 Engine • 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. • Remove the head cover. • Rotate the crankshaft to TDC position in com- bustion phase (closed valves) for the left cylinder.

  • Page 110: Removing The Valves

    GRISO 850 Engine • 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 111: Checking The Valve Guides

    GRISO 850 Engine Checking the valve guides Use a punch to extract the valve guides from the heads. The valve guides should be replaced only if the clearance between them and the stem cannot be eliminated by simply replacing the valves. To refit the valve guides on the head, follow this procedure: •...

  • Page 112: Installing The Valves

    GRISO 850 Engine • The planes of contact with the cover and with the cylinder are not scored or damaged so as to compromise a perfect seal. • Check that the clearance between the valve guide holes and valve stanchions is within the prescribed limits.
  • Page 113 GRISO 850 Engine 10.90.72.00 Tool for valve removal and refitting NOTE UPON REFITTING, PLACE THE O-RING CORRECTLY ON THE VALVE. • Remove the special tool 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.
  • Page 114 GRISO 850 Engine • Install the rocking lever rods if they have been previously removed. • Install the rocking lever support and re- place the four O-rings. • Place the four washers and screw the four nuts. • Place the six washers and install the rocking levers.

  • Page 115: Chain Removal

    GRISO 850 Engine • Rotate the crankshaft to TDC position in combustion phase (closed valves) for the left cylinder. • Tighten the two screws. See also Installing the rods Timing Chain removal • Remove the engine assembly. • Remove the alternator. •...
  • Page 116 GRISO 850 Engine • Unscrew the central sealing nut of the camshaft gear and collect the washer. • Remove the cotter. • Unscrew and remove the central seal- ing nut of the timing system control gear on the crankshaft and collect the washer.
  • Page 117 GRISO 850 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 118: Removing The Camshaft

    GRISO 850 Engine 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. See also Removing the engine from the vehicle Removing the phonic wheel •...

  • Page 119: Installing The Camshaft

    GRISO 850 Engine • Unscrew and remove the three screws and collect the washers. • Remove the flange. • Remove the camshaft. Installing the camshaft NOTE 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.

  • Page 120: Installing The Chain

    GRISO 850 Engine Installing the rods • Install the head if it has been previously removed. • Replace the four O-rings. • Install the two rocking lever rods. Installing the chain For the installation of the three gears and of the timing chain carry out the operations indicated in section "Timing".
  • Page 121 GRISO 850 Engine with the fixed reference on the crank- case. • Position the locking tool on the flywheel and tighten the six flywheel sealing screws operating diagonally and in stages. • Fit the clutch. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
  • Page 122 GRISO 850 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 123 GRISO 850 Engine Timing To check distribution timing, follow these instruc- tions: • Obtain a clearance between rocking levers and valves equal to 1.5 mm (0.059 in); • Place the hub for graduated dial and the relative graduated dial on the crankshaft slot, inserting the spacer and fixing it to the shaft with the nut.
  • Page 124 GRISO 850 Engine • Rotate the crankshaft until the left cyl- inder piston is actually at the top dead centre (with valves closed). • Reset the dial gauge and make sure the references (on the timing system gears and the engine pinion) are per- fectly aligned, so that looking through the checking hole on the gearbox, the reference line marked 'S' is perfectly...
  • Page 125 GRISO 850 Engine • Screw the dial gauge support and then the gauge itself on the right cylinder outer spark plug hole. • With a screw, fix the arrow to the threa- ded hole to the right of the crankcase. •...
  • Page 126 GRISO 850 Engine • 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. • Measure the clearance between the fixing plate and the cover with a feeler gauge.

  • Page 127: Removing The Cylinder

    GRISO 850 Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Remove the head. • Slide off the gasket. • Slide off the cylinder from the stud bolts, paying attention not to damage the piston.

  • Page 128: Fitting The Piston

    GRISO 850 Engine • Remove the pin. • 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 129: Installing The Cylinder

    GRISO 850 Engine • Insert the pin clip. Installing the cylinder • Fit the piston. • Remove the cloth used to prevent foreign bodies coming into the crankcase. • Turn the rings so that the junction ends are 120 degrees from each other. •...

  • Page 130: Installing The Cylinder Head

    GRISO 850 Engine • Place the gasket on the cylinder base. • Fit the head. See also Fitting the piston Installing the cylinder head Installing the cylinder head • Fit the valves if they have been previ- ously removed. • Replace the gasket between head and cylinder.
  • Page 131 GRISO 850 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. ENG - 131...
  • Page 132 GRISO 850 Engine • Install the outer spark plug. • Replace the gasket and install the head cover. See also Installing the head cover Installing the head cover • Replace the gasket and fit the head cover. • Place the bushings and cross tighten the eight screws.

  • Page 133: Crankcase - Crankshaft

    GRISO 850 Engine Crankcase - crankshaft Removing the crankshaft • Remove the connecting rods. • 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.
  • Page 134 GRISO 850 Engine Disassembling the connecting rod • Remove the heads. • Remove the cylinders and the pistons. • Remove the clutch. • Remove the flywheel. • Remove the timing system. • Remove the oil sump. • Loosen the coupling screws 'A' from inside the crankcase and remove the connecting rods 'B'.

  • Page 135: Checking The Connecting Rod

    GRISO 850 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) FLYWHEEL SIDE MAIN JOURNAL DIAMETER (C) Specification Desc./Quantity...
  • Page 136 GRISO 850 Engine CONNECTING ROD BEARING THICKNESS Specification Desc./Quantity Connecting rod bearing regular (production) 1.535 - 1.544 mm (0.06043 - 0.06079 in) Regular 'Blue' connecting rod bearing (production) 1.539 - 1.544 mm (0.06059 - 0.06079 in) Regular 'Red' connecting rod bearing (production) 1.535 - 1.540 mm (0.06043 - 0.06063 in) CRANKPIN DIAMETER (B) Specification...

  • Page 137: Installing The Crankshaft

    GRISO 850 Engine • Place the connecting rods and the caps (B) on the crankshaft and fasten them with new screws (A). • Remember these recommendations: • The screws fixing the connecting rods to the crankshaft must be replaced with new ones at the following refitting as they are subject to high loads and stress;...
  • Page 138 GRISO 850 Engine • Apply Teflon tape on the two lower fix- ing screws at the back in order to pre- vent oil leaks. • Screw the eight flange screws on the flywheel side proceeding diagonally. Lubrication Oil pump Removing •...
  • Page 139 GRISO 850 Engine 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. • Fit the timing system. • Fit the alternator.
  • Page 140 GRISO 850 Engine • 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 cover. • Unscrew and remove the two screws. •...
  • Page 141 GRISO 850 Engine • Remove the black flange and collect the gasket. • Unscrew and remove the plug. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com- ponents ENG - 141...
  • Page 142 GRISO 850 Engine Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug. • In case of overpressure, the engine oil goes back into the oil sump through the hole indicated in the picture. •...
  • Page 143 GRISO 850 Engine • Place a new gasket and refit the black flange. • Place a new gasket and refit the mesh filter tightening the two screws. • Tighten the two screws. • Place the oil sump cover. • Tighten the four screws. •...
  • Page 144 GRISO 850 Engine Blow-by • Loosen the oil return pipe sealing joint and remove the oil return pipe from the crankcase. • Remove the clamp. • Release the two straps retaining the oil breather pipe. • Remove the two oil breather pipes. ENG - 144...
  • Page 145 GRISO 850 Engine • Unscrew and remove the oil return pipe positioning screw. • Release the oil return pipe • Remove the complete blow-by system. ENG - 145...

  • Page 146: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 147: Circuit Diagram

    GRISO 850 Power supply Circuit diagram Key: 1 Complete fuel pump assembly 2 Flange screw 3 Union 4 Clamp 5 Fuel pipe 6. Three-way joint 7 Clamp 8 Pipe Injection P SUPP - 147...
  • Page 148 GRISO 850 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 149 GRISO 850 Power supply 13 Lambda probe 14 Fall sensor Cylinders synchronisation • With engine off, connect the Navigator tool to the diagnosis connector and to the vehicle battery. • Turn on the scanner. • Screw the joints connecting the vacuometer pipes on the inlet pipe holes. •...
  • Page 150 GRISO 850 Power supply • Turn the key to "OFF" and leave it for at least 30 seconds. • Turn the key back to "ON" and restore the Axone session. • Check that the "Throttle" value reading is 4.7 +/- 0.2°. If the value is incorrect, replace the control unit and repeat the procedure from the start.
  • Page 151 GRISO 850 Power supply Recovery function If the signal of the following sensors is interrupted, the control unit determines some values to keep the engine running or it uses a different parameter. The instrument panel and the Axone also signal the problem.
  • Page 152 GRISO 850 Power supply Engine parameter reading screen page ENGINE PARAMETER READING This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.) NGINE PARAMETER READING SCREEN PAGE Specification Desc./Quantity...

  • Page 153: Device Status

    GRISO 850 Power supply Device status screen page DEVICE STATUS This screen page shows the status (usually ON/ OFF) of the vehicle devices or the operation con- dition of some vehicle systems (for example, lamb- da probe functioning status). EVICE STATUS Specification Desc./Quantity Engine status...

  • Page 154: Errors Display

    GRISO 850 Power supply Specification Desc./Quantity Right coil operation for 2.5 m, 5 times Left injector Operation for 4 m, 5 times Right injector Operation for 4 m, 5 times Error clearing By pressing the 'enter' button, the stored errors (MEM) become part of the historical data (STO).

  • Page 155: Adjustable Parameters

    GRISO 850 Power supply Specification Desc./Quantity CAN line diagnosis <span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New Roman"; mso-fareast-font-family: "Times New Roman"; mso- ansi-language: IT; mso-fareast-language: IT; mso-bidi-lan- guage: AR-SA">Possible error on line CAN: short circuit or line break or no signal or plausibility error detected. RAM memory Possible internal control unit error.
  • Page 156 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 157: Removing The Front Wheel

    GRISO 850 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. • Unscrew and remove the wheel axle fixing nut and collect the sealing wash- •...

  • Page 158: Front Fork

    GRISO 850 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. Front fork SUSP - 158...
  • Page 159 GRISO 850 Suspensions Diagram Key: 1 Locking ring 2 Spring preloading regulator 3 Spring preloading pusher 4 Sleeve upper cover 5 Washer 6 Slider 7 Complete pumping member 8 Centring bushing 9 Spring pressing pipe 10 Spring 11 Spring support washer 12 Lower collar SUSP - 159...
  • Page 160 GRISO 850 Suspensions 13 Sleeve 14 Sliding bushing 15 Guide bushing 16 Stop washer 17 Gasket 18 Snap ring 19 Dust guard gasket 20 Wheel holder stem 21 Copper washer 22 Central screw 23 O-ring 24 O-ring 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 161: Removing The Fork Legs

    GRISO 850 Suspensions Specification Desc./Quantity 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 use adjustment) Take your vehicle only to a Moto Guzzi Official Dealer for this type of adjustment.
  • Page 162 GRISO 850 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 • Push the tool against the spring and compress it.
  • Page 163 GRISO 850 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. Remove the spacer. SUSP - 163...

  • Page 164: Disassembling The Fork

    GRISO 850 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 165 GRISO 850 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 166 GRISO 850 Suspensions • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal. SUSP - 166...

  • Page 167: Checking The Components

    GRISO 850 Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem.
  • Page 168 GRISO 850 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 169 GRISO 850 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 - 169...
  • Page 170 GRISO 850 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- ing ring 8140146 Weight to be applied to the tool: 8140145 and 8140189...
  • Page 171 GRISO 850 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 8140146 Weight to be applied to the tool: 8140145 and 8140189 •...

  • Page 172: Filling Oil

    GRISO 850 Suspensions Filling oil • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stem. • Pour part of the fork oil into the sleeve. • Wait some minutes until the oil fills all the ducts.
  • Page 173 GRISO 850 Suspensions • Fit the spring. • Fit the complete preloading pipe. • Fit the specified tool on the spring cou- pling so that the cartridge stem is locked in position. Specific tooling AP8140147 Spacer tool 8140148 Spacer / pumping member separating plate •...

  • Page 174: Steering Bearing

    GRISO 850 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 Steering bearing SUSP - 174...
  • Page 175 GRISO 850 Suspensions Adjusting play • Undo and remove the two front screws. • 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.
  • Page 176 GRISO 850 Suspensions • Unscrew and remove the fork upper plate cover; collect the shim. • 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.
  • Page 177 GRISO 850 Suspensions • Using the suitable special tool, un- screw and remove the upper ring nut. Specific tooling AP8140190 Tool for steering tightening • Remove the safety washer. • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening •...

  • Page 178: Removing The Rear Wheel

    GRISO 850 Suspensions • Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut. Specific tooling AP8140190 Tool for steering tightening • Rivet the tongues of the new safety washer.

  • Page 179: Shock Absorbers

    GRISO 850 Suspensions • Engage the first gear. • Undo and remove the four screws, col- lect the spacers and the dust-protec- tion ring. • Remove rear wheel. Shock absorbers Removing • Secure the vehicle handlebar from the front with a hoist. •...
  • Page 180 GRISO 850 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 181 GRISO 850 Suspensions • Undo and remove the suspension up- per screw. SUSP - 181...

  • Page 182: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 183: Swinging Arm

    GRISO 850 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 184 GRISO 850 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 185 GRISO 850 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. Checking •...
  • Page 186 GRISO 850 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 187 GRISO 850 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 188 GRISO 850 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. See also Recommended products chart Bevel gears...
  • Page 189 GRISO 850 Chassis • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint. Checking Support unit CHAS - 189...
  • Page 190 GRISO 850 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 191 GRISO 850 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 192 GRISO 850 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. NOTE THIS OPERATION DESTROYS THE SEALING RING.
  • Page 193 GRISO 850 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 194 GRISO 850 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS 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 195 GRISO 850 Chassis FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle. 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.
  • Page 196 GRISO 850 Chassis Assemble the casing to the special fastening tool. Clean the casing faying surfaces carefully. Heat the casing. Insert the support group in the casing. Assemble the cap and the ring. CHAS - 196...
  • Page 197 GRISO 850 Chassis Fit the cap on the support. Fit the clamp. 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. CHAS - 197...
  • Page 198 GRISO 850 Chassis Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture. Fit the casing. Remove the two dowel pins. Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant.
  • Page 199 GRISO 850 Chassis Tighten the fixing screws to the prescribed torque. 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 200 GRISO 850 Chassis Assemble the cap with the clamps. Fit the cap in its seat. Casing unit removal CHAS - 200...
  • Page 201 GRISO 850 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 - 201...
  • Page 202 GRISO 850 Chassis Collect the ring (15). Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). CHAS - 202...

  • Page 203: Troubleshooting

    GRISO 850 Chassis Collect the ring (13). Remove the support unit (8). TROUBLESHOOTING Possible Cause Operation 1. Fitting error of the radial seal or seal damaged 2. Sliding 1. Replace the sealing ring and fit it correctly with the suitable surface of the wheel axle seal spoiled or damaged tool 2.
  • Page 204 GRISO 850 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 205 GRISO 850 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. Exhaust Removing the tail pipe •...
  • Page 206 GRISO 850 Chassis Silencer to chassis connecting pipe retainer • Remove the exhaust end. CHAS - 206...

  • Page 207: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 208: Front Brake Pads

    GRISO 850 Braking system Front brake pads Removal • Turn the pins and remove both split pins. • Remove both pins. • Remove the vibration-damping plate. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.

  • Page 209: Rear Brake Pads

    GRISO 850 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. • Position the anti-vibration plate. •...
  • Page 210 GRISO 850 Braking system Removal • Free the brake pipe and the throttle grip cable from the clamps. • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. •...
  • Page 211 GRISO 850 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 • Insert two new pads, placing them so that the holes are aligned with the cal- liper holes.
  • Page 212 GRISO 850 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. The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency. CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CON- DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
  • Page 213 GRISO 850 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 214 GRISO 850 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 215 INDEX OF TOPICS BODYW ODYWORK...
  • Page 216 GRISO 850 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 217 GRISO 850 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. • Unscrew and remove the rear upper screw and collect the nut.
  • Page 218 GRISO 850 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 219 GRISO 850 Bodywork • Slide off and remove the secondary fuse box from its holder. • Undo and remove the two screws. • Disconnect the low pressure pipe. • Disconnect the blow-by tank breather pipe. • Free the pipes from the clamps. BODYW - 219...
  • Page 220 GRISO 850 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 221 GRISO 850 Bodywork • Disconnect the connector. • Remove the fuel tank. BODYW - 221...
  • Page 222 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 223 GRISO 850 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 front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...

  • Page 224: Road Test

    GRISO 850 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

  • Page 225: Static Test

    GRISO 850 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
  • Page 226 Air filter: 34 Air temperature sensor: 55, 57 Battery: 48, 53 Brake: 208, 209 Brake pads: 208, 209 Chain: 115, 118, 120 Clutch: 88, 91–93, 101, 103, 104 Coil: 56 Connectors: 57 Crankcase: 19, 133 Crankshaft: 19, 133, 134, 137 Cylinder: 18, 107, 109, 111, 127, 129, 130, 134 Desmodromic drum: 90 Display: 154...
  • Page 227 Maintenance: 8, 29 Oil filter: 33 Oil pressure sensor: 56 Oil sump: 139, 142 Primary shaft: 83, 89, 91 Rear wheel: 178 Recommended products: 20, 188 Secondary shaft: 85, 90, 91 Shock absorbers: 179 Side stand: Speed sensor: 53 Stand: Start-up: 49 Starter motor: 78, 100 Tank: 220...

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